IKA® Mixing and Processing Technology
German technologymade in the USA
Process engineering that will inspire you!
Benefits of IKA® machines and plants
> GMP Compliant
> Surface finishes and materials meet FDA, 3A and
EHEDG requirements
> CIP / SIP capable
> Save time and energy
> Reproducible mixing quality and results
> Reliable and predictable scale-up
High Shear Mixing
Blending
Wet – Grinding
Emulsifying
Homogenizing
Dispersing
Suspending
De-Flaking
Solid / Liquid Dispersing
Solid / Liquid Blending
Colloid Milling
Droplet Size Reduction
Particle Size Reduction
Pulping
Neutralizing
Polymerizing
Dissolving
Pulp Disintegrating
Extracting
De-agglomeration
Shear – Pumping
Gas Injection
Reaction Acceleration
> food > cosmetic > colors
> chemical> plastic > pharma
The Partner for the Food, Pharmaceutical, Cosmetic Industry
www.ikaprocess.com
IKA® Mixing and Processing Technology
The IKA® Process division offers turnkey solutions and state-of-the-art manufacturing options. IKA® solutions include: dispersing machines, homogenizers, agitators, jet mixers, kneaders, vacuum dryers, and process plants, all manufactured to IKA® high product quality standards. Consulting, design and execution of complex projects as well as proactive after-sales service complete the IKA®
solution portfolio.
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SERVICE QUALITY AVAILABILITYIKA® Proudly Manufactures in the USA
UTLsingle-stage module for homogenizing of emul-sions and suspensions
DR3-stage disperser for applications with high shear requirements
DRS2-stage disperser for emulsions in the sub-micron range and finest suspensions
MKcolloid mill for extremely stable emulsions and suspensions
CMSpowder / liquid mixer creates a vacuum that draws in the solids and blends, all in one step
MHDcontinuous in-line pro-portional incorporation of powders into liquids
Modular construction: Labor / Process Pilot -
A series of different high-shear mixing and size reduction
modules, adapted to the application. This makes the
Labor / Process Pilot ideal for the requirements of the
food, pharmaceutical and cosmetic industries.
NEW!
High-Pressure-Homogenizer moduleWith up to 29,000 PSI.
> Labor-Pilot
> Labor-Pilot
It all starts in the Lab…..
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DISPAX REACTOR® DR 2000The DISPAX REACTOR® is a high shear, three sta-
ge dispersing machine used for the production
of micro-emulsions and very fine suspensions.
Three rotor-stator combinations (generators) in
a series produce a fine droplet or particle size,
with a very narrow distribution. The generators
can easily be interchanged, offering the ultimate
in flexibility and processing.
> IKA® MHD Series: Powder / Liquid Dispersing
> Suspension
Plants
> Batch Solid /
Liquid Dispersing
Plants
> Semi-Solids Plants
Continuous
> Blending
> Dilution Plants
> Inline Reaction
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Generators available:
> Shear-Pump
> Coarse (2G)
> Medium (4M)
> Fine (6F)
> Superfine (8SF)
APPLICATION:
Neutralization &PH adjustment
Tooth paste
Salt solutions
Edible oil refining & degumming
Shampoos & Conditioners
Polymerizations
Pesticides
HerbicidesReaction Enhancements
Microencapsu-lations
Viscosity Control
Creams
Lotions
Fuels
...and ends up in Production,... …or as part of an IKA® System,…
Yogurt
Milkshakes
Cheese spread
Proteins
Ice Cream
Pudding
Cocoa
Chocolate masses
Soups / Sauces
Dressings
Baby food
Liquid spices
Sugar / Salt
Mayonnaise
Ketchup
Edible oil
Margarine
Peanut butter
Jams
Jellies
Starches
Polysaccharides
Alginates
Juices
Beverages
Liquid flavors
Extracts
Pet food
…or as an IKA® Masterplant. Food and Beverage Industry
Do you want to increase production?
Do you want to expand your production capabilities?
Do you want to reduce operating costs?
IKA® has the solution for you!
The new IKA® Masterplant is unlike any other mixer. Its design is multi-purpose and practical. The patent-pending Masterplant offers these functions in an all-in-one mixing and dispersing machine: Pumping, powder and liquid incorpo-ration, mixing, dispersing, and CIP.
Food sauces or dressings are O/W-emulsions which spe-cially serve for flavor improvement. They are typical side products of the fast food industries. The goal is to obtain a tasty sauce to suit your salad within short period of time. Moreover, you do not have to compose the respec-tive components and mix them manually to create an emulsion. Emulsions for food sauces and dressings are typically produced in 2 steps.
First, salt, colorants, preservatives, spices, etc. are dis-persed into the continuous phase, i.e. water with vinegar. High shear dispersing machines such as the IKA® ULTRA-TURRAX® UTL 2000 or DBI 2000 are preferably used for this purpose.
Second, an emulsion is created by adding the disperse phase, i.e. oil and a suitable emulsifier. For stabilization and thickening, stabilizers such as guar gum, pectin, or xanthan are used. Often so-called "visible" spices are ad-ded at the end of the emulsifying process.
The term "polysaccharides" is a collective name for macromolecular carbohydrates, linked with monosac-charide molecules. Pectin gained from apples, quinces, xanthan, guar, or agar also belongs to this group. They have very good gelling properties and are thus mainly used in the beverage industry, but also used for the pro-duction of jams, jellies and similar products. Due to their fine particle size (fine powder), hydrocolloids tend to ag-glomerate and, in connection with humidity, form lumps. Therefore, a quick wetting and homogeneous repartition is of great importance. It is known that heat accelera-tes the swelling behavior, i.e. the increase of viscosity. It is therefore recommended to mix the phases homoge-neously at a low temperature and within a short period of time. For the inline process, the IKA® inline powder wetting and dispersing machine CMS 2000 is the ideal machine. For continuous processes and very high con-centrations we recommend using the IKA® mixing and dispersing machine MHD 2000.
Food sauces or dressings Polysaccharides
Control monitor with touch screen
Integrated control cabinet
Rotary union for supplying heating or cooling medium to the spiral agitator
The DBI (Dispersing Batch In-line) is the heart of the new innovative
mixing system “Masterplant” (MP). The unique design features of the MP
improve product quality and shorten production time, even for products
with a wide viscosity range. More info: www.ikaprocess.com
Plant is completely enclosed with stainless steel
Feed solids or liquid additives directly into the dispersing chamber. This results in a quick and complete wetting out of the product and prevents lumps from forming.
Load cells
Viewing port for the seal cooling system
Motor is completely enclosed
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Pharmaceutical and Cosmetic Industry The IKA® philosophy:
Production of a silicone/water-emulsion; It is recom-mended to first make a preparation with water (approx. 15%) and to produce a gel-like emulsion. The suitable machine for this purpose is a colloid mill such as the IKA® MK 2000 or high shear DR 2000. Moreover, it has to be
There are wax emulsions of many different types, used either for water repellent finishing or for the coating of medically active substances. The main process step is melting the wax at moderate stirring, e.g. with the IKA®-TURBOTRON®. The additives and hot water are then ad-ded and dispersed in a circulating operation. Ideal for this process are the IKA® inline dispersing machines DISPAX-REACTOR® DR 2000/.., ULTRA-TURRAX® 2000/... or colloid mill MK 2000/..
Saline- or silicone emulsions
> IKA® designs complete production plants
> IKA® proudly manufactures in the USA
> IKA® conducts trials and product development
> IKA® plans and conducts mechanical, electrical, and
pneumatic installations
> IKA® conducts repair and service work on site or at
the IKA® facility in Wilmington, NC
> IKA® offers spare parts service within 24 hours
> More info at www.ikaprocess.com
Make use of our many services:Paraffin emulsions
Ointments
Paraffin emulsions
Body care lotions
Gels
Eye drops
Contact lens
Solutions
Plant extractions
Cough mixtures or
similar mixtures
Serums / vaccines
Starch solutions
Suntan lotions
Makeup
Bubble bath
Tooth paste
Oral hygiene tonic
Shampoos
Conditioners
Hair rinses
Fumed silica
Carbopol
Nail polishes
Lipsticks
Suppository masses
Skin cremes
Mascara
Liquid Ibuprofen
Nasal spays
Silicon emulsions
Wax emulsions
worked with high shear gradient. As soon as a homoge-neous, transparent and high viscosity mixture is reached, any desired viscosity can be adjusted by further adding wa-ter and emulsifier.
IKA® is one of the leading manufacturers of mixing and dispersing machi-nes, employing approximately 450 people worldwide with 70 employees at the Wilmington, NC facility. 10% of the total personnel are involved in the field of research and development. An IKA® product is a combination of the latest innovative technology and the highest quality. The use of an IKA® machine or system must be economically justified and guarantee a constant product quality with reproducible results over a long period of time. IKA® carefully establishes a clear plan to determine which machines or systems are best suited for each and every application.
The IKA® philosophy is; "The product result and the production time have to be matched in order to achieve the optimum result".
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ixing_Processing_Technology_EN
IKA®-Works, Inc. 2635 Northchase Pkwy SE, Wilmington, NC 28405-7419, USA Tel. +1 800-733-3037Tel. +1 910 452-7059 Fax +1 910 452-7693 [email protected]
designedto work perfectly
IKA® Process Technology:Superior Quality, Innovative Design
IKA® uses high quality materials for exceptional
mechanical strength and corrosion resistance in all
process machinery, ensuring first class quality. In
addition, by working closely with the customers and
research institutions, IKA® is continually developing
new technologies and applications. This partnership
allows IKA® to deliver the most innovative solutions
for the process industry. The IKA® commitment to
continuous research and development, provides the
basis for the IKA® philosophy: superior quality and
innovative design.
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