Design and Output Analysis of a Homogenizer

ABSTRACT

Homogenizers are used as mixers that reduce particle size in an emulsion or force immiscible liquids
to mix. Pressure imparted on a product by the homogenizer is largely determined by pump pressure or
flow diversion through valves and nozzles. These machines have grown to be an indispensable unit of
diary, pharmaceutical, food & beverage, and the grease & lubricants industry. From the perspective of
a Grease manufacturing unit, the homogenizer is a critical component that is instrumental in
improving the structure and functionality of the produced greases. In recent times, very few attempts
have been made systematically trying to define the output efficiency of homogenizers owing to the
age-old design and working of the homogenizers. This project presents a comprehensive insight to
achieve a reasonable methodology to look into the output of homogenizers in the form of a graphical
relationship between the pressure applied by the homogenizing unit and the Penetration Number * of
the grease, which can be later used to optimize production. The results were tabulated and are
attached later in this document for reference. Firstly, samples were collected at different pressures
from the outlet of the homogenizer, in addition to an unhomogenized top sample, for different grades
and types of greases. The samples were subjected to penetration tests in the laboratory and the results
were plotted. However, it should be noted that the results were subjected to errors arising out of the
age of the machine, inherent faults in the machine components, and the calibration errors in the
instrument gauges. That being said, the plot points give us an accurate idea about the trend, and
considering the ease of this method, the time taken, and the cost effectiveness this study can open up a
new perspective for research in the field.

INTRODUCTION

Homogenization is a fluid mechanical process of making a product completely uniform in terms of

particle or globule size. It involves the subdivision of particles into micron size to create a stable
dispersion or emulsion for further processing. Depending upon the area of application, products need
to homogenized for a variety of reasons. The homogenized products look better, has an enhanced
structure and texture, and are thermodynamically and physiochemically more stable thereby having a
prolonged shelf life. Though, the first ever homogenizer was developed in the context of the diary
industry to make uniform and better tasting milk-cream emulsions, these powerful machines have
grown to become an integral part of the grease manufacturing industry. Homogenized greases have a
more compact structure, and a finer texture, making the application of the greases easy and effective.

The Gaulin Homogenizer is a machine used to create stable emulsions and dispersions in many
industries including food and dairy, pharmaceutical, petroleum, and chemical. Gaulin Homogenizer is
a high pressure, multi-piston pump with a small, variable sized orifice. As product is forced through
the orifice, the resultant forces break fat/oil globules/soap particles down to sizes small enough to
prevent (or at least considerably delay) the natural separation of a single component from the rest of
the emulsion.

After patenting the process in France in 1899, Auguste Gaulin introduced his machine for “treating
milk” at the Paris World’s Fair in 1900. The machine consisted of a 3-piston pump designed to push a
combined stream of milk and cream through a set of tiny capillary tubes – an early version of a
homogenizing valve. While the piston pump and homogenizing valve have changed over the following
century, Auguste Gaulin’s basic design remains the simplest and most economical way of creating
emulsions from liquids that would normally tend to separate over time.

Auguste Gaulin was awarded a US patent in 1904. Robert Manton Burnett was a Massachusetts
businessman and part of a large family of “gentleman dairymen” who had helped popularize many
advances in dairy technology. In 1909, he formed a company bearing his middle name to produce the
Gaulin Homogenizer -- the Manton-Gaulin Company.

Ice cream manufacturers were the first large-scale commercial customers for Gaulin’s new machine as
homogenization of ice cream mix markedly improved the smoothness and creaminess of the product.
Oddly enough, it was possibly the Burnett family’s own previous work in popularizing glass milk
bottles that hindered acceptance of homogenized bottled milk by the public. Since the introduction of
the glass bottle, consumers had become accustomed to seeing the cream floating on top of the milk in
the bottle. If the cream wasn’t visible, the milk was assumed to have been “skimmed” of cream and
was considered less desirable. It took nearly 30 more years before homogenized milk became the
standard for bottling.

In 1924, Manton-Gaulin introduced the 2-stage homogenizing valve. Capillary tubes had given way to
a more durable “annular orifice” design constructed from hardened materials. This same basic design
is still in use today.

Over time, homogenization has evolved in more than one way. Some machines, like simple blenders
or centrifuges, apply a single force to a sample and are oftentimes small and affordable, even for the
non-scientist consumer. Others, like the ultrasonic homogenizer, use sonic pressure waves to create
cavitation. And still others, like the high-pressure homogenizer, are large machines that impart
multiple mechanical forces, through a process similar to Gaulin’s, and can be customized based on the
sample being processed. Additionally, homogenizers are no longer used solely for milk treatment;
other industries, like the pharmaceutical, chemical, biotechnology, and food, use homogenization to
optimize product qualities like bioavailability, consistency, and texture.

BASICS OF GREASE MAKING

Before we delve deeper into the types, design, and working of homogenizers, it is instrumental to
understand the anatomy of greases in short. With this knowledge, it will be easier for us to understand
the working of the homogenizer.

There are three components that form lubricating grease. These components are oil, thickener and
additives. The base oil and additive package are the major components in grease formulations, and as
such, exert considerable influence on the behavior of the grease. The thickener is often referred to as a
sponge that holds the lubricant (base oil plus additives).

Base Oil
Most greases produced today use mineral oil as their fluid components. These mineral oil-based
greases typically provide satisfactory performance in most industrial applications. In temperature
extremes (low or high), a grease that utilizes a synthetic base oil will provide better stability.

Thickener
The thickener is a material that, in combination with the selected lubricant, will produce the solid to
semifluid structure. The primary type of thickener used in current grease is metallic soap. These soaps
include lithium, aluminium, clay, polyurea, sodium and calcium. Lately, complex thickener-type
greases are gaining popularity. They are being selected because of their high dropping points and
excellent load-carrying abilities.
Complex greases are made by combining the conventional metallic soap with a complexing agent. The
most widely used complex grease is lithium based. These are made with a combination of
conventional lithium soap and a low- molecular-weight organic acid as the complexing agent.
Non-soap thickeners are also gaining popularity in special applications such as high-temperature
environments. Bentonite and silica aerogel are two examples of thickeners that do not melt at high
temperatures. There is a misconception, however, that even though the thickener may be able to
withstand the high temperatures, the base oil will oxidize quickly at elevated temperatures, thus
requiring a frequent relube interval.
Additives
Additives can play several roles in a lubricating grease. These primarily include enhancing the existing
desirable properties, suppressing the existing undesirable properties, and imparting new properties.
The most common additives are oxidation and rust inhibitors, extreme pressure, antiwear, and
friction-reducing agents.
In addition to these additives, boundary lubricants such as molybdenum di-sulphide (moly) or
graphite may be suspended in the grease to reduce friction and wear without adverse chemical
reactions to the metal surfaces during heavy loading and slow speeds.
The Process

Greases can be manufactured using different processes like open kettle, closed kettle under pressure,
autoclave/Stratco contractor process and continuous process. Kumar notes that “processing makes a
considerable difference” in the end product’s properties and performance. For example, lithium
greases made through the Stratco contractor process are popular and an industry standard, while
open kettle lithium greases, made through continuous process units, are still efficient for producing
large volumes.

The thickener (or soap) is usually prepared in situ and the choice of the base is usually Lithium,
Sodium or Calcium and fatty acids are used as the organic acids. The components are mixed together
in open or closed cooking kettles with paddles to mix the ingredients. The produced soap (functioning
as the “sponge”) is mixed with different amounts of base oil and additives to produce grease of
required consistency and characteristics.

Types and Theories of Homogenizations

There are many types of homogenizers, ranging from common kitchen implements like mortars and
pestles and blenders to more sophisticated equipment like bead mills and cell lysers. They are
classified according to the type of force they supply, with the most basic ones being:

1. Mechanical Homogenizers - which make use of turbulent agitation, stirring, shearing and/or
impact to effectuate the breakdown and mixture of substances. Specific examples
of mechanical homogenizers include bead mills, rotor-stator homogenizers and blade
homogenizers. A rotor-stator homogenizer comprises a metal shaft (rotor) which rotates
rapidly within a stationary outer case (stator). This creates a suction effect such that the
sample is drawn into the space between the two components. Here it is subject to very high-
shear forces which help to homogenize the liquid or particles. A continuous process is formed
as the sample is pushed through slots in the stator. The rapid motion of the fluid results in
more sample entering the space to be subjected to shear.

2. High-Pressure Homogenizers (HPH) - which force pressurized cell suspensions through small
tunnels or holes in order to disrupt their bonds. Many of these types of homogenizers also
include some sort of high velocity impact of the product (in addition to pressure) to better
ensure cell disruption. There are various types of high-pressure homogenizers out there and
this is more of a general term for the process rather than a description of the equipment itself.
High-pressure homogenization involves a primarily liquid sample being subjected to a strong
force that homogenizes it. A common setup involves the sample being forced through a
channel, for example through a valve or tiny slits in a membrane. The resulting shear,
pressure drop, and cavitation will homogenize the sample. In some cases, homogenization is
aided by the high-pressure stream colliding with a blade, plate, or ring.
 3. Ultrasonic Homogenizers - which combine extreme sonic pressure waves in varying types of
vessels to form microbubbles that eventually implode (also called cavitation), breaking
covalent bonds and prompting the blending process. Ultrasonic homogenizers (also known as
sonicators) also involve the use of a probe (horn). The probe vibrates rapidly and transfers its
ultrasonic energy to the surrounding sample. In addition, the sonication process results in
cavitation, which involves the rapid formation and collapse of bubbles. This creates
shockwaves which homogenize the surrounding sample. Ultrasonic homogenizers can achieve
small particle sizes with relatively short processing times. Using one of these homogenizers
will result in a lot of noise being created so ear protection should be used.

Several theories have been developed so as to explain the breaking of the particles that occur during
homogenization. More often than not, homogenization occurs as a result of 2 or more of these
processes combined. A few of them is discussed as below for better understanding.

1. Shattering and Impact: - The particles in the emulsion are shattering and broken down into
smaller bits by impinging them on the retaining valve or impact ring. This is mostly found in
high pressure homogenizers where the product to be homogenized is pumped into the valve
system and pushed by a positive displacement piston pump, thereby breaking the clumps.

2. Cavitation: - Considerable pressure drop with change of velocity of fluid. Liquid cavitates
because its vapor pressure is attained. Cavitation generates further eddies that would produce
disruption of the fat globules. The high velocity gives liquid a high kinetic energy which is
disrupted in a very short period of time. Increased pressure increases velocity. Dissipation of
this energy leads to a high energy density (energy per volume and time). Resulting diameter is
a function of energy density.

3. Turbulence: - Energy, dissipating in the liquid going through the homogenizer valve,
generates intense turbulent eddies of the same size as the average globule diameter. Globules
are thus torn apart by these eddy currents reducing their average size.

4. Shearing and Grinding: - As grease is passed at high pressure (velocity ~ 200-300 m s-1)
through the homogenizer valve (~ 100 mm gap), soap particles undergo shearing action. The
shear between soap particles and the surface of the homogenizer wall coupled with wire
drawing effect results in elongation of the soap particles which progressively becomes
unstable. These phenomenon result in subdivision of the soap particles. Furthermore, the
difference in velocity of the faster moving serum phase at the center of the liquid stream as
compared to the liquid near the edge of the stream causes the soap particles to grind against
each other. The turbulence created by the difference in velocity and eddy currents of the liquid
add to the shear effects and thus enhance the process of disruption of the soap particles.

Basic Design and Working Principle of a Gaulin Homogenizer

A homogenizer is a single acting reciprocating multi-plunger pump with an adjustable valve, the
homogenizing valve, able to create the pressure used to micronize various products. The homogenizer
consists of a Triplex plunger model single acting reciprocating, high pressure pump, and the
homogenizing valve, which is the “Heart” of the system.

The major components can be listed as follows: -

1. Drive Housing and Crank mechanism

2. Pump Block with Suction and Discharge port.
3. Suction and Discharge Valve Assembly
4. Homogenizer two stage valve.
A Gaulin Homogenizer consists of 2 main sections – a Piston Pump and a Homogenizing Valve:

Piston Pump: A reciprocating piston pump comprised of 3 or 5 pistons working in tandem and driven
by a single crankshaft. Check valves above and below each piston keep the fluid moving forward
during the suction & discharge strokes of the piston. The suction/discharge valves are available in
different styles based on the viscosity of the product.

The Piston Pump can be further divided into two primary sections – the Power Frame and the Liquid
End. The size of Power Frame is determined by the total horsepower required by the application –
proportional to both flow and pressure. The Liquid End is available in multiple pressure ratings and
check valve styles – again selected based on the application.

Homogenizing Valve Assembly: The homogenizing valve assembly is essentially an adjustable orifice
– or series of adjustable orifices. The pressure created by the piston pump forces product through the
homogenizing valve, causing a very significant pressure drop across the orifice. The valve design and
degree of pressure drop determine the effect on the product. In general, the greater the pressure drop,
the greater the effect on the particle size of the product being homogenized.

The homogenizing valve assembly has three crucial smaller components: The ‘Valve’, ‘Valve Seat’, and
‘Impact Ring’. The Valve and Valve Seat are the pieces that actually form the orifice. The Impact Ring
is a sacrificial piece that prevents the high-pressure annular fan from damaging the chamber that
surrounds it. All three components are made from a special wear-resistant hardened alloy

The working of the homogenizer can be discussed simply. The homogenizing valves are hydraulic
controlled. In homogenization, as the liquid travels from the high-pressure zone in the cylinder
through the area between the valve and seat, there is a large increase in fluid velocity and a
corresponding decrease in fluid pressure. The fluid velocity initiates very intense turbulence in the
fluid jet exiting from the valve and seat. This turbulence disrupts the disperse phase and produces the
homogenization effect. The additional use of a second-stage valve will serve to exert a backpressure on
the fluid moving through the first-stage valve and, consequently, will influence the intensity of the
turbulence by suppressing cavitation of the liquid. Cavitation of the liquid creates a two-phase flow of
gas-in-liquid which makes the liquid “spongy”.
Aim of the Study

The study was conducted to obtain a relationship between the pressure applied at the homogenizing
assembly and the penetration number of the grease at 25°C. The obtained results were plotted in
Microsoft Excel with Pressure (in kg/cm2) on the abscissa and Penetration number (in 10th of mm) on
the Ordinate.

Apparatus

1. Cone Penetration (ASTM D217)

2. Metriplex Grease Homogenizer

Process

1. About 500 gm of unhomogenized sample is collected from the cooking kettle

2. Various pressures are set on the homogenizer and samples are collected in tubs corresponding
to each pressure.
3. It must be noted that we have to wait for sometime to collect the subsequent sample, allowing
the pipelines to clear out the old sample.
4. The samples are chilled in a freezer where the temperature is brought down to 25⁰C.
5. Finally the grease samples are subjected to the penetration test and the results are noted.