For many mixing processes in food and beverage applications, high shear mixing has become the preferred solution because it can handle multiple processes in a single operation. High shear mixing experts Silverson explains more here.
A high shear mixer utilises specialised rotor/stator technology to generate extremely high shear rates. The rotor creates a powerful suction effect that continuously draws materials into the high shear workhead. Centrifugal force then drives materials towards the periphery of the workhead where they are subjected to a milling action in the precision machined clearance between the ends of the rotor blades and inner wall of stator. This is followed by intense high shear as the materials are forced, at high velocity, out through the perforations in the stator and circulated into the main body of the mix.
Unlike low shear devices such as stirrers and agitators, high shear mixers actively process the ingredients in the mix, enabling faster and more consistent results. This enables them to excel in mixing tasks and processes which are difficult or impossible for simple stirrers.
For example, rapid, lump-free dispersion of gums and thickeners can be extremely difficult to achieve using a low shear device. Once agglomerates have formed, the stirrer or agitator simply moves them around the vessel. However, high shear mixing equipment can achieve agglomerate-free dispersions at ambient temperature. Obtaining full yield of the raw materials and eliminating agglomerates from the mix means that filtration steps aren’t required, reducing processing times as well as ingredient waste, whilst improving product quality.
Similarly, when trying to create fine, stable emulsions the key is obtaining the finest possible droplet size. When mixing it can appear that stirrers and agitators are forming an emulsion, but no energy is introduced into the mix, so when the agitation is removed the phases will separate.
The more shear energy introduced into the mix, the smaller the suspended droplets will become, intensely mixing the oil and water phases and creating a stable emulsion. High Shear rotor/stator mixers can achieve exceptionally small droplet sizes without the need for additional equipment like high-pressure homogenisers. By utilising high shear mixing, manufacturers can simplify the homogenisation process, reduce production costs, and enhance overall efficiency.
For manufacturers seeking to streamline their production processes and achieve superior product quality, Silverson High Shear mixers offer a proven and reliable solution.
If you’d like to find out more about high shear mixers, visit the Silverson Machines website, or visit Stand F54 at the PPMA Show 2026.
