Electric Heating Emulsifying Tanks with Hygienic Pumps

Core Design and Compliance

• Structural Layout: A dual-opening upper lid for easy access, a lower elliptical head for optimal mixing, bottom discharge ports, and a built-in hygienic pump for smooth material transfer.
• Sanitary Construction: All wetted parts are crafted from 316L stainless steel, with mirror-polished interiors (Ra ≤ 0.6μm) to prevent bacterial adhesion and ensure easy cleaning—critical for pharmaceutical and food-grade applications.
• Electrical Safety: The system operates on a 380V three-phase four-wire power supply, with grounded components and overload protection to meet industrial safety standards.

Functional Capabilities

1. Heating, Insulation, and Cooling

• Indirect Heating System: Electric heating elements warm the thermal medium in the jacket, which then transfers heat to the materials inside the tank. A PID temperature controller maintains precision within ±1°C, ideal for heat-sensitive processes like dairy pasteurization or cosmetic emulsion preparation.
• Cooling Option: Jackets can be flushed with cold water or glycol for rapid temperature reduction, supporting processes requiring strict thermal control.
• Insulation: The tank exterior is clad with polyurethane foam insulation (50–80mm thick) to minimize heat loss and protect operators from accidental burns.

2. Agitation and Emulsification

• High-Shear Agitation: A combination of a central stirrer (e.g., anchor or turbine impeller) and a hygienic rotor-stator emulsifier ensures thorough mixing. The emulsifier generates intense shear forces to break down droplets into sub-micron sizes, critical for creating stable emulsions in products like mayonnaise or skincare lotions.
• Variable Speed Control: A frequency inverter adjusts agitation speed (0–200 RPM for mixing, 2000–3000 RPM for emulsification), offering flexibility across different recipes.

3. Material Handling with Hygienic Pumps

• Integrated Pump Design: The hygienic pump (typically a lobe or centrifugal type) is directly mounted to the tank’s bottom outlet, enabling gentle, pulsation-free transfer of viscous or shear-sensitive materials.
• CIP/SIP Compatibility: The pump can be flushed with cleaning agents or steam alongside the tank, ensuring no residue remains in the pipeline—a key requirement for sterile environments.

Installation and Operational Simplicity

• Plug-and-Play Setup: Connect the control cabinet to the specified power supply, fill the tank with materials, and add a thermal medium (e.g., heat transfer oil) to the jacket. No specialized tools are required for initial setup.
• User-Friendly Controls: The control panel features intuitive HMI (human-machine interface) displays for monitoring temperature, agitation speed, and pump operation. Alarms trigger for over-temperature or low-flow conditions, enhancing process safety.
• Maintenance Efficiency:
  • Quick-Release Heating Elements: Designed for tool-free installation/removal, allowing easy inspection or replacement without downtime.
  • Modular Design: The emulsifier and pump can be disassembled for deep cleaning, while the tank’s open-top design facilitates manual inspection.

Advantages of Sote’s Unique Heating Element Design

1. Tool-Free Maintenance: Heating elements slide into dedicated slots in the jacket, eliminating the need for specialized tools and reducing maintenance time by 50%.
2. Enhanced Heat Transfer: Fully submerged elements ensure direct contact with the thermal medium, achieving 30% higher heat efficiency compared to external coil systems.
3. Cost and Energy Savings: The design minimizes heat loss and allows for precise wattage selection, reducing energy consumption by up to 20% during prolonged operations.

Applications Across Industries

1. Food & Beverage

• Dairy Products: Production of homogenized milk, cream, and yogurt with consistent texture.
• Beverages: Emulsification of oil-based flavors or nutraceutical additives into water-based drinks.
• Condiments: High-shear mixing for sauces, dressings, and spreads to achieve smooth, lump-free textures.

2. Cosmetics & Personal Care

• Emulsion-Based Products: Lotions, creams, and shampoos require precise emulsification to blend oil and water phases into stable formulations.
• Suspensions: Mixing of pigments or exfoliants into gels or creams using gentle agitation to prevent particle degradation.

3. Biopharmaceuticals

• Drug Formulation: Production of liposomes, suspensions, or emulsified drug carriers with strict sterility requirements.
• Bioprocessing: Mixing of cell cultures or fermentation media, with temperature control critical for maintaining microbial viability.

Selecting the Right System

1. Capacity: Tanks range from 50L (pilot scale) to 5000L (industrial production), with custom sizes available.
2. Emulsification Intensity: High-shear vs. low-shear designs based on product viscosity and particle size requirements.
3. Regulatory Compliance: GMP, 3-A Sanitary Standards, or ASME BPE certifications for specific industries.
4. Integration Needs: Compatibility with upstream/downstream equipment (e.g., fillers, pasteurizers) and automation systems.

Conclusion