Helical Ribbon Agitator with Bottom-Mounted Homogenizer Configuration
This integrated mixing system is designed specifically for high-viscosity applications, combining the mechanical power of a helical ribbon agitator with the precision shear performance of a rotor-stator homogenizer. The configuration is widely used in cosmetics, pharmaceutical, and food industries for processing dense emulsions, creams, and suspensions with optimal thermal and mixing efficiency.
Challenges
Processing High Viscosity Products
Formulations exceeding 100,000 cP require robust agitation solutions that ensure full batch circulation and avoid stagnant zones. Traditional mixers often fail to provide sufficient axial flow and wall scraping, leading to uneven texture and poor heat transfer.
Uniform Heat Transfer in Dense Media
In high-viscosity environments, effective thermal exchange becomes a challenge. Without active wall scraping, product near the vessel walls may overheat or fail to mix properly.
Stable Emulsification in Complex Systems
Creating and maintaining stable emulsions in viscous systems requires a balance between bulk flow and intense shear. Shear must be carefully calibrated to avoid over-processing or destabilizing the emulsion.
Solutions
Helical Ribbon Agitator
Mounted inside the vessel, the helical ribbon agitator delivers strong axial flow from the wall to the center, continuously circulating the product mass. Simultaneously, it scrapes the inner vessel walls to maintain homogeneity and promote uniform heat transfer. This is especially critical for viscous products like creams, gels, and ointments.
Bottom-Mounted Rotor-Stator Homogenizer
Designed to deliver high shear force directly into the product base, the homogenizer breaks down droplets and particles to form stable emulsions. Its modular configuration allows tuning of the shear gap, rotor/stator profile, and flow path—enabling adaptation to products with viscosities up to 250,000 cP.
Modular High Shear Design
The rotor-stator head can be configured to match product characteristics, including viscosity range, required shear rate, and recirculation capacity. This flexibility ensures optimized performance for a wide variety of process requirements.
Applications
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MGT Industries is a global leader in the design and manufacturing of high-performance industrial agitators and mixing solutions. Since 1969, we’ve specialized in high shear mixers, low shear mixers, industrial agitators, and fully engineered mixing systems for a wide range of industries, including food, cosmetics, chemicals, pharmaceuticals, and more. With decades of innovation and expertise, MGT delivers reliable, energy-efficient, and customized mixing technologies to clients worldwide.