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IKA ® Mixing and Processing Technology German technology made in the USA

IKA Mixing and Processing Technology - ikausa.com€¦ · The Partner for the Food, Pharmaceutical, Cosmetic Industry IKA® Mixing and Processing Technology The IKA® Process division

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Page 1: IKA Mixing and Processing Technology - ikausa.com€¦ · The Partner for the Food, Pharmaceutical, Cosmetic Industry IKA® Mixing and Processing Technology The IKA® Process division

IKA® Mixing and Processing Technology

German technologymade in the USA

Page 2: IKA Mixing and Processing Technology - ikausa.com€¦ · The Partner for the Food, Pharmaceutical, Cosmetic Industry IKA® Mixing and Processing Technology The IKA® Process division

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

Page 3: IKA Mixing and Processing Technology - ikausa.com€¦ · The Partner for the Food, Pharmaceutical, Cosmetic Industry IKA® Mixing and Processing Technology The IKA® Process division

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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Page 4: IKA Mixing and Processing Technology - ikausa.com€¦ · The Partner for the Food, Pharmaceutical, Cosmetic Industry IKA® Mixing and Processing Technology The IKA® Process division

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,…

Page 5: IKA Mixing and Processing Technology - ikausa.com€¦ · The Partner for the Food, Pharmaceutical, Cosmetic Industry IKA® Mixing and Processing Technology The IKA® Process division

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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Page 6: IKA Mixing and Processing Technology - ikausa.com€¦ · The Partner for the Food, Pharmaceutical, Cosmetic Industry IKA® Mixing and Processing Technology The IKA® Process division

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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Page 7: IKA Mixing and Processing Technology - ikausa.com€¦ · The Partner for the Food, Pharmaceutical, Cosmetic Industry IKA® Mixing and Processing Technology The IKA® Process division

201210_IKA_M

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.