QuadroYTRON PDF
QuadroYTRON PDF
A D VA N C E D SINGLE
- PA S S
FLUID
MIXING
Q UA D R O
Y T R O N
by applying the required shear to all the material in a quick, single pass. And its wide range of tooling can be specifically tailored to the difficulty of the application.
MEETING
Predictable, consistent quality. Easy to clean. These are the demands that are challenging process engineers in large-scale manufacturing today. However, traditional in-tank fluid mixing continues to impose limitations on productivity causing bottlenecks that industry has reluctantly learned to live with, or work around by introducing costly additional processes.
This in-tank velocity profile of a conventional mixer shows high velocity at the impeller, and low velocity throughout the bulk of the tank (blue and green areas). The result is random distribution of shear, which is impossible to control. Quadro Ytron single-pass technology delivers uniform shear to all material in a predictable, repeatable and scalable process.
"Not only did Quadro Ytrons speed and versatility allow us to reduce our batch times from 72 to 8 hours, we were able to free up manufacturing space, plus reduce inventory and warehouse demands while still meeting tight 3-day deliveries."
Quadro was approached by a large personal care product manufacturer producing privatelabel shampoos, creams and lotions for global distribution by health & beauty product retailers. Their conventional in-tank process was impeding productivity, and limiting batch quality and consistency. Deliver y deadlines were potentially at risk. At the Quadro R&D Test Center, we audited their process, providing a solution that eliminated lumps, fish eyes and air entrainment, rapidly dispersing high-viscosity thickeners such as Carbopol, HPMC and Keltrol into water and alcohol during the liquid fill cycle. In addition, wax flakes are instantly dissolved at reduced temperatures, saving cooling time.
Conventional hit-and-miss
Percentage of process solution
Traditional in-tank dispersion and emulsifying methods are, at best, hit-and-miss. Powders and immiscible liquids introduced into a vessel of liquid must find their way to the mixing impeller in order to be effectively sheared and dispersed. In theor y, the vor texing created by a conventional impeller draws the powder down into the action zone. In reality, only a por tion of the material introduced will reach the tooling for processing. The result? Random, uncontrollable rates of shear. Some materials are continually recirculated back into the action zone leading to over processing. Other components, most often in "dead zones" nearer the vessel walls and sur face, remain virtually untouched. This incomplete dispersion not only promotes waste as materials "raft" on the tank sur face or build-up on walls and baffles, it encourages the creation of "fish eye" lumps.
Its easy to see why even the most power ful mixer often has limited impact. To compound the situation, traditional vortexflow induction introduces unwanted air into the batch mix, fur ther compromising the desired results. And because these results are the product of so many randomly impacting processing variables, batch-to-batch quality and consistency becomes wholly unattainable. Processors have traditionally attempted to overcome these problems by extending processing times or using more costly, higher horsepower mixers. However, these approaches can damage heat- and/or shear-sensitive products.
100
50
Powders are dumped from a mezzanine into the hopper of a ZC3 Powder Disperser, with a liquid feed from the water supply line and short discharge directly into the mixing vessel. A full-flow ball valve maintains the mass flow of powder through the hopper.
Shear Rate
TM Quadro Ytron in-line mixer
Quadro Ytron in-line technology applies maximum controllable rates of shear to process 100% of the product in a single pass.
Q UA D R O
Y T R O N
n over 40 years of delivering the most efficient processing solutions for our customers worldwide, Quadro
of the science of shear and dispersion through extensive R&D in our state-of-the-ar t, in-house Test Center. This, along with ongoing feedback from our customers about their changing processing challenges, has enabled us to engineer a line of liquid mixing technologies that delivers industr y-leading per formance, predictability, repeatability, ease of maintenance and long-term reliability.
U LT R A H I G H
Z EMULSIFIER
Deagglomeration Emulsions Fine dispersions Homogenizing Texturing
IN-LINE
Ytron
in the way. In fact, thinking outside the box is at the hear t of our way of doing business. We continually develop innovative solutions that exceed expectations and break traditional assumptions about processing limitations.
ZC DISPERSER
Lump-free dispersion of difficult-to-disperse powders into a liquid stream
IN-LINE
Continuous innovation
To ensure each new generation of the Quadro
Ytron
line raises
XC DISPERSER
IN-LINE
Integrating Quadro Ytron single-pass technology into your process can significantly boost quality and throughput.
Y J E T M I X E R & B Y - PA S S T U B E
Sub-surface dispersion of floating powders Efficient mixing/blending without baffles Solids suspension & dissolving
LOW
I N - TA N K B AT C H
Q UA D R O
Y T R O N
Z Emulsifier
U LT R A H I G H S H E A R
I N G L E
- PA
S S
M U L S I O N
A N D
O M O G E N I Z AT I O N
D Y N A M I C
P R I N C I P L E S
T
Normalized Count 100 % 50 0 .1
he Quadro
Ytron
Z Emulsifier
consistent, repeatable quality at capacities exceeding those of conventional multiple-pass technology, such as in-tank high-shear mixers, colloid mills and shear pumps.
INTEGR SOLUTI
A T E D O N S
applications such as immiscible phase emulsifying/homogenizing, wet grinding, deagglomeration and fine solids dispersing.
Tooling flexibility
Rotors/stators for the Z Emulsifier come in a wide variety of slot widths which allow for a
10
high degree of multi-processing flexibility. Through tooling selection and var ying rotor tip speed the amount of shear can be
0 1 10 100 Particle Size (m) Cumulative Volume Particle Size Distribution
precisely controlled.
Scalable throughput
Four sanitary-design models are available
In a single pass, the Z Emulsifier achieves a very tight particle size distribution with 80% of the pigment less than 1 micron.
providing scalability from pilot plant capacities to >300 gpm (1,136 L/min). By maintaining the same tip
speed while changing the tooling diameter, throughput can be scaled up or down without altering product characteristics, texture or particle size distribution.
4
3
Equipped with an infeed pump, this Z Emulsifier delivers outstanding quality and high throughput for the production of an oil/ water emulsion liquid medication for a major pharmaceutical manufacturer.
1. Product enters housing axially. 2. One or more liquid phases and suspended particles are pumped through 1, 2 or 3 sets of toothed rotors/stators. 3. Controlled, high-intensity shear is delivered equally to all fluid elements, regardless of product characteristics. 4. Shear rate is constant, dependent only on rotor/stator tooth selection and rotor tip speed.
SPECIFICATIONS
MODEL
TYPICAL APPLICATIONS
Z0
5
CHEMICAL Pitch/bitumen emulsions Fungicides & insecticides Toners Pigments Laquers Resins
Unique three-stage tooling
COSMETIC/ PERSONAL CARE Perfumes Toothpastes Hair dyes Creams & lotions Shampoos Soaps
FOOD & BEVERAGE Yogurt Salad dressings Mayonnaise Cheese sauce Condiments Creams BBQ sauce Spreads
PHARMACEUTICAL Antibiotics Topical creams & gels Ointments Injectables Suppositories Nutritional drinks Oral suspensions
HP
kW
Gal/min L/min
3 2.2 15 60 10,000 1
FEATURES
1 Sanitary design with clamped housing, easily dismantled for cleaning; CIP and SIP options available. Meets 3A standards. 2 All stainless steel construction. 3 Single and double mechanical seals provide for high-temperature, high-pressure performance. 4 Single-speed drive with variable speed options. 5 Stainless steel base with portable, locking castors.
OPERATING PRESSURE
psi bar
0 - 60 0-4 1 25
*Actual capacities will var y depending upon inlet pressure, tooling selection and product characteristics.
Q U A D R O Y T R O N
ZC Disperser
H I G H S H E A R
S I N G L E - PA S S D I S P E R S I O N O F E X T R E M E LY D I F F I C U LT- TO - W E T P O W D E R S
D Y N A M I C
P R I N C I P L E S
he Quadro
Ytron
ZC Powder
high shear technologies. In addition, the over-processing common with conventional dispersing technologies is entirely eliminated, preser ving the rheological proper ties of shear-sensitive products. Batch time reductions as high as 75% can be realized with the Quadro Ytron ZC Disperser technology. No dispersion aids such as pre-heating the water or the predispersion of ingredients into non-aqueous solvents are required. Even with difficult products such as hydrocolloid gums, cellulose gums and carbomers you can expect complete dispersion in a single pass. 1. ZC Disperser operation is based on a close-tolerance, highshear, slotted rotor/stator design.
Close-tolerance rotor/ stator tooling
1
INTEGR SOLUTI
A T E D O N S
Intense shearing
The advanced design of the ZC Dispersers rotor/stator and reactor head provides for intense shearing of powders prior to hydration, to produce homogeneous dispersions that are completely free of lumps and "fish eyes".
The Quadro Ytron PID Powder Inductor Disperser uses ZC technology to convey, incorporate and disperse difficult-to-wet powders with the push of a single button.
2. Rotor creates a liquid ring, generating a significant vacuum build in the reactor head. 3. This vacuum ensures that powders from the hopper above are drawn into the head where they are sheared into the liquid phase, before hydration takes place.
SPECIFICATIONS
MODEL
ZC0
TYPICAL APPLICATIONS
ZC5 60 45 150 - 400 568 - 1500 1000 453 2,220 3 75 4 100 Yes
POWER
3 2.2 3 - 12 11 - 45 30 14 6,500
4
COSMETIC/ PERSONAL CARE Lotions Gels Creams Deodorants Hair gels & sprays Mouthwash Shampoos Hair conditioners Toothpastes Sunscreen Liquid makeup FOOD & BEVERAGE Jams Pet foods Egg substitutes Salad dressings Syrups Condiments Gums Stabilizers PHARMACEUTICAL Antacids Cough syrups Granulation solutions Tablet coatings Vitamin dispersions Topical creams Ointments Lotions Gels CHEMICAL Airplane de-icer Detergents Paint Drywall compound Oilfield products LIQUID CAPACITY POWDER CAPACITY* RPM INLET FITTING SIZE
in mm in mm
1 25 1 25 Yes
FEATURES
1 Steep-walled, mirror-polished hopper for superior powder flow. 2 Butterfly valve or optional full-port ball valve eliminates hindrances to powder flow. 3 Sanitary design with clamped housing, easily dismantled for inspection; most CIP designs meet 3A standards, USDA Dairy approved. 4 All stainless steel construction.
CIP CLEANABILITY
*Actual capacities will var y depending upon tooling selection and product characteristics.
Q U A D R O Y T R O N
XC Disperser
M E D I U M S H E A R
H D
1
I G H
-C
A PA C I T Y O F
I S P E R S I O N
, S I N G L E - PA POWDERS
S S
D Y N A M I C
P R I N C I P L E S
he Quadro
Ytron
XC Powder
quantities of moderately difficult-to-wet powders into a liquid stream with minimal air entrainment.
High concentrations
Processing at ambient temperatures, the XC Dispersers dual-stage reactor generates a near-per fect vacuum that ensures the intensive wetting of powders while delivering high discharge capacity, to enable concentrations up to 40% by weight to be produced in a single pass.
Impact design tooling Shear design tooling
INTEGR SOLUTI
A T E D O N S
High throughput
Two portable, sanitary-design models of the XC Disperser are available, offering throughputs up to 200 gpm
1. The XC Powder Disperser has a dual-stage reactor. 2. The first stage creates a strong vacuum to draw the powders into the reactor head.
Batch-to-batch repeatability
Not only does this innovative technology reduce dispersion times by up to 80%, but product characteristics are completely reproducible from batch-to-batch. And theres no plugging of screens, typical of other in-
(760 L/min). Powder deliver y options include feeding from hoppers, bag dump stations, bulk bags or super sacs and wanding from bags or our
4 3
This XC Disperser provides high concentrations with fast dispersion of protein hydrolysate for the Dair y industr y.
3. Immediately after the powder comes in contact with the liquid, the premix is subjected to intense directional and velocity changes as it impacts the stationary baffles. 4. The lower stage tangentially discharges a smooth, lump-free, homogeneous product.
SPECIFICATIONS
line blenders.
4
TYPICAL APPLICATIONS
MODEL
XC1 POWER
HP kW USGPM L/min lbs/min kg/min
XC3 25 18.5 120 - 200 450 - 760 400 180 3,000 2 50 3 75 Yes
FOOD & BEVERAGE Milk powders Whey powders Protein powders Gums and stabilizers Cocoa Starches Maltodextrin Ice cream mix Drink syrups/concentrates Infant formula Yogurt mixes Liquid beverages
PHARMACEUTICAL Nutrient replacement drinks Antacids Cough syrups Growth media Cell cultures Gelatin Pigment dispersions
INDUSTRIAL Paint TiO2 Oxides Pigments/stabilizers Coatings Carbon dispersions Ink Resins Textile color Cleaning solutions
in mm in mm
FEATURES
1 Steep-walled hopper for superior powder flow. 2 Butterfly valve or optional full-port ball valve eliminates hindrances to powder flow. 3 Sanitary design with clamped housing, easily dismantled for cleaning; CIP design meets 3A standards, USDA Dairy approved. 4 All stainless steel construction.
*Actual capacities will var y depending upon tooling selection and product characteristics.
Q U A D R O Y T R O N
T E M
F O R
I Q U I D
N C O R P O R A T I O N
D Y N A M I C
P R I N C I P L E S
Ytron
dispersion of powders and viscous pastes into the liquid phase. Shear is applied to the product as it is discharged from the bypass for single-pass incorporation.
The computer model shows how the product is accelerated through the rotor/stator head while the bulk contents of the tank experience uniform velocity, without stratification or dead areas.
unique rotor/stator mixing head that creates a pure axial flow discharge jet
6 3
to provide efficient in-tank mixing and blending. The wasteful radial flow and vortexing that are the downfall of conventional open-impeller design mixers are gone forever. Air entrainment is vir tually eliminated without the use of baffles.
4 5
powders to the bypass tube. In addition to ensuring maximum mixing per formance, dust-free handling reduces health and safety concerns, minimizes cross-contamination and eliminates the need for expensive material conveyors.
2
Typical applications for this side-entr y model include storage silos, tall tanks, horizontal vessels and low-liquidlevel mixing.
3. By means of a by-pass tube, product is delivered directly to the head for single-pass processing. 4. The Y Jet Mixer is mounted near the tank wall to ensure strong top-to-bottom roll that results in a uniform velocity profile of the tank contents, without vor texing or air entrainment.
TYPICAL
APPLICATIONS SPECIFICATIONS
COSMETIC/ PERSONAL CARE Shampoos/ conditioners Make-up bases Lotions Creams Toothpastes Pigments
FOOD & BEVERAGE Pectins Skim milk powder Fruit blending Gum acacia Starches Guar Gelatin Sugar solutions Cocoa Citric acids Powdered egg Cinnamon Juice and beverage concentrates Lactose Ice cream mix Stabilizers Tomato paste Pasta sauce Ketchup Salad dressings Syrups Yogurt mixes
PHARMACEUTICAL Pigments HEC CMC HPMC HPC Vitamins and minerals Bentonite clay Cab-o-Sil (fumed silica) Sodium alginate Starches Polyethylene glycol Medicated syrups Antibiotics Antacids Tablet coatings
CHEMICAL
MODEL
1
Automotive coatings Pigments Bentonite clay Cab-o-Sil (fumed silica) Resins Calcium carbonate Diatomaceous earth Polyvinyl alcohols Paper coatings Paint Ink Carbon black
1 Unique rotor/stator tooling for strong 1. axial flow pattern. 2 Innovative by-pass tube provides single2. pass sub-surface powder dispersion directly into rotor/stator.
POWER (Maximum)
HP kW
LIQUID BLENDING/ SOLIDS SUSPENSION Gal Liters (Batch size) POWDER INCORPORATION (Batch size) POWDER FEED RATE
Gal Liters
FEATURES
4. 4 Simple, direct-driven spindle provides long bearing life and easy maintenance. 5. , 5 Seal options include V-ring, double Varilip single and double mechanical seals. 6. 6 Stainless steel construction.
25 100 2 1
300 1,140 50 23
N/A
lbs/min kg/min
N/A
*Actual volumes and capacities will vary depending upon product characteristics.
Q U A D R O Y T R O N
t Quadro, we love challenges. After delivering industr y-leading per formance in thousands of
to achieve the per formance your specifications demand. In most cases, the per formance and quality improvements to our customers existing process are dramatic. Available in USDA Dairy approved, CIP and SIP designs meeting 3A standards, Quadro Ytron products are available in accordance with many international standards including UL, CSA and Halal certifications, and comply with OSHA, FDA, CE, cGMP, ATEX and 21CFR11 guidelines and directives.
applications from the simple to the most complex weve seen some of the toughest processing challenges. In fact, we like nothing more than a customer with a seemingly impossible problem to solve. Meeting the requirements of the toughest applications requires more than experience. It requires engineering depth. When you par tner with Quadro, you work hand-in-hand with some of the most knowledgeable engineers in the business, processing experts who understand how to apply the unique advantages of Quadro Ytron technology to maximize your process.
The Quadro CDS Continuous Dispersion System offers automatic in-line control of liquid and powder feeds, maintaining exact concentrations for direct downstream packaging or further processing and eliminating the need for batch tanks.
Ytron
DRAMATICALLY
HIGHER PRODUCTIVITY,
"With Quadro Ytron weve been able to substantially increase production, without having to expand our facility. In addition to reducing overall batch times by 75%, the increase in viscosity we achieved has allowed us to re-formulate and use less powder saving time and money."
A leading North American developer of innovative professional dentistr y products brought us their challenge. They needed to rapidly and uniformly disperse Carbopol and 40% carbamide peroxide into a low pH glycerine solution, without overprocessing. After analyzing the problem, Quadro engineered a solution that not only met their requirements, but optimized batch-to-batch consistency, reduced air entrainment and eliminated the need for filtering undispersed powders.
This ZC1 Dispersion System performs a two-step process to manufacture a cosmetic product. The first step in this liquid foundation manufacturing system disperses pigments and thickeners into an aqueous phase. The second step creates a water/ silicone emulsion, in a single pass.
A ZC1 In-line Disperser is skid mounted with a dual PD pump arrangement and Quadro Vac powder transfer system for full control over addition rates and viscosity. Pre-set operating points on inlet and discharge pumps facilitate addition of individual ingredients. An automated powder valve with level sensors in the hopper controls powder addition on/off. Quadro Ytron Model ZC1Q
At the Quadro R&D Test Center, we work with a vast array of applications, developing advanced solutions for leading processors worldwide.
Another thing to consider. With distribution, service and support in vir tually ever y industrialized
Application-specific solutions
First, we look at your process train, to see how we can optimize your application. Then, in our state-ofthe-art R&D Test Center, we verify your process using various configurations of Quadro technology, providing product samples and video-taped results,
region of the world, we can meet your needs no matter where youre doing business. Just one more reason why global leaders choose Quadro as their processing partner.
Q UA D R O P R O C E S S P R O D U C T I V I T Y S O L U T I O N S
For more than 30 years, Quadro has made an unparalleled commitment to delivering the highest production ef ficiencies, product quality and consistency to market leaders in the Pharmaceutical, Food, Fine Chemical, Personal Care and Cosmetics industries worldwide.
With the engineering experience gained from developing reliable application-specific solutions for major processors in more than 80 countries, our knowledge of size reduction and dispersion is unmatched. In fact, meeting the evolving needs of our customers drives the development of some of the industr ys most advanced processing technologies and systems such as the and Quadro Vac vacuum transfer systems. Since 1976, Quadro has led the industry in research & development. Through the Quadro R&D Test Center we work directly with our customers, to run real-world tests of their processes on the latest Quadro equipment. The result has been technical breakthroughs that have changed the way many of our customers process, and led to new global processing industry standards. As the worlds leading supplier of size reduction technology with a vast global network of agents, distributors, OEMs and partners Quadro provides a level of service and technical support that is unequaled in the industry. Our passion for technology is exceeded only by our dedication to meeting the needs of our customers.
Quadro
SIZE
REDUCTION
FLUID
MIXING
PNEUMATIC
TRANSFER
YLINE08
L O C A L R E P R E S E N TAT I V E
Quadro Engineering Corp. 613 Colby Drive Waterloo, ON, CA N2V 1A1 T 519-884-9660 F 519-884-0253 [email protected] www.quadro.com
Quadro (US) Inc. 55 Bleeker Street Millburn, NJ, USA 07041-1414 T 973-376-1266 F 973-376-3363 [email protected] www.quadro.com