A recirculation-loop inline homogeniser integrates the rotor–stator homogeniser into a closed pipe loop connected to a jacketed batch vessel — processing the vessel contents through the inline workhead in multiple recirculation passes until the required particle size and homogeneity are achieved. Processing 50–50,000 L batch vessels at 0.5–100 m³/h recirculation rates, it combines the gentle batch temperature control of a vessel with the high shear capability of a rotor–stator — ideal for viscous semi-solid and high-solids formulations unsuitable for continuous single-pass processing.
Batch product in the jacketed vessel is drawn out through the vessel bottom valve by the inline homogeniser self-pumping action (or an auxiliary pump for high-viscosity systems). The homogeniser processes product continuously and returns it to the vessel through the return inlet — establishing a closed recirculation loop. Total recirculation passes are controlled by the ratio of homogeniser flow rate to vessel volume and total processing time. Each pass reduces particle size progressively toward the target D90. The batch vessel jacket maintains product temperature throughout — the homogeniser generates heat that the vessel jacket continuously removes to maintain isothermal processing.
Challenges
Non-Uniform Number of Passes Across Full Vessel Volume
Recirculation creates a residence-time distribution — some product receives more passes than others.
Vessel Dead Zones Not Swept by Recirculation Outlet
Product at vessel top, baffles, or agitator zone not drawn into recirculation outlet — unprocessed.
Heat Accumulation in High-Viscosity Batches
High-viscosity product dissipates more shear energy as heat — vessel jacket cannot remove heat fast enough.
Pipeline Dead-Leg Between Vessel Outlet and Homogeniser Inlet
Product stagnates in pipe section between vessel bottom valve and homogeniser inlet during pauses.
Scale-Up of Recirculation Time from Lab to Production Vessel
Loop flow rate and vessel volume ratio must be maintained to achieve equivalent pass number at scale.
Solutions
- Validated Recirculation Number (n = Q×t / V) as Scale-Up Criterion: Constant recirculation number (passes = flow rate × time / vessel volume) maintains process equivalence.
- Side-Entry Return Nozzle Below Liquid Surface (No Splashing): Submerged return inlet prevents surface aeration; tangential entry creates vessel-wide circulation.
- Jacketed Recirculation Loop Pipework (Same Media as Vessel Jacket): Loop pipe jacket maintains product at setpoint temperature between vessel and homogeniser — no heat spikes.
- Zero Dead-Leg Outlet Valve (Flush-Bottom, Full-Bore Design): Flush-bottom outlet valve eliminates stagnant pool between vessel and recirculation loop.
- NIR Inline Particle Size Sensor on Loop Return Line: Real-time PSD measurement on return line terminates recirculation automatically at D90 target.
Applications
- Pharmaceutical: Cream, ointment, and semi-solid recirculation homogenisation in GMP batch vessels.
- Cosmetics: Premium cream and lotion batch emulsification with vessel temperature control — large batch.
- Food & Beverage: Viscous sauce, paste, and thick beverage concentrate batch homogenisation.
- Chemical: High-solids dispersion, polymer emulsion, and resin batch recirculation homogenisation.
- Nutraceuticals: Protein paste, supplement slurry, and extract batch recirculation processing.
Product Catalogue & Technical Datasheet
 | Type 5 — Recirculation Loop Inline Homogeniser (5 L Lab Tank to 100,000 L Production Tank) |  | ||||||||||||
Model | Scale | Tank Volume [L] | Recirculation Flow [L/h] | Rotor Speed [RPM] | Tip Speed [m/s] | Passes per Batch | D90 [µm] | Motor [kW] | Inlet/Outlet Ø [mm] | Op. Temp [°C] | Overall System L×W×H [mm] | Weight [kg] | ||
IH-RL-LAB-015 | Lab | 5–50 | 50–1,000 | 3,000–12,000 VFD | 5–23 | 3–10 | 0.5–50 | 0.37 | DN 10 | 2–95 | 500×300×600 | 18 | ||
IH-RL-LAB-037 | Lab | 20–200 | 100–3,000 | 3,000–10,000 VFD | 7–28 | 3–10 | 0.5–50 | 0.75 | DN 20 | 2–95 | 600×350×700 | 32 | ||
IH-RL-PIL-150 | Pilot | 100–1,000 | 500–10,000 | 1,500–8,000 VFD | 8–25 | 3–8 | 0.5–100 | 1.5 | DN 32 | 2–95 | 800×450×900 | 75 | ||
IH-RL-PIL-370 | Pilot | 200–2,000 | 1,000–20,000 | 1,500–7,000 VFD | 9–28 | 3–8 | 0.5–100 | 3.7 | DN 50 | 2–95 | 950×550×1,050 | 145 | ||
IH-RL-P-075 | Production | 500–5,000 | 3,000–40,000 | 1,000–5,500 VFD | 10–25 | 2–6 | 0.5–150 | 7.5 | DN 65 | 2–95 | 1,200×680×1,200 | 320 | ||
IH-RL-P-150 | Production | 1,000–10,000 | 8,000–80,000 | 800–5,000 VFD | 10–25 | 2–5 | 0.5–150 | 15 | DN 80 | 2–95 | 1,450×800×1,400 | 550 | ||
IH-RL-P-300 | Production | 2,000–20,000 | 15,000–150,000 | 600–4,000 VFD | 10–25 | 2–4 | 0.5–200 | 30 | DN 100 | 2–95 | 1,700×950×1,600 | 900 | ||
IH-RL-LP-550 | Large Prod | 5,000–50,000 | 30,000–300,000 | 400–3,000 VFD | 10–22 | 1–3 | 0.5–300 | 55 | DN 150 | 2–95 | 2,100×1,150×1,900 | 1,650 | ||
IH-RL-LP-900 | Large Prod | 10,000–100,000 | 60,000–600,000 | 300–2,500 VFD | 10–20 | 1–2 | 1–500 | 90 | DN 200 | 2–95 | 2,600×1,350×2,200 | 2,800 | ||