Each functional module of the equipment is optimized through rigorous structural design and performance testing, ensuring that every link of the production process is controllable, efficient, and stable. The following is a detailed description of the core functions, structural characteristics, and working principles:
1.1 High-Shear Homogenization Module (Core Emulsification Component)
Structural Details: Adopts a 4-stage integrated stator-rotor structure, made of food-grade 316L stainless steel with precision polishing (surface roughness Ra ≤ 0.2 μm). The shear gap is adjustable (0.02-0.06 mm) and equipped with a wear-resistant coating on the rotor surface. The module is driven by a high-power frequency conversion motor (1.5-7.5 kW, depending on the model) with a stepless speed regulation range of 3000-18000 rpm, and the maximum linear speed of the rotor reaches 65 m/s.
Working Principle: When the equipment is running, the high-speed rotating rotor generates strong centrifugal force, which quickly draws the mixed materials (oil phase, water phase, functional additives) into the shear gap between the stator and rotor. Under the combined action of three-dimensional forces (shear force, impact force, turbulence), large oil droplets (original particle size 50-100 μm) and solid particles (such as aloe vera extract powder) are broken down into micro-particles with an average particle size of ≤ 2 μm (minimum 0.5 μm), and evenly dispersed in the continuous phase to form a stable emulsion system.
Refined Advantages: The 4-stage shear structure increases the shear frequency by 35% compared with the traditional 3-stage structure, ensuring sufficient emulsification of high-viscosity materials; the adjustable shear gap can be matched with different products (0.02-0.04 mm for aloe vera gel, 0.04-0.06 mm for high-viscosity creams); the wear-resistant coating extends the service life of the stator and rotor by 50%.
1.2 Vacuum Mixing Module (Bubble-Free & Anti-Oxidation)
Structural Details: Composed of a rotary vane vacuum pump (power 1.5-3.0 kW), a precision digital vacuum gauge (measurement range -0.1-0 MPa, accuracy ±0.001 MPa), a full-sealed pipeline system (316L stainless steel, pipeline diameter 25 mm), and a double-layer sealing tank cover (inner layer: fluorine rubber sealing ring, high temperature resistance 200℃; outer layer: food-grade silicone rubber sealing ring). The vacuum retention time is ≥ 12 hours under the condition of no material.
Working Principle: Before emulsification, the vacuum pump starts to extract the air in the mixing tank, and the vacuum gauge monitors the pressure in real time. When the vacuum degree reaches the set value (-0.095 to -0.098 MPa), the system automatically maintains the pressure. During the mixing and emulsification process, the module continuously extracts the air entrained in the materials and the air generated by chemical reactions, avoiding bubble residue in the product. At the same time, the vacuum environment isolates the contact between materials and air, preventing the oxidation of easily oxidized ingredients (aloe vera polysaccharide, vitamins, plant essential oils).
Refined Advantages: The double-layer sealing structure reduces the air leakage rate to ≤ 0.002 MPa/h; the precision digital vacuum gauge realizes real-time monitoring and automatic adjustment, avoiding material boiling caused by excessive vacuum; the pipeline is equipped with a 100-mesh detachable filter to prevent material particles from entering the vacuum pump and causing damage.
1.3 Precise Emulsification Module (Dual Paddle Coordinated Operation)
Structural Details: Equipped with two sets of independent frequency conversion motors to drive the frame-type mixing paddle and the wall-scraping paddle respectively. The frame-type paddle (width 80-120 mm, 15° inclination angle) has a speed regulation range of 10-80 rpm; the wall-scraping paddle adopts a detachable PTFE scraper (thickness 3 mm) with a fit gap of ≤ 0.5 mm with the tank wall, and the speed regulation range is 5-40 rpm (synchronized with the frame paddle or independent operation).
Working Principle: In the pre-emulsification stage, the frame paddle rotates at a low speed (30-40 rpm) to realize the initial mixing of oil and water phases and uniform dispersion of emulsifiers; in the high-shear emulsification stage, the frame paddle rotates at a medium speed (50-60 rpm) to push the materials to the homogenizing head continuously, avoiding local material stagnation; the wall-scraping paddle rotates synchronously to scrape off the materials adhered to the tank wall and jacket surface, preventing local overheating and under-emulsification of the adhered materials.
Refined Advantages: The dual-motor independent control realizes the matching of different mixing speeds for different production stages; the 15° inclined frame paddle increases the material circulation speed by 25%; the detachable PTFE scraper is easy to clean and replace, and avoids scratching the mirror-polished tank wall.
1.4 Intelligent Temperature Control Module (Heating & Cooling)
Heating System: Adopts a jacketed heating structure (jacket thickness 8-10 mm) with uniformly distributed electric heating tubes (304 stainless steel, power 10-24 kW, 3-gear adjustable). Equipped with a PT100 platinum resistance temperature sensor (measurement range 0-150℃, accuracy ±0.1℃) and a PID intelligent temperature controller, the temperature control accuracy is ±0.5℃.
Cooling System: Shares the jacket with the heating system, with a cooling water inlet and outlet (diameter 20 mm) equipped with a flow control valve (adjustable flow rate 0-50 L/min). The cooling method adopts circulating cooling water (inlet water temperature 5-15℃), and the cooling rate is adjustable (3-12℃/h). The system is equipped with a temperature feedback device to automatically adjust the cooling water flow rate according to the material temperature.
Refined Advantages: The 3-gear adjustable heating power adapts to different heating needs (rapid heating for large batches, slow heating for small batches); the PT100 sensor with high accuracy ensures precise temperature control, avoiding emulsion breakdown caused by temperature fluctuations; the adjustable cooling rate can match the cooling needs of different heat-sensitive ingredients.
1.5 CIP In-Place Cleaning Module (No Dead Corner & Efficient)
Structural Details: Composed of a cleaning liquid tank (volume 50-100 L, 316L stainless steel), a high-pressure centrifugal pump (power 1.1-2.2 kW, pressure 0.3-0.6 MPa), 4-6 360° rotating high-pressure nozzles (nozzle diameter 1.5-2.0 mm), and a liquid level monitoring sensor. The cleaning process includes four stages: pre-rinsing (pure water), detergent cleaning (neutral detergent, concentration 2-3%), rinsing (pure water), and hot air drying (hot air temperature 70-80℃, wind speed 3-5 m/s).
Working Principle: The operator sets the cleaning parameters through the touch screen, and the system automatically completes the entire cleaning process. The 360° rotating nozzles ensure that the cleaning liquid covers all parts in contact with materials (tank inner wall, homogenizing head, paddles, feeding port, discharge port). After cleaning, the hot air drying system starts to dry the equipment to avoid water residue and detergent residue.
Refined Advantages: The cleaning dead corner elimination rate reaches 100%; the entire cleaning process takes 30-55 minutes (depending on the model), which is 40% shorter than traditional manual cleaning; the conductivity detection after cleaning ensures that the detergent residue is ≤ 10 μS/cm.
