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Wenzhou Suote - Professional Pharmaceutical, Chemical And beverage Processing Equipment Manufacturer Since 1998.

Electric Heating Emulsifying Tanks with Hygienic Pumps

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Electric Heating Emulsifying Tanks with Hygienic Pumps

Core Design and Compliance

The integrated design of electric heating emulsifying tanks and hygienic pumps adheres to rigorous Good Manufacturing Practice (GMP) regulations, ensuring no compromise in product quality or safety. Key features include:

  • 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

When specifying an electric heating emulsifying tank with a hygienic pump, consider:

  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

Electric heating emulsifying tanks with hygienic pumps embody the perfect blend of functionality, hygiene, and efficiency for modern industrial applications. Whether used in the precise formulation of pharmaceutical emulsions or the large-scale production of food products, these systems deliver consistent results while adhering to the strictest regulatory standards. Sote’s innovative design—prioritizing ease of maintenance, energy efficiency, and process control—sets a benchmark for reliability in demanding manufacturing environments.

Contact us to discuss custom configurations tailored to your process requirements and production scale.

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