Dissolving: High-Performance Dissolvers
Ultrasonic dissolvers are powerful mixing tools used in various industries to disperse and homogenize powder-liquid slurries with unparalleled efficiency. Unlike traditional mixing methods, ultrasonic dissolvers utilize high-intensity ultrasound waves to create intense cavitation and micro-turbulence within the liquid. These effects of cavitation and turbulences lead to a rapid and uniform dispersion of particles. Therefore, ultrasonic dissolvers are particularly effective for breaking down agglomerates, reducing particle size, and achieving consistent distribution of solids within the liquid medium. The result is a homogenous, finely dispersed mixture that meets the stringent quality standards of modern manufacturing processes.
Dissolving with Power Ultrasound
Dissolvers by Hielscher Ultrasonics use the mechanical forces of acoustic cavitation in order to disperse and deagglomerate powders into a colloidal suspension. Ultrasonic dissolvers are widely used in the paint and pigment industry, where pigment powder is dispersed in a binder. Intense ultrasound waves break agglomerates into uniform primary particles. Ultrasonicators are an established dissolving technology used in paint manufacturing as well as in the chemical, plastic, and food industry.
- Deagglomeration of powders
- Preparation of brines
- Saturated and supersaturated solutions
- Dissolving sugar in food formulations
- Dispersion of paint pigments
- Mixing of reagents
- Dissolving tablets and capsules (drug release test)
The Ultrasonic Dissolver – Equipment and Workings Principle
The core of a high-performance sonicator for dissolving consists of an ultrasonic generator and transducer. The generator sends electrical signals to the transducer that converts these signals into mechanical vibrations. The transducer is equipped with an ultrasonic probe or sonotrode, which is metal rod commonly made of high-quality titanium alloy. The ultrasound waves are delivered through the sonotrode into the liquid.
Using high-intensity ultrasound, an ultrasonic dissolver creates acoustic cavitation in liquids and slurries, resulting in intense agitation and high shear forces. These ultrasonic or sonomechanical forces facilitate rapid and thorough mixing of even the most challenging powder-liquid combinations. The ability to achieve micron- and nano-scale particle distribution as well as uniform dispersion makes ultrasonic dissolvers indispensable for industries that demand precise and consistent product quality.
The versatility of ultrasonic dissolvers extends beyond simple mixing and dispersion. They can also be employed for various additional processes, including emulsification, disintegration, degassing, and sonochemical reactions. This multifunctional capability makes ultrasonic dissolvers a valuable asset across a wide spectrum of industrial applications, from pharmaceutical formulation and cosmetic production to the manufacturing of specialty chemicals and advanced materials.
How Does an Ultrasonic Dissolver Work?
Ultrasonic dissolvers harness the power of high-intensity ultrasound waves, which are defined as high-frequency sound waves above the audible range of humans. When powerful ultrasound waves are coupled into a liquid, they induce intense acoustic cavitation and micro-turbulence within the liquid medium, facilitating the rapid and uniform dispersion of particulate matter. The ultrasound waves are transmitted through the sonotrode (also ultrasonic tip or probe) as mechanical vibrations into the liquid medium. As the ultrasonic waves propagate through the liquid, they create alternating high-pressure and low-pressure cycles. During the low-pressure cycle, minute vacuum bubbles or voids are formed in the liquid. Over several alternating high-pressure / low-pressure cycles, the cavitation bubbles grow until the stage, at which they cannot absorb any additional energy. When the cavitation bubbles have achieved their maximum size, they implode violently in a phenomenon known as cavitation. The implosion of these cavitation bubbles generates locally extreme intense energy, resulting in micro-jets, high-shear and micro-turbulence that disperse and disintegrate agglomerates and particles within the liquid. The liquid jets accelerate the particles within the medium so that they collide with each other and shatter into small pieces.
Ultrasonic cavitation induced by ultrasonic dissolvers facilitate the breakup of agglomerates, the reduction of particle size, and the uniform distribution of solids within the liquid. This process results in a finely dispersed mixture with enhanced homogeneity and stability, meeting the rigorous requirements of modern manufacturing and scientific applications. The ability of ultrasonic dissolvers to achieve micron- and nano-scale particle distribution and uniform dispersion makes them a preferred choice for industries that demand precise and consistent product quality.
What are Ultrasonic Dissolvers Used for?
The versatility and efficiency of ultrasonic dissolvers make them essential processing equipment in a wide range of industries and applications.
- For paint and pigment producers, ultrasonic dissolvers are crucial as ultrasound-assisted milling and dispersing of pigments delivers highly uniform particle sizes. At the same time, ultrasonic dissolvers ensure a uniform distribution of single-dispersed particles through the paint formulation. Since particle size and particle distribution are in-negotiable quality criteria for pigment master batches and final paint formulation, paint and pigment producers do not forgo the advantages of ultrasonic dissolvers.
For the same reasons, sonicators are well-established in the manufacturing of inks and ink-jet inks, too.
- In the pharmaceutical industry, ultrasonic dissolvers play a crucial role in formulating drug suspensions, preparing liposomal drug delivery systems, and producing nanoemulsions for pharmaceutical formulations. The ability of ultrasonic dissolvers to achieve fine particle size reduction and uniform dispersion is particularly beneficial for enhancing the bioavailability and stability of pharmaceutical products.
- In the cosmetic industry, ultrasonic dissolvers are utilized for creating stable emulsions, dispersing pigments and nanoparticles in skincare and makeup formulations, extracting bioactive compounds, and producing high-quality fragrances and essential oil blends. The precise and gentle mixing action of ultrasonic dissolvers ensures that cosmetic products maintain their desired texture, appearance, and performance, meeting the quality standards of discerning consumers and regulatory authorities.
- Within the chemical sector, ultrasonic dissolvers contribute to the production of specialty chemicals, adhesives, coatings, and catalysts, where achieving uniform dispersion and particle size control is critical for product performance and consistency. The ability to efficiently disperse powders into solvents, resins, or polymers enables chemical manufacturers to optimize their processes, reduce agglomeration, and enhance the quality and functionality of their end products.
- The food and beverage industry also benefits from ultrasonic dissolvers, using them for creating stable emulsions, dispersing functional ingredients, and producing nano-sized particles for food fortification and flavor encapsulation. With their ability to achieve precise mixing and dispersion without altering the nutritional or sensory properties of food products, ultrasonic dissolvers contribute to the development of innovative and high-quality food formulations.
Beside the above listed field of application, ultrasonic dissolvers are used in nanotechnology, biotechnology, botanical extraction, environmental remediation, and research laboratories, where the need for precise and efficient dispersion technologies is paramount. The diverse applications of ultrasonic dissolvers underscore their significance as indispensable tools for achieving optimal dispersion and mixing performance across various industries and scientific disciplines.
High-Performance Dissolvers for Any Volume
Hielscher Ultrasonics is specialized in the design, manufacturing and wordwide distribution of reliable high-power dissolvers, homogenizers and high-shear mixers, that use ultrasound and ultrasonic / acoustic cavitation to dissolve, disperse and deagglomerate powders and particles into uniform products such as paint, chemical, plastic, and food formulations. Hielscher dissolving equipment is available from compact laboratory batch devices to fully-industrial flow-through systems.
Read more about the mechanism of ultrasonic dissolving!
Highest Quality – Designed & Manufactured in Germany
The sophisticated hardware and smart software of Hielscher ultrasonicators are designed to guarantee reliable ultrasonic processing such as the production of (super-)saturated solutions, pigment formulations, and nano-dispersions with reproducible outcomes and in user-friendly manner.
Hielscher Ultrasonics systems are used worldwide in the production of well-known paint, chemical, and food producers. Proven to be reliable for the preparation with high efficiency of high-quality dispersions, colloidal suspensions and solutions, Hielscher ultrasonicators are not only used on laboratory scale, but mostly in the industrial production for dissolving applications. Due to their robustness and low maintenance, Hielscher ultrasonic processors can be easily installed, operated and monitored.
Hielscher Ultrasonics in Teltow, Germany is an owner-managed family business. Hielscher Ultrasonics is ISO certified. Of course, Hielscher ultrasonicators are CE compliant and meet the requirements of UL, CSA and RoHs.
Automatic Data Protocolling
In order to fulfil production standards (e.g., cGMP), production processes must be detailed monitored and recorded. Hielscher Ultrasonics digital ultrasonic dissolvers and homogenizers feature an automatic data protocolling. Due to this smart feature, all important process parameters such as ultrasonic energy (total and net energy), temperature, pressure, time, and date are automatically stored onto a built-in SD-card as soon as the device is switched on.
Process monitoring and data recording are important for continuous process standardization and product quality. By accessing the automatically recorded process data, you can revise previous sonication runs and evaluate the outcome.
Another user-friendly feature is the browser remote control of our digital ultrasonic systems. Via remote browser control you can start, stop, adjust and monitor your ultrasonic processor remotely from anywhere.
Want to learn more about the advantages of ultrasonic dissolving and homogenizing? Contact us now to discuss your dissolving process! Our well-experienced staff will be glad to share more information about ultrasonic dissolving applications, ultrasonic mixers and homogenizers including prices!
- high-performance ultrasound
- state-of-the-art technology
- reproducibility / repeatability
- reliability & robustness
- batch & inline
- for any volume
- intelligent software
- smart features (e.g., data protocolling)
- low maintenance, easy installation
- CIP (clean-in-place) / SIP (sterilize-in-place)
The table below gives you an indication of the approximate processing capacity of our ultrasonicators:
|1 to 500mL
|10 to 200mL/min
|10 to 2000mL
|20 to 400mL/min
|0.1 to 20L
|0.2 to 4L/min
|10 to 100L
|2 to 10L/min
|15 to 150L
|3 to 15L/min
|10 to 100L/min
|cluster of UIP16000
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Literature / References
- Siti Hajar Othman, Suraya Abdul Rashid, Tinia Idaty Mohd Ghazi, Norhafizah Abdullah (2012): Dispersion and Stabilization of Photocatalytic TiO2 Nanoparticles in Aqueous Suspension for Coatings Applications. Journal of Nanomaterials, vol. 2012.
- Zanghellini,B.; Knaack,P.; Schörpf, S.; Semlitsch, K.-H.; Lichtenegger, H.C.; Praher, B.; Omastova, M.; Rennhofer, H. (2021): Solvent-Free Ultrasonic Dispersion of Nanofillers in Epoxy Matrix. Polymers 2021, 13, 308.
- Vikash, Vimal Kumar (2020): Ultrasonic-assisted de-agglomeration and power draw characterization of silica nanoparticles. Ultrasonics Sonochemistry, Volume 65, 2020.
- Pohl, M. and Schubert, H. (2004): Dispersion and deagglomeration of nanoparticles in aqueous solutions. PARTEC 2004.