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Process Plants
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The innovative process plants represent a consistent continuation of IKA's machine portfolio. IKA specializes in systems for continuous or discontinuous powder incorporation into liquids, mixing and dispersing plants for the production of emulsions and suspensions (Standard Production Plant and Master Plant), as well as dilution plants. In addition to these standard solutions, IKA also projects and builds customer-specified turn-key process plants. Here, we consider all aspects that are important when it comes to a successful and economical production: Optimal process runs and customized electric control, hygienic design, project-based materials selection, explosion protection, and individual customer requirements. The assembly & start-up of the process plants is carried out by professional IKA installation and process technicians as well as our electrical engineers. |
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IKA turnkey plants at a glance:
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The new, pioneer mixing concept of the Master Plant guarantees for highest product quality and extreme shortening of production times The heart of the plant is the dispersing machine DBI 2000/.. directly mounted to the vessel. The machine has a two stage design which, contrary to usual systems, does not force you to make compromises. 1st stage: Special pumping rotor for
2nd stage: Dispersing with an optimum generator for
Excellent and constant mixing of the vessel content is guaranteed by a special spiral agitator:
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The IKA DPV dilution plant is suitable for all those applications where two or more liquids are to be quantity-based and homogenously mixed by using a one pass operation. The continuous process enables a highly efficient and economical production. The core of the plant is a single-stage inline dispersing unit ULTRA-TURRAX®, which is sufficient for the most standard applications. When it comes to higher demands concerning dispersing quality, the homogenizer can be replaced by a three-stage machine DISPAX-REACTOR® or a colloid mill type MK. The ingredients are metered with a high accuracy into the dispersing unit by means of pumps that feature very stable characteristics. Various sensors and an electric control with optional upgrades for the process automation round out the entire unit. All devices of the plant are arranged on a common base frame as a compact skid with full piping and internal electrical wiring. The plant is tested for operation before delivery and the requirements for the installation on site are herewith minimized. After connecting the feed lines and utilities, the plant is ready for operation. The distinctive feature of the IKA dilution plant is the optimal procedure of the dispersing process. The phases to be mixed don't come in contact with each other until right before the dispersing tool. This entirely prevents unwanted reactions such as lump formation. The main application of the standard IKA dilution plant type DPV is the thinning of 70% lauryl ether sulphate (LES) down to a concentration of approx. 28% during the production of liquid detergents. Due to the delivery of concentrated LES and on-site dilution, transportation costs are greatly reduced so that a DPV plant is amortized in a short period of time. In addition, the unit provides high flexibility in the adjustment of the concentration as well as for the formulation of multiple ingredient mixtures. Whether it's utilized for the production of household dish liquid or of skin care products, the DPV plant has proven itself many times over. Depending on individual customer demands, the following options can be realized:
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The IKA mixing plant MHD essentially consists of the patented IKA inline mixing machine MHD, metering units, an electrical control system and a periphery which is customized to fit the customer's application. The MHD plant enables the dust-free mixing of liquids and solids (powders or granules) in a continuous process. The phases to be mixed are fed into the MHD machine in proportion to quantity, then mixed in the working chamber and subsequently dispersed, allowing for a ready final product to be produced in just one passage. The plant is able to process solids contents of up to 80% and mixtures with viscosities of up to 50,000 mPa?s. The funds invested into dosing are considerably lower than the purchasing costs for holding tanks and the appropriate mixing vessels with stirrers. Furthermore, the MHD plant offers great flexibility as any product quantities can be produced with a constant quality. As for electric control of the plant, different versions are available, depending on customer demands:
Advantages of the MHD plant:
The IKA MHD plants are suitable for a broad range of applications, particularly in the chemical, cosmetic, pharmaceutical and food industries. The following can be processed as liquid phases, among others: Water, oils, resin, kerosene, alcohols, liquid polymers, low to highly-viscous dispersions, molten urea, syrup and solvents. Other Information
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The IKA Master Plant homogenizing and emulsifying system is a universal mixing system developed for the production of emulsions and suspensions in the pharmaceuticals industry in particular, but also in the food, beverages, cosmetics and chemical industries. The plant is GMP-compliant and guarantees a high degree of precision, safety and reproducibility of the results. The Master Plant system enables the direct feed of solids and liquids, mixing and dispersing of the vessel contents, heating or cooling of the product and processing under vacuum or under pressure. The required degree of homogenization and particle crushing is achieved by circulation of the mixture via a DBI dispersing unit integrated into the base of the vessel. The proven technology of this patented IKA DBI homogenizer involves a two-stage operation:
A special mixing element which switches the direction of rotation ensures thorough, uniform, vertical and horizontal mixing. For the processing of products of relatively high viscosity – up to 100,000 mPas – a counter-rotating stirrer system is recommended, comprising an outer stirrer and inner stirrer. They rotate in opposite directions and can be heated and cooled. The alternative spiral stirrer can be fully heated or cooled and is suitable for viscosities up to approx. 30.000 mPas. Additional flexible PTFE scraper attachments prevent deposits adhering to the vessel wall. After processing, the product can be discharged completely without further pumping. The process is controlled via a modern touch-screen monitor. The electric control can be extended as required. The complete system is also available in an explosion-protected version. The Master Plant MP series comes in 9 sizes ranging from 10 to 4,000 liters. Advantages of the mixing system Master Plant MP:
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The new "Standard Production Plant" SPP... is a standardized mixing and dispersing plant. It can be used for all essential processes. Due to the special vessel geometry the Standard Production Plant got the advantage of a lower construction height. Optionally the vessel cover can be opened by means of a tilting device, thus allowing an easy access to the vessel internals for maintenance work or visual checks. For emulsifying or suspending the plant can be delivered with 2 different types of dispersing machines: the high-sophisticated multi-functional DBI 2000/.. (same as in the Master Plant series) or the cost favourable ULTRA-TURRAX UTL 1000/... Both dispersers are directly mounted to the vessel and can be used for dispersing as well as for mixing. Regarding its equipment, the Standard Production Plant is limited to what is necessary for the process and contributes to a high mixing quality. When we developped this plant, special attention was paid to a favourable price-performance relation, but at the same time keeping a high quality level. Other Information
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Product Name : MHD-Plant
Advantages of the MHD plant:
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The IKA DPV dilution plant is suitable for all those applications where two or more liquids are to be quantity-based and homogenously mixed by using a one pass operation. The continuous process enables a highly efficient and economical production. The core of the plant is a single-stage inline dispersing unit ULTRA-TURRAX®, which is sufficient for the most standard applications. When it comes to higher demands concerning dispersing quality, the homogenizer can be replaced by a three-stage machine DISPAX-REACTOR® or a colloid mill type MK. The ingredients are metered with a high accuracy into the dispersing unit by means of pumps that feature very stable characteristics. Various sensors and an electric control with optional upgrades for the process automation round out the entire unit. All devices of the plant are arranged on a common base frame as a compact skid with full piping and internal electrical wiring. The plant is tested for operation before delivery and the requirements for the installation on site are herewith minimized. After connecting the feed lines and utilities, the plant is ready for operation. The distinctive feature of the IKA dilution plant is the optimal procedure of the dispersing process. The phases to be mixed don't come in contact with each other until right before the dispersing tool. This entirely prevents unwanted reactions such as lump formation. The main application of the standard IKA dilution plant type DPV is the thinning of 70% lauryl ether sulphate (LES) down to a concentration of approx. 28% during the production of liquid detergents. Due to the delivery of concentrated LES and on-site dilution, transportation costs are greatly reduced so that a DPV plant is amortized in a short period of time. In addition, the unit provides high flexibility in the adjustment of the concentration as well as for the formulation of multiple ingredient mixtures. Whether it's utilized for the production of household dish liquid or of skin care products, the DPV plant has proven itself many times over. Depending on individual customer demands, the following options can be realized:
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Contact Us
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IKA Group Ms. Nandini Ramesh (Marketing Executive) No. 814 / 475, Survey No. 129 / 1, Mysore Road, Kengeri Bengaluru - 560 060, Karnataka, India |
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