ultrasonic homogenizer

Types of ultrasonic homogenizers

The ultrasonic homogenizer is a device that disperses solid particles in liquid in the form of a homogeneous emulsion using high-frequency sound waves. Ultrasonic devices vary in design and functions, but all models share the same working principle. Here are some common types of ultrasonic emulsifiers.

• Ultrasonic Cell Disruptors: Also known as ultrasonic homogenizer cell disruptors, they are primarily used for breaking open cells to release cellular components for biological research and molecular analysis. Cell disruptors work by applying short bursts of high-frequency sound waves to cell suspension. The generated energy causes mechanical shear forces that break the cell walls, membranes, and matrices to release the contents inside the cells.
• Ultrasonic Probe Homogenizers: They are handheld or portable devices with a probe or sonotrode attached to a generator and control unit. The probe is immersed in the liquid sample to be homogenized, and ultrasonic waves are transmitted through the probe to generate high shear forces that homogenize the sample. Ultrasonic probe homogenizers are suitable for small batch samples, spot treatment, and laboratory applications.
• Ultrasonic Bath Homogenizers: Also called ultrasonic cleaners, are devices that use ultrasonic waves to homogenize samples submerged in a liquid-filled bath. The baths create uniform cavitation fields that process multiple samples at once. Bath homogenizers are limited to low-power applications, and users have little control over parameters.
• Ultrasonic Tip Homogenizers: These are handheld devices featuring a generator and an adjustable homogenizing tip. The homogenizing tip is dipped in the target sample liquid, and the device is turned on to start homogenization. The tips can vary in size and shape depending on the application. Tip ultrasonic homogenizers are ideal for processing small-volume samples in the range of milliliters and microliters.

Specifications & maintenance of ultrasonic homogenizers

The main specifications to consider when looking for ultrasonic homogenizers for sale are the frequency and power output, as well as the volume. These are also the main ultrasonic homogenizer specifications buyers need to pay attention to.

The general rule is that more power and higher frequencies will produce finer emulsions. It is also essential to note that the ultrasonic homogenizer for the tissue sample will differ in power and frequency from the ones used in the chemical industry or for food.

Ultrasonic homogenizers usually work in the watt-range of 400 to 6,500. The higher the wattage, the greater the power and efficiency. The ultrasonic homogenizer with a capacity of 400 to 500 watts is generally used for low-volume samples. For more excellent volumes, ultrasonic homogenizers with power outputs of at least 1,000 watts and higher are needed.

For best results, buyers need to ensure that the ultrasonic homogenizer's frequency is compatible with the samples. An ultrasonic homogenizer for tissue disruption will have a frequency of 20 kHz to 25 kHz because cell walls are denser and require more significant cavitation. A homogenizer used for food or emulsions in the cosmetic industry will have a frequency of 15 kHz, which is more effective for breaking oil molecules.

The maintenance of the ultrasonic homogenizer is quite easy. Most devices come with a cleaning solution that prevents debris build-up. If users follow the manufacturer's cleaning instructions and maintain the unit's integrity, it will last for many years. Some manufacturers claim their devices can last up to ten years with the right care.

The ultrasonic homogenizer parts that need to be cleaned regularly to prevent any build-up are the probe, cup, and flushing channels. Users can use ultrasonic cleaning solutions, such as detergents, solvents, or preservatives, to keep the probe and cup clean. Using warm water and the cleaning solution is usually enough. Rinse with distilled water and air dry.

It's essential to keep the flushing channels free of debris. A brushed wire is usually included in the accessories to clean the flushing channel. Users should run the channels under running water while using the brush to unclog any debris or build-up.

The ultrasonic homogenizer manual should give more details about specific cleaning solutions and more information about the accessories that may be included for cleaning.

Application of Ultrasonic Homogenizers

Ultrasonic homogenizers are widely used in various industries for different applications. The food industry uses ultrasonic homogenizers for emulsifying fat molecules. The process results in fat molecules of equal sizes. Equal sizing of fat molecules leads to better distribution and stability of food products like milk, salad dressing, and cream.

Ultrasonic homogenizers are also used in the pharmaceutical industry for drug formulation and delivery. The devices break down and disperse drug compounds to produce stable solutions. Antibiotics and anti-inflammatory drugs are some examples of drugs that use ultrasonic homogenizers during production.

Biotechnology industries use ultrasonic homogenizers to lyse cells and release intracellular components. The process creates stable dispersions of proteins, enzymes, and antibodies used in testing and diagnostics.

Cosmetics industries use ultrasonic homogenizers to create stable emulsions and dispersions for creams, lotions, and serums. The devices break down the particles and ensure uniformity in the final products. Ultrasonic homogenizers help cosmetics manufacturers improve the shelf life of their products by preventing separation.

Paint and coating industries use ultrasonic homogenizers to ensure even color distribution in their products. The devices break down aggregates to improve clarity and stability of paint and coating products. Ultrasonic homogenizers also improve the flow properties of paints and coatings for easy application.

Nanotechnology industries use ultrasonic homogenizers to produce nanoparticles. The devices help in formulating dispersions of nanoparticles in solvents used in catalysis, environmental remediation, electronics, and drug delivery systems.

How to Choose an Ultrasonic Homogenizer

Several ultrasonic homogenizer factors should be considered when choosing an ultrasonic homogenizer for specific applications, such as sample volume, quantity, and pressure required to disperse the samples.

• Sample Volume:

  Ultrasonic homogenizers are typically available in two formats: bench-top models and hand-held models. Bench-top models are suitable for homogenizing larger sample volumes—more than 10 mL. In contrast, hand-held models are ideal for smaller sample volumes—typically between 100 μL and 10 mL.

• Homogenizer Power:

  Different homogenizers produce varying power levels. Ultrasonic homogenizers, for example, produce more power than other homogenizers, such as blade or sieve homogenizers. Higher power levels are more effective at dispersing samples and achieving the desired outcome, but they may also create excessive heat that could affect the sample.

• Frequency:

  Ultrasonic homogenizers function at specific frequencies within the ultrasonic sound wave range. Common frequencies include 20 kHz, 30 kHz, 35 kHz, 40 kHz, and others. Some models even allow users to shift frequencies. Lower frequencies produce more powerful amplitudes and are ideal for breaking up tough samples, while higher frequencies are better for working with samples requiring gentle treatment.

• Temperature Control:

  Ultrasonic waves generate heat when the probe is working on the sample. Homogenizers with temperature control units allow users to maintain the sample's integrity by controlling probe dilation and cryogenic cooling.

• Accessories:

  Some homogenizers come with extra accessories to improve sample processing. For example, a sample cup with an interior well that disperses heat from the probe during the homogenizing process. Check which accessories are included with the homogenizer to ensure it comes with the necessary add-ons for hassle-free sample processing.

• Safety:

  Ultrasonic homogenizers can emit dangerous noise levels, which, if caught, can lead to serious health issues. Therefore, buyers must ensure that the machines they purchase have safety features such as noise level cut-off and probe holder locks during operation.

Ultrasonic homogenizer FAQ

Q1: What capacity ultrasonic homogenizer should B2B buyers get?

A1: Ultrasonic homogenizers come in different power levels, from portable units with around 100 watts of power to more powerful lab-scale models at 500 watts or higher. The more powerful the homogenizer, the larger the volume and higher the viscosity of the material it can process. For small batches of liquid up to 10 liters per hour, a unit with 300 to 500 watts should suffice. Ultrasonic homogenizers with one kilowatt or more are better for larger batches of 100 liters or more per hour. These also tend to cost more.

Q2: What are the main applications of an ultrasonic homogenizer?

A2: Homogenizers are crucial in material processing and manufacturing. They help achieve uniformity in liquids like emulsions, suspensions, and solutions. Ultrasonic homogenizers are widely used in the food industry to process items such as sauces, juices, dairy products, and emulsified dressings. Cosmetics, pharmaceuticals, and chemical industries also use ultrasonic homogenizers to make high-quality creams, serums, emulsions, antibiotics, vaccines, and chemical solutions. Ultrasonic homogenizers are also used to break down nanoparticles and synthesize nanomaterials in research labs.

Q3: What should buyers look for when choosing an ultrasonic homogenizer?

A3: First, buyers should determine the application–what material they will process. Buyers should also consider the capacity (volume) they need to process per hour and the device’s frequency and power. Next, buyers should get homogenizers made of corrosion-resistant or sterilizable material. If homogenizers are used in hazardous or sterile environments, the devices should come with explosion-proof or bio-secure designs. Consider the separator or filters used to segregate dispersed phases from the continuous ones, as this may affect the overall efficiency of the homogenization process.

Q4: Can an ultrasonic homogenizer be used for high viscosity samples?

A4: Yes. An ultrasonic homogenizer is suitable for processing materials with very high viscosity, such as polymer solutions and gels, due to its high power and speed. If the viscosity is extremely high, it is better to preprocess the material first by cutting it into smaller pieces or adding more liquid to thin it out.