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Dissolvers 

Dissolvers are used for high-quality mixing or dissolving of various products. With their help, you can create suspensions and solutions of ingredients that would ordinarily not be so easily soluble. In the food industry, dissolvers are used when making ketchup, mayonnaise, sauces, mustard, dairy products, fruit juices, and purees.

 

Synonyms: Dissolver, mixer, mixing device, mixers and dissolvers.

 

List of products made by means of a dissolverpastes, solutions of salt, sugar, flavor additives, pectins; flavor enhancers; thickeners; marinades; syrups; cosmetic creams and pastes; pharmaceutical products in the form of emulsions, suspensions, pastes, or creams.

Dissolvers are machines equipped with a special mixing mechanism to ensure a more complex process of mixing. They can include several mixing devices simultaneously, and they can be equipped with features to automate the mixing process.

With the help of dissolvers the following processes are carried out: 

Process

Description of process

Examples of products obtained

Mixing

Mechanically combining substances that are initially separate in order to obtain a homogeneous mixture from them

Confectionery creams, fillings, sauces, ketchup, mustard, fruit juices, purees, pigments of various colors, as well as elements in cosmetics

Dissolving

Mixing solid particles with liquid at the molecular level until a homogeneous fluid results, where no particles or suspensions remain visible

Brines, marinades, syrups

Dispersion

 

Grinding of solids and uniformly distributing them through a liquid or gas, provided that they do not react with one other

 

Sauces, purees, fruit juices, as well as aerosols in the cosmetics and pharmaceutical industries

 

Emulsification

Mechanical mixing of liquids that are difficult to mix, creation of “fat-in-water” or “water-in-fat” substances

Mayonnaise, sauces, spreads

Homogenization

Mixing solids in a fluid medium until they are uniformly distributed throughout the medium

Yogurt and other dairy products

 

 

 

How dissolvers are classified:

Type of mixing device

Mixing speed

Mobility

blade type

high speed

stationary

plate type

low speed

moving

folding

 

 

propeller type

 

 

turbine type

 

 

anchor type

 

 

frame type

 

 

conical

 

 

milling

 

 

 

Dissolvers featuring different mixing devices can differ significantly in their design, but they share the same principle of operation: the operating part repeatedly moves inside a volume filled with a substance.

Mixing takes place directly within the dissolver’s tank.

A dissolver generally consists of a reservoir and a powerful mixer shaped to ensure that there are no dead zones (unmixed areas) when the input ingredients are mixed.

The mixer itself can be of various designs (plate/bladed, propellor, etc.). The type of mixer determines the method and intensity of mixing and is selected based on your specific process requirements.

A dissolver can also consist of two reservoirs. In such dissolvers, the main solution, e.g. a salt solution, is prepared in the first tank. When the solution is drained into the second container, additional ingredients are then added to it, namely ingredients that are more volatile and prone to evaporation like flavors, spices, and essences. It is in this way that you can obtain high-quality concentrated marinades and brines, where flavorings are uniformly distributed and their properties are maximally preserved.

The drive part (geared motor) can also be different, depending on the required power and the required speed of the mixing part.

Most effective are vertical dissolvers with a cylindrically shaped tank.

Dissolvers with vertically mounted mixers can have multiple tanks (bowls) of varying volume that can be switched out.

High-capacity dissolvers are mounted on their own frame (frame-type) to ensure stability and convenience during mixing.

High-speed dissolvers are generally used for liquid products. The speed at which they rotate reaches up to 1500 RPM, and in some cases up to 3000 RPM. Low-speed dissolvers, with a low rotation speed (under 60 RPM) are used for viscous products and are generally frame-type and anchor-type.

In terms of mobility, dissolvers can be either stationary or mobile. Stationary dissolvers are attached to the floor or a wall, and the moving elements are installed on the bowl (tank). Mobile dissolvers can be moved to containers that are fixed in place. A subtype of the stationary dissolver is the rotary dissolver, which works with several stationary containers in turn.

If your process requires that the ingredients be heated, the dissolver can be optionally equipped with electrical heating elements and a  heat-insulating jacket.

The temperature at which the product is heated depends on the product’s heat resistance, density, and viscosity.

 

Dissolvers are manufactured from high-quality stainless steel, which meets sanitary standards and norms for working with foodstuffs, cosmetics, and pharmaceutical products, and it also ensures a longer service life for the equipment.

 

Dissolvers work according to the following principle:

One or more products are placed into the tank, and then the mixer is lowered manually or mechanically into the tank. The mixing speed depends on the volume and viscosity of the product. During the mixing process, additional ingredients in dry or liquid form, and in quantities large or small (e.g. colorings, flavor additives and enhancers, spices, etc.) can be added to the main product.

 

Process and products obtained using dissolvers:

Initial product

Process

Final product

Salt, sugar, flavor additives and enhancers, essences, pectins, thickeners

Dissolving

Marinades, brines, syrups,

Liquid and solid components in the confectionery industry, pharmacology, and cosmetology

Emulsification

Cosmetic and pharmaceutical emulsions made from insoluble ingredients

Viscous components in pharmacology, cosmetology and the food industry

Homogenization

Homogeneous emulsions, creams, and pastes

 

 

The various types of dissolvers:

Combined, closed type

Combines the grinding of solid particles with the mixing thereof in a liquid medium

Stationary, closed type

Can feature two mixing devices at once: a low-speed anchor-type mixer  and a high-speed milling-type mixer; the speed of rotation and the heating/cooling product temperature can be controlled.

Triple-drive, closed type

Features three mixing devices: disc, screw, and anchor with scrapers; used to disperse solid particles across a viscous liquid

Vacuum type

Can feature up to three mixing devices; used to mix dry ingredients in liquids of low viscosity

Wall type

Fixed to the wall and features switchable stirrers, changeable mixing speeds, and movable tanks.

High-speed

Operates at higher mixing speeds; features a hydraulic lift.

Laboratory

Small, with a capacity of 5–20 liters

 

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