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Module Overview

The Vacuum Emulsification Process Module achieves efficient mixing and stable emulsification of oil and water phases through vacuum deaeration, high-shear homogenization, and precise temperature control, producing uniform and stable emulsions or creams. The system enables fully closed production from pre-mixing, homogenization, deaeration, to filling, compliant with GMP, ISO 22716, and FDA 21 CFR Part 211 standards, ideal for sterile or high-active-ingredient formulations.

Core Components

Raw Material Pre-Treatment Module

Oil phase tank with magnetic stirring + nitrogen blanketing (anti-oxidation)

Water phase tank with high-speed dispersion + heating (dissolves thickeners/emulsifiers)

Main Emulsification Module

Vacuum emulsification vessel (50L–5000L) with sight glass, sampling valve, and vacuum defoamer

Low-speed anchor stirring (10–60 rpm) + high-shear homogenizer (linear speed 20–40 m/s)

Optional colloid mill integration

Vacuum & Temperature Control Module

Water-ring vacuum pump/dry screw vacuum pump (ultimate vacuum ≤5 mbar)

Dual-channel thermal fluid units

Automation Control System

PLC + HMI touchscreen with preloaded formulation recipes

Intelligent coordination: Homogenizer-vacuum pump interlock to prevent dry-running damage

Filling & Finished Product Module

Vacuum transfer pipelines, buffer tank (with slow-speed stirring), automatic filler (±1% accuracy)

Cleaning & Environmental Module

Fully automated CIP system: Multi-directional spray balls for dead-angle coverage, ≥90% cleaning fluid recovery

RTC-Emul-AP Series Lifting Emulsifier

Lifting design with high-precision homogenization and adaptable operation.

RTC-Emul-VP Series Vertical Emulsifier

Stable homogenization and precise emulsification enhance product quality.

RTC-Emul-KP Series Lifting Emulsifier

Lifting mechanism design ensures flexible operation and stable homogenization, improving production precision and efficiency.

RTC-Emul-MP Series Lifting-Tilting Emulsifier

Lifting-tilting mechanism facilitates easy cleaning and high-precision homogenization, ideal for high-viscosity materials.

RTC-Emul-LP Series Top-Homogenizing Lifting-Tilting Emulsifier

Top-mounted homogenization with lifting-tilting operation achieves ultimate mixing performance for challenging processes.

AES Online Dilution Unit

AES Online Dilution System

Rapid Dilution Solutions for the Cosmetic & Household Chemicals Industry Engineered to overcome challenges in conventional dilution processes, delivering optimal precision and efficiency.

AES Online Dilution Unit

AES Online Dilution System

Rapid Dilution Solutions for the Cosmetic & Household Chemicals Industry Engineered to overcome challenges in conventional dilution processes, delivering optimal precision and efficiency.

RTC-Emul-AP Series Lifting Emu

Lifting design with high-precision homogenization and adaptable operation.

RTC-Emul-VP Series Vertical Em

Stable homogenization and precise emulsification enhance product quality.

RTC-Emul-KP Series Lifting Emu

Lifting mechanism design ensures flexible operation and stable homogenization, improving production precision and efficiency.

RTC-Emul-MP Series Lifting-Til

Lifting-tilting mechanism facilitates easy cleaning and high-precision homogenization, ideal for high-viscosity materials.

RTC-Emul-LP Series Top-Homoge

Top-mounted homogenization with lifting-tilting operation achieves ultimate mixing performance for challenging processes.

Key Process Control Points

Vacuum Deaeration & Foam Control

● Precise vacuum adjustment (-0.08~-0.1 MPa), ≥95% deaeration efficiency, eliminating bubbles to prevent oxidation or filling defects

● Online foam sensors linked to vacuum pumps for dynamic defoaming

High-Shear Homogenization

● Multi-stage homogenizer control (rotor-stator design, 1000–10000 rpm adjustable), D90 particle size ≤5μm (nanoemulsions: 100–500 nm)

● Real-time shear energy monitoring (torque sensors) to prevent localized overheating and ingredient degradation (e.g., pharmaceutical creams)

Precision Temperature Control

● Jacketed emulsification vessel (double/triple layers), PID temperature control (±0.5°C), rapid heating/cooling (oil melting + water phase dissolution), thermal fluid/ice-water circulation for high-viscosity materials (e.g., high-wax-content creams)

Emulsion Stability Control

● Online viscometer+ conductivity meter to monitor phase transition, auto-adjust stirring speed and homogenization intensity

● Closed-loop pH control (acid/alkali auto-dosing) for formulation stability (e.g., personal care products pH 5.5–6.5)

Cleaning & Sterility Assurance

● Full CIP/SIP system (acid/alkali cleaning + pure steam sterilization), dead-leg residue ≤0.1%

● 316L stainless steel, Ra ≤0.4μm mirror finish, compliant with 3D-ASTM E2700 cleanliness standards (pharmaceutical grade)

Data Traceability & Compliance

● Automated electronic batch records with critical parameters (vacuum level, homogenization time, temperature curves)

● Role-based access + audit trails aligned with EU GMP Annex 11 data integrity requirements

Industry Applications

Cosmetics

Creams, lotions, sunscreens

Personal Care

Shampoos, serums, body washes

Pharmaceuticals

Topical ointments, nanoemulsions, softgel capsules

Fine Chemicals

Specialty lubricants, electronic coating materials

Core Advantages

High Efficiency & Energy Savings

Vacuum deaeration reduces emulsification time by 40%; heat recovery cuts energy use by 25%

Flexible Configuration

Modular design with expandable homogenization units

Safety & Compliance

ATEX explosion-proof certification (solvent-based formulations), sterile-grade design (pharmaceutical ointments)

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Module Overview

Core Components

Key Process Control Points

Industry Applications

Core Advantages

Service Support

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