Ramp-up Slow and Insufficient Manufacturing Processes

Ultrasonication is a well-established process intensifying technique, which is used in many kinds of liquid applications such as homogenization, mixing, dispersing, wet-milling, emulsification as well as improving heterogeneous chemical reactions. If your production process is underperforming and does not achieve specific manufacturing goals, you might want to consider ultrasonication as process booster.

Ultrasonic Mixing, Homogenization, and Dispersion

Ultrasonication is a highly efficient technique to mix, blend, homogenize, disperse and emulsify solid-liquid and liquid-liquid systems. Ultrasonic high-shear mixers break particles and droplets and reduce their size efficiently so that a stable, homogeneous mixture is obtained. An important advantage of ultrasonic mixing is the effortless handling of liquids and slurries with very slow to very high, paste-like viscosities. Even abrasive particles are no problem for ultrasonic mixers.
Learn more about ultrasonic high-shear mixing!

Sonochemical Applications

Mixing solid-liquid and liquid-liquid systems with high-power ultrasound, mass transfer between two or more phases or components of the mixture is improved. Increased mass transfer is well known to positively influence many chemical reactions such as heterogeneous catalysis. Additionally, ultrasonic cavitation introduces high energy into chemical systems thereby initiating reactions and/or changing reaction pathways. This leads to significantly improved chemical conversion rates and yields. Sonochemical equipment and reactors are commonly used for transesterification, polymerization, desulphurization, sol-gel processes and many other heterogeneous catalytic and synthetic organic reactions. Read more about sonochemical reactions!

Ultrasonic Applications in the Food Industry

Ultrasonic high-shear homogenization is a non-thermal technology that is used in manifold manufacturing processes of food, beverages and dietary supplements. Ultrasonic extraction is used in the production of sauces, soups, juices, smoothies, dietary supplements (e.g., elderberry, cannabis) in order to release flavour compounds, colour pigments, vitamins and nutritional components in order to create a more flavour-intense, healthier food product. Due to the extracted flavour compounds and natural sugars, the addition of refined sugar and synthetic flavour additives can be avoided. Read more about ultrasonic processing of food and beverages!

Ultrasonication is applied during food processing in order to intensify and improve

• extraction
• homogenization
• pasteurization
• emulsification
• encapsulation (liposomes, solid lipid nanoparticles)

Ultrasonic Synthesis and Functionalization of Nanomaterials

Ultrasonic processing and the resulting acoustic cavitation can put extreme stress on particles and break them controlled down to sub-micron and nano size. The phenomenon of acoustic cavitation creates high shear, turbulences, very high pressure and temperature differentials. These intense conditions occur as result of the bubble implosion which can be observed when high power ultrasound creates alternating high-pressure, low-pressure cycles in the medium. Whilst liquid jets and interparticle collision impinge, erode and shatter particles, the occurring quasi-hydrostatic pressure can modify particle microstructures such as porosity. Ultrasonic nanoparticle functionalization allows to synthesize high-performance materials with improved thermal stability, extraordinary tensile strength, ductility, thermal and electrical conductivity, optical properties etc. of the nanomaterials.
Read more about ultrasonic nanoparticles synthesis and functionalization!

Ultrasonication – Synergistic Effects

Ultrasonication can either replace an underperforming machine or be combined with almost any available liquid processing technique in order to refine and upgrade the subpar results. Hielscher probe ultrasonicator are integrated in existing manufacturing lines with

• colloid mixers & mills
• bead / pearl mills
• high-shear mixers
• high-pressure homogenizers
• blade mixers / rotor-stator mixers
• heat pasteurization (HTST)
• High-intensity pulsed electric field (HELP)
• microwave
• ultraviolet light (UV)
• electrochemistry
• hurdle technologies
• CO₂ extractors

Whether installed alone or in combination with conventional processing techniques for synergistic effects, the integration of ultrasonication results in improved and intensified processes.

High-Performance Ultrasonic Systems for Process Intensification

Hielscher Ultrasonic designs, manufactures and distributes high-performance ultrasonicators for heavy-duty applications. Our portfolio covers the whole range from compact lab ultrasonicators to bench-top and fully-industrial ultrasonic processors, which enables us to recommend the ideal ultrasonic setup for your application and processing volume.
Read more about industrial sonicators and why they are the solution for your challenging application!
Get in contact with us now to discuss how your process can profit from ultrasonic process intensification! Our long-experienced and well-trained staff provide you with in-depth information and technical details.

The table below gives you an indication of the approximate processing capacity of our ultrasonicators: