Enclosed shaft high speed Rotor/Stator dispersion system makes short work of paint premixes, agglomerate free dispersions, full range of models batch and inline system cover viscosities from 1 cps to 50,000 cps.
Wahal offers a complete range of multipupose batch mixers. The machines are able to perform the widest variety of applications – mixing, emulsifying, homogenising, disintegrating, dissolving. With an efficiency and flexibility unmatched by other machines. Capacities from 5 to 30,000 litres
Designed to be fitted into the bottom or side of a mixing vessel, these mixers are typically used in conjunction with slow speed anchor stirrer or scraper units although they can be used by themselves on low viscosity products. The high speed rotation of the rotor within the stator draws material downwards into the work head where they are subjected to high shear processing followed by radial expulsion from the head parallel to the bottom/side of the vessel. The stirring/scraper units and the Wahal Mixer head are complementary to one another, the Wahal High Shear Mixer head giving high shear homogenisation which the slow
speed stirrer/scraper assists by distributing the homogenised output of the Wahal High Shear Mixer head uniformly through the vessel, permitting the unit to produce high viscosity products which would be impossible to manufacture on a high shear mixer alone. The combination of stirring and homogenisation is particularly valuable for toiletry, cosmetic or pharmaceutical creams which solidify on cooling and where delicate perfumery compound or active medicinal products may only be added at low temperature. It is also valuable in the food industry where high viscosities may be experienced after cooking. As with all Wahal High Shear Mixer units, rapidly interchangeable stators, disintegration heads or screens are available to adapt machines for varying processes. Sealing is normally by means of a single carbon/ceramic mechanical shaft seal. Special single or double sealing is also available for products that demand it.
Stage 1. The high speed rotation of the rotor blades within the precision machined mixing work head exerts a powerful suction, drawing liquid and solid materials upwards from the bottom of the vessel and into the center of the work head.
Stage 2. Centrifugal force then drives materials towards the periphery of the work head where they are subjected to a milling action in the precision machined clearance between the ends of the rotor blades and the inner wall of the stator.
Stage 3. This is followed by intense hydraulic shear as the materials are forced, at high velocity, out through the perforations in the stator and circulated into the main body of the mix.
Stage 4. The materials expelled from the head are projected radially at high speed towards the sides of the mixing vessel. At the same time fresh material is continually drawn into the work head maintaining the mixing cycle. The effect of horizontal(radial) expulsion and suction into the head is to set up a circulatory pattern of mixing which is all below the surface. As a result of this there is no unnecessary turbulence above the surface. So long as the machine is correctly chosen for size and power, the entire contents of the vessel will pass hundreds of times through the work head during the mixing operation to give uniform progressive processing and homogenisation. A further benefit derived from the controlled mixing pattern is that aeration is almost completely eliminated.
Speed : The exceptionally rapid high shear mixer mixing action substantially reduces process times compared with conventional agitators and mixers and can reduce mixing times by upt to 90%
Versatility : The advantages of the High Shear Mixer approach to mixing that any one machine can perform the duties that in the past may have required several different pieces of process equipment.
Unrivalled versatility allows any machine to be adapted to perform the widest range of mixing applications: Mixing, Emulsifying, homogenizing, disintegrating, dissolving, dispersing, blending, particle size reduction and de-agglomerating
Blending : In blending operations of liquids of similar or greatly varying viscosities, the unique Wahal High Shear Mixer mixing action can rapidly produce a guaranteed homogeneous product. Without the need of in – tank baffles, so improving hygiene, the Wahal Mill batch mixer out – performs all conventional agitators. and mixers in both speed, efficiency and product uniformity
Emulsifying & Homogenizing : The special high shear rotor/stator design means that emulsions (typically) in the range of 0.5 to 5 microns) can be easily achieved, in many cases dispensing with the need for more costly and complicated equipment such as high pressure homogenisers.
Disintegration : All Wahal High Shear Mixers are able to disintegrate matter of animal, vegetable, mineral or synthetic origin in a single operation.
Wahal Expertise : Distinguishes it from all other manufactures in its ability to disintegrate large blocks of solid material. From the Duplex Dissolver to the mighty Be 1500 capable of disintegration whole bales of rubber 80x40x15 cms, a single Wahal High Shear Mixer is capable of performing duties that in the past would have required several operation.
Particle Size Reduction : This same rotor/stator action will ensure the rapid and uniform milling of both solid and semi – solid materials into either solution or fine suspension. The degree of size reduction will always depend on the hardness or toughness of the product but in many applications the use of a Wahal High Shear Mixer may dispense with the need for conventional size reduction equipment, such as dispensers/cavitation mixers, grinders and mills, and at a fraction of the cost.
Gelling & Solubilizing : The solution of gums, alginates, C.M.C., Carbopols, etc., Can be a slow and difficult process if a conventional agitator or mixer is used. Agglomerates frequently form and these can only be removed slowly by the washing action of the agitator. With a Wahal High Shear Mixer however the high shear action of the rotor/stator rapidly disperses the material, constantly exposing increasing areas of the solid to the surrounding liquid.
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