A single-stage inline homogeniser is a continuous-flow, high-shear rotor–stator reactor processing liquid and semi-liquid products through one precision-engineered workhead at 3,000–3,600 RPM (tip speed 15–25 m/s, Re >10,000). Handling 1–250,000 cP at flow rates of 0.5–20 m³/h, it reduces particle size to <5–20 µm, achieves >90% dispersion uniformity, and delivers self-pumping discharge — eliminating secondary transfer pumps for standard emulsification, dispersion, and homogenisation duties in food, cosmetic, and pharmaceutical lines.
Product enters the inlet continuously; the high-speed rotor (3,000–3,600 RPM) generates centrifugal suction drawing material into the single rotor–stator gap (clearance 0.1–0.5 mm). Intense shear (10³–10⁴ s⁻¹), turbulence, and hydraulic impact at the gap reduce droplets and agglomerates to <5–20 µm. The self-pumping rotor expels homogenised product at high velocity through stator slots — continuing to the next process step without additional pump. No-bypass design ensures 100% of product passes through the workhead every pass.
Challenges
Particle Size Limited to <5–20 µm per Pass
Single workhead cannot achieve sub-micron emulsification without multiple recirculation passes.
Phase Separation Risk in High Oil-Phase Systems
Single-pass shear insufficient to stabilise emulsions with oil-phase above 40% v/v.
High-Viscosity Pumping Limitation (>50,000 cP)
Self-pumping head capacity falls sharply — external pump assistance required above viscosity limit.
Temperature Rise (5–15°C per Pass)
Shear energy at rotor–stator gap raises product temperature — degradation risk for thermolabile APIs.
Rotor–Stator Wear from Abrasive Slurry
Hard mineral particles or abrasive pigments score rotor–stator gap — shear performance declines.
Solutions
- Optimised Single-Stage Gap (0.1–0.5 mm) per Application: Gap selected at commissioning for target particle size at minimum power — validated by PSD measurement.
- Self-Pumping Rotor Design (Centrifugal Pumping Action): Rotor blade geometry provides positive pressure at outlet — eliminates secondary pump for low-to-medium viscosity.
- Jacketed Housing with Cooling Water Circuit: Temperature-controlled jacket limits product temperature rise to <5°C per pass for heat-sensitive materials.
- Hard-Faced Rotor–Stator (Tungsten Carbide / Ceramic): TC gap surface extends service life 5–10× against hard abrasive particles and mineral slurries.
- VFD Speed Control (3,000–3,600 RPM): Adjustable shear intensity optimised to product viscosity and target particle size per recipe.
Applications
- Food & Beverage: Sauces, dressings, beverages, syrups, mayonnaise — single-pass continuous emulsification.
- Pharmaceutical: API suspensions, syrups, oral emulsions, liquid formulations — GMP inline homogenisation.
- Cosmetics: Lotions, creams, shampoos, serums — continuous fine particle emulsification for filling lines.
- Dairy: Milk homogenisation, flavoured milk, cream processing — 3-A hygienic certified configurations.
- Chemical: Pigment dispersions, adhesive emulsions, lubricant blending — standard inline processing.
Models & Capacities
Type 1 — Single-Stage Inline Rotor-Stator Homogeniser (20 L/h Lab to 350,000 L/h Large Production) | |||||||||||||
Model | Scale | Flow Rate [L/h] | Rotor Speed [RPM] | Tip Speed [m/s] | Particle Size D90 [µm] | Max Viscosity [cP] | Motor [kW] | Inlet/Outlet Ø [mm] | Op. Temp [°C] | Op. Pressure [bar] | Overall L×W×H [mm] | Weight [kg] |
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IH-SS-LAB-015 | Lab | 20–200 | 3,000–12,000 VFD | 5–23 | 0.5–50 | <5,000 | 0.37 | DN 10 | 2–95 | Up to 10 | 280×150×200 | 8 |
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IH-SS-LAB-037 | Lab | 50–500 | 3,000–10,000 VFD | 7–28 | 0.5–50 | <8,000 | 0.55 | DN 15 | 2–95 | Up to 10 | 320×170×220 | 12 |
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IH-SS-PIL-075 | Pilot | 200–2,000 | 1,500–8,000 VFD | 8–25 | 0.5–100 | <10,000 | 0.75 | DN 25 | 2–95 | Up to 10 | 380×200×260 | 22 |
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IH-SS-PIL-150 | Pilot | 500–5,000 | 1,500–7,200 VFD | 9–28 | 0.5–100 | <12,000 | 1.5 | DN 32 | 2–95 | Up to 10 | 440×230×290 | 38 |
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IH-SS-PIL-220 | Pilot | 1,000–8,000 | 1,200–6,000 VFD | 10–28 | 0.5–100 | <15,000 | 2.2 | DN 40 | 2–95 | Up to 10 | 500×265×320 | 58 |
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IH-SS-P-040 | Production | 3,000–20,000 | 1,000–5,000 VFD | 10–25 | 0.5–150 | <20,000 | 4.0 | DN 50 | 2–95 | Up to 6 | 580×310×370 | 92 |
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IH-SS-P-075 | Production | 5,000–35,000 | 800–4,000 VFD | 10–25 | 0.5–150 | <25,000 | 7.5 | DN 65 | 2–95 | Up to 6 | 680×360×430 | 145 |
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IH-SS-P-110 | Production | 8,000–55,000 | 600–3,600 VFD | 10–25 | 0.5–200 | <30,000 | 11 | DN 80 | 2–95 | Up to 6 | 780×420×490 | 210 |
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IH-SS-P-150 | Production | 12,000–75,000 | 500–3,000 VFD | 10–23 | 0.5–200 | <35,000 | 15 | DN 100 | 2–95 | Up to 6 | 890×480×560 | 300 |
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IH-SS-LP-220 | Large Prod | 20,000–120,000 | 400–2,500 VFD | 10–22 | 0.5–300 | <40,000 | 22 | DN 125 | 2–95 | Up to 4 | 1,020×560×650 | 450 |
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IH-SS-LP-370 | Large Prod | 35,000–200,000 | 300–2,000 VFD | 10–20 | 0.5–300 | <50,000 | 37 | DN 150 | 2–95 | Up to 4 | 1,180×650×760 | 680 |
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IH-SS-LP-550 | Large Prod | 60,000–350,000 | 200–1,500 VFD | 10–18 | 1–500 | <60,000 | 55 | DN 200 | 2–95 | Up to 4 | 1,400×780×900 | 1,050 |
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