emulsatoren

An emulsator is a device used to produce emulsions by dispersing one liquid into another immiscible liquid with the aid of mechanical energy and emulsifying agents. Emulsators are used in food, cosmetics, pharmaceuticals, paints, and chemical manufacturing to create stable mixtures such as oil-in-water or water-in-oil systems.

Principle: The device forces the dispersed phase through narrow gaps or across rapidly moving blades, generating high shear, turbulence, and sometimes cavitation. The energy breaks droplets of the dispersed phase to micro- or nano-scale. Emulsions are stabilized by emulsifiers or surfactants that lower interfacial tension and provide steric or electrostatic stabilization to prevent coalescence.

Common designs include rotor–stator high-shear emulsifiers, colloid mills, ultrasonic emulsifiers, and high-pressure homogenizers, as well as inline or batch configurations. The choice depends on target droplet size, viscosity, flow, and product sensitivity.

Operation: In batch systems a pre-emulsified product is subjected to successive passes or staged heads; in continuous systems the product flows through inline heads with controlled residence time. Process variables include speed, torque, temperature, phase ratio, and energy input, all affecting droplet size distribution and stability.

Applications: In foods such as dressings, sauces, and creams; in cosmetics such as creams and lotions; in pharmaceuticals for emulsified suspensions; in paints, coatings, and agrochemical formulations.

Advantages and limitations: Emulsators can produce fine, stable emulsions quickly and are scalable from laboratory to production. They require energy input and generate heat; shear can damage sensitive ingredients; equipment requires cleaning and maintenance to avoid contamination.