Industrial High-Shear Homogenizer using Power Ultrasound

As ultrasonic applications can be scaled up on a straight-line basis, the processing capacity increases with the ultrasonic power. At production level, processes often require more power than 40kW. For such processing applications, we recommend using a cluster of UIP10000 or UIP16000. The UIP16000 combines a very high power with a minimal footprint. In a typical setup, the UIP16000 requires 2 cabinets of 600mm x 600mm footprint only. This makes it easy to retrofit the ultrasonic processor into existing systems. Each UIP16000 works as a self contained unit, including generator, transducer, sonotrode, flow cell and closed loop refrigeration. The stainless steel cabinets come with noise-insulated walls to reduce the noise emissions outside of the cabinet.

Process Scale Up

Each ultrasonic application requires a certain optimal combination of sonication amplitude, liquid pressure and temperature. This optimal configuration can be found in small lab or bench-top scale test, e.g. by using a UIP1000hd (1kW) with flow cell. The UIP1000hd allows for a variation of the sonication parameters in a wide range. Once the optimal parameter configuration has been identified, the process efficiency can be scaled up linearly. Therefore, the turnkey system comes pre-configured to work at the optimal parameter configuration. The table below shows general processing capacities for a 4x16kW system. 

4x16kW Processing Capacity

Process                                              Flow Rate

biodiesel transesterification            12 to 50m³/hr

emulsification, e.g. oil/water             6 to 32m³/hr

cell extraction, e.g. algae                 1 to 12m³/hr

dispersing / deagglomeration          0.3 to 6m³/hr

wet milling and grinding                   0.2 to 4m³/hr

High-Performance Sonicator: Easy Installation, Simple System Start-Up

The UIP16000 is designed to facilitate the installation and start-up. The cabinets come pre-configured. It needs to be connected to the process media supply, power supply, and cooling water, only. Data interfaces are optionally available.

As mentioned above we recommend the conduct of process feasibility trials and a process optimization in small to medium scale. We will be glad to assist you in selecting the right equipment for such preliminary tests and for the final full-scale setup. Alternatively, you can conduct process trials in our process laboratory.

Why Hielscher Ultrasonics?

• high efficiency
• state-of-the-art technology
• reliability & robustness
• adjustable, precise process control
• batch & inline
• for any volume
• intelligent software
• smart features (e.g., programmable, data protocolling, remote control)
• easy and safe to operate
• low maintenance
• CIP (clean-in-place)

Design, Manufacturing and Consulting – Quality Made in Germany

Hielscher ultrasonicators are well-known for their highest quality and design standards. Robustness and easy operation allow the smooth integration of our ultrasonicators into industrial facilities. Rough conditions and demanding environments are easily handled by Hielscher ultrasonicators.

Hielscher Ultrasonics is an ISO certified company and put special emphasis on high-performance ultrasonicators featuring state-of-the-art technology and user-friendliness. Of course, Hielscher ultrasonicators are CE compliant and meet the requirements of UL, CSA and RoHs.

Find the Right Sonicator for Your Process Volumes

Hielscher sonicators are available at any power and processing capacity. Whether you want to ultrasonically homogenize small volumes in a vial or lab beaker or you want to industrially process large liquid streams for mass production, Hielscher has the suitable ultrasonic homogenizer in the portfolio.
The table below gives you an indication of the approximate processing capacity of our ultrasonicators:

Related Topics

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Ultrasonic High-Shear In-Line Mixers

SonoStation – Hielscher’s Ultrasonic Pump Solution Setup

Ultrasonic Homogenizers for Liquid Processing

How to Mix Varnishes with Nanofillers

High-Performance Adhesive Formulations – Improved by Ultrasonic Dispersion

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