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Wet milling is a process that is used in the food industry as an important step in the making of many different food products. Some of the end products that are created with wet milling include food colouring and flavours, salad dressing, yogurt, mayonnaise, cheese sauce, spreads, creams, condiments and barbecue sauce. These types of products are often used as more of an after thought after the main meal is served, but if they are made improperly it can really put a damper on the meal. If they are made unsafely the results could create serious or even death. When high quality wet mills are used for making food products, the desired capacity of product can be achieved in just a single pass. This avoids over processing, and saves a lot in the way of machine wear and production resources.

An efficient wet milling operation can reduce capital equipment costs by up to 70 percent over other machines, and wasted product is greatly reduced during the processing stage. When high shear wet milling is used, additional containment facilities are often unnecessary and the process is a wise choice for heat sensitive ingredients as the liquid that is part of the wet milling slurry helps remove heat that is created by the milling process.

In the food industry, wet milling often begins with corn, then continues on to make many different products. To start, feed material is steeped in water to soften the seed kernel and separate its components. A type of corn known as dent corn is the most common one used in wet milling, and is made into food starch, high fructose corn syrup, animal feed and ethanol. Another type of corn known as waxy corn is also used in wet milling to make thickeners and emulsifiers for different food products. The corn kernels are milled coarsely into different components, then a slurry is formed so the germ, fiber and gluten can be separated and sent through different processes.

The real purpose of wet milling in the food industry is to blend and emulsify the various components of a product into the proper concentration and texture that makes that product unique. With products such as mayonnaise, barbecue sauce or yogurt, it is crucial to have the end product the proper consistency for consumers. Wet milling helps to simplify the production process, which not only gets the products out the door and onto store shelves sooner, it saves on resources in the manufacturing facility.

An efficient wet milling machine is also easy to clean and is designed to maintain the highest food safety standards. Mixing of ingredients in a commercial setting always has the potential for glitches and defective batches, which is why high quality equipment is a must. With food products, the quality of the machinery and finished product is of paramount importance. This is why a high quality wet milling machine is important to make different sauces and spreads in large quantities.

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Using equipment in a manufacturing process that is going to improve the efficiency of your operation is a key ingredient in running a successful business. Efficient equipment benefits the company as a whole in many different ways. When equipment runs efficiently, the machinery itself isn’t taxed as hard and usually has a longer life. In businesses that require different materials to be mixed to create an end product, the mixing equipment used is of the utmost importance. Whether the end result is a powder, solid or liquid, it must be mixed properly and to the right consistency to meet specifications and be delivered to the marketplace as intended. For some liquid products, wet milling equipment is used to emulsify the mixture so it is the perfect consistency.

Wet milling is used often in the food industry to make corn-based products or other sauces, creams and spreads. When a high quality, efficient wet milling machine is used as part of the production cycle, production is improved in a few different ways. Wet milling generally includes the creation of a slurry, effectively wetting the product as part of the process.

In standard mixing, small and lightweight product called “fines” are often produced when product passes between different stages within a production cycle. With wet milling, the fact that the product is wet during the process cuts down on the risk of fine generation and wasted materials are reduced. Heat sensitive materials work well in an efficient wet milling process because the temperature of the materials is reduced when the liquid is added and the slurry is created. This helps eliminate an entire step and is one more way that wet milling is an advantage to overall production.

Anytime waste can be eliminated or reduced in any type of production setting, expenses are reduced and it can have a filter effect all the way through the business and onto the customers. Efficient wet milling equipment means the batches of product will be mixed correctly more often, the machines will last longer and employee overtime can be cut back, saving the company money. When the process stream is optimized with high efficiency wet milling equipment, the cost of raw materials will decrease simply due to increased efficiency in the product yield. The benefits realized by wet milling as part of the production process also gives added flexibility to those in charge of scheduling.

Along with the quality of the product, improved customer relations and reduced expenses, freedom in scheduling the production of the facility is a premier benefit of wet milling. With fewer mistakes, faster product creation and improved quality, the production equipment will be available more often to fill new orders and expand the business. The wet milling equipment and other mixing equipment can be used to explore new markets, or take on larger orders from existing markets. When an efficient wet milling operation is set in place, capital equipment costs may be reduced by as much as 70 percent.

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Inline mixers or in-line mixers are used in the chemical industry for a variety of different functions. Many different businesses from many different industries use inline mixers to make complex chemical creations that end up being brand name products on store shelves.

Generally, mixing equipment is used to combine liquids with solids, liquids with liquids or solids with solids to change the structure of the materials and make the desired product. In-line mixers are actually a part of the process line and are set up before or after a homogenizer or disperser. This characteristic helps to simplify and speed up the entire chemical mixing process to make the production line more efficient. Inline mixers also help improve the viscosity of different products, as well as the particle distribution within a suspension.

Some of the uses of in-line mixers in the chemical industry include different pigments, automotive coatings, resins, calcium carbonate, paper coatings, ink, paint, carbon black, Cab-o-sil, polyvinyl alcohols and bentonite clay.

With automotive coatings, it’s easy to see the influence of in-line mixers as you drive the streets or walk through a dealership. Cars are available in a multitude of different shades and colours, and before the final coating finds its way onto the surface of the car, it likely went through an inline mixer as part of the process to mix the chemicals sufficiently. Calcium carbonate is best known in the form of blackboard chalk, but it also created for chemical purposes with the help of inline mixers. Calcium carbonate can be created by combining carbon dioxide and calcium hydroxide. This mixture is known as precipitated calcium carbonate and the particles are very fine and controlled. Variations of calcium carbonate can also be made from marble or limestone and used for different applications.

In-line mixers also process diatomaceous earth or DE, which is a talc type of powder with an off-white colour. DE is actually the fossilized remains of marine phytoplankton and is processed by inline mixers for use in the food industry. DE is added to many grain-based foods to help keep bugs away. Polyvinyl alcohol is a cream coloured or white powder that is created in in-line mixers and added as a moisture barrier for supplement tablets or other foods that must be protected from excess moisture.

Carbon black is a product that in-line mixers help to make and is used in a variety of different applications. It looks like a black, fine powder and about 90 percent of it is used in making rubber products like tires. Carbon black is also used in different pigments, plastic products, printing inks and coatings. The use of inline mixers in the chemical industry will help to make more efficient production lines, higher quality products and financial savings over older methods. Mixing chemicals is an exact, sometimes dangerous science, and having your process set up with in-line mixers to do the job will only benefit the business in the end.

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Whether your business is a busy office, a large factory or an open field, the equipment and processes used must be efficient for the business to succeed. Efficiency is a crucial factor in all forms of business across every industry. If the business requires any mixing of different products to create your end product, efficiency becomes even more important. Using efficient mixing equipment such as homogenizers or high shear mixers provides many benefits to a business, the most important being a higher quality end product. Once you have installed mixing equipment that results in a superior product for your customers, other benefits are sure to follow.

One of the main characteristics of efficient mixing equipment like high shear mixers is that time is shaved off of the process without having to sacrifice quality. A faster mixing process means the customers will get their products sooner, the life of the mixing equipment itself is extended, and more orders can be handled over the same period of time. Basically, high shear mixers and other efficient mixing equipment gives company officials more freedom in scheduling, which will result in repeat business, savings on resources and increased profits over time.

High shear mixers, homogenizers, high speed dispersers and other mixing equipment is a common sight for companies that make a wide variety of products. Mixing equipment must be used in the food industry to make products such as fruit blends, gelatin, powdered eggs, cocoa, ketchup, mayonnaise, starches, pasta sauce, yogurt mixes, syrup, salad dressing and tomato paste. In the cosmetics industry, mixing equipment is used for lotions, creams, shampoo, conditioner, make-up bases and toothpaste. Vitamins, bentonite clay, antacids, antibiotics and other medications use mixing equipment in the pharmaceutical industry, and mixing equipment is always used for any number of chemical mixing jobs. Any time you’re in the grocery store, pharmacy, car dealership, department store or home improvement store, you’re sure to see products that were created with the help of mixing equipment.

There are a handful of important factors to consider when purchasing high shear mixers and other mixing equipment for your business. Not just any old machine is going to give you the results you need to compete. Purchasers should look for mixing equipment with low shear rotor-stator mixing heads that will uniformly maintain suspensions during the mixing process.

Mixing equipment with discharge jets will create a top to bottom rollover and mixers that won’t create a liquid vortex mean no unwanted air entrainment. No air entrainment aids in the cleaning of the tank, which speeds up the time it takes to be ready for the next order, and the top to bottom rollover removes the inefficiency of the radial flow pattern that’s a trademark of traditional agitators. Efficient mixing equipment eliminates dead mixing areas inside the mixing vessel and improves the rate of heat transfer significantly. If a business takes the time to do diligent research and consider all of the important factors necessary to find top quality mixing equipment, the entire production process will benefit as will the company bottom line.

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A homogenizer is a piece of equipment that is used to achieve homogenization with two or more substances. Homogenization refers to making a mixture the same all the way through. Milk is one product that most people will recognize as using homogenization, but it certainly isn’t the only one. Homogenizers are used in many different industries, including the pharmaceutical industry, food and cosmetics.

All different types of cosmetics must be made into a homogenous mixture and homogenizers help to make that happen. In the cosmetics industry, homogenizers are used for products such as creams, face and skin lotions and sunscreens. Many cosmetic companies choose to use homogenizers as part of the cosmetic making process because it makes it easier to achieve the required particle sizing within the finished product. Efficient homogenizers have the capacity to fit into virtually any process stream, even if it is already in place. A homogenizer is also a practical choice when heat sensitive materials are used, which are often the case with cosmetics. An efficient process creates benefits for everyone involved, including the cosmetic company and the customers.

With products such as creams that must be absorbed into the skin to work effectively, homogenizers help to reduce the particle size and make absorption more efficient. If an effective homogenizer isn’t in place for such products, a company can lose large amounts of money due to product returns, and subsequent poor word of mouth advertising. Customers who didn’t like the product may also switch to a different brand and affect future sales. With a homogenizer, creams are absorbed as advertised and customers will keep coming back. Other cosmetic products that benefit from homogenization include shampoos, nail varnishes and different mixtures that contain oils to create the texture you want.

The end result is also a stable product, unlike some other types of stirrers or mixers. Stability in the end product gives it a longer shelf life, while maintaining the same quality as when it was first created, and homogenizers help achieve this result. A long shelf life means that products that aren’t selling quickly for whatever reason can still be sold, with less wasted product.

The cosmetic industry is one that regular customers take very seriously, and if the products they put on their faces, in their hair and on their skin are not up to par, it can mean substantial losses for individual companies. Homogenizers help to create superior end products, which are the most important thing, but it isn’t the only thing. Once a homogenizer is added to the production process, the efficiency of the product creation is increased, which means less wear and tear on machines, less employee overtime and a faster time to market for specific products. It isn’t often that a piece of equipment can increase the speed of production as well as the quality of the finished product, but homogenizers make that happen in the cosmetics industry.

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A process that is included as part of the production line for mixing and emulsifying different materials or ingredients into one product is powder dispersion. A high speed disperser is a valuable for any company that mixes product for the food industry, cosmetics or personal care industry, pharmaceutical industry or for chemical applications.

Efficient powder dispersion equipment is a must for a higher quality end product, and to make the process of creating the product more efficient. When it comes to powder dispersion for chemical applications, the process can be used for products such as airplane de-icer, oilfield products, paints, drywall compounds, oxides, pigment stabilizers, detergents, resins, ink and carbon dispersion.

These chemical applications are used in a wide variety of products found across many different industries. Depending on the particular product and volume of product that is being mixed and created, companies will look for a high speed disperser with characteristics to fit the specifications of the job. If you are running a large job that requires a high yield and high concentration of materials, your powder dispersion equipment should be set up to reflect that.

A high speed disperser with high shear capabilities is ideal when working with materials that are difficult to wet. Setting up a high speed disperser inline as a part of the process stream enables a continuous feed and output of product that greatly enhances production.

The use of efficient powder dispersion equipment as part of the production line helps to create a vacuum that allows inline concentrations up to 25 percent by weight to be created with just a single pass. This helps to reduce air entrainment in the product, increase the product yield and eliminate or drastically reduce waste. When you can utilize a high speed disperser that cuts down on the waste produced during production, the entire process may be streamlined to benefit both the manufacturing company, the customers and the end users of the product.

A quality high speed disperser is able to wet those hard to wet materials to a degree that makes the overall yield greater for the same amount of raw materials. Once the yield can be maximized, savings on powder ingredients is realized and the over processing that is common with many conventional dispersing processes can be eliminated. The single pass capabilities of high speed powder dispersion equipment save time, and in a production setting, time means financial savings and opportunities for the company.

The fact that less time is required means the powder dispersion equipment can be used to take on new orders within the chemical industry. The efficiency of high speed disperser equipment also helps to ensure that batches won’t have to be mixed again because the proper ratio and consistency of materials is where you want it to be more often. Consistency in batch to batch processing through efficient powder dispersion is what enables the process to continue without delay or issues with product quality.

Maximize your production yields by using state-of-the-art Homogenizers in your manufacturing processes.