1、均质技术均质技术 和和 细胞破碎细胞破碎 均质的作用原理均质的作用原理什么是高压均质技术什么是高压均质技术?均质前的脂肪颗粒均质前的脂肪颗粒均质后的脂肪颗粒均质后的脂肪颗粒粉碎、乳化均质使脂肪球破裂成比原来小得多的脂肪球 减少脂肪上浮，减小脂肪成团或聚结的倾向。所有的均质产品基本上是通过机械的方法来生产的。物料以很高的速度被强制通过一个窄缝。可以通过几个决定因素，如湍流和气穴的联合作用来实现最初的脂肪球破裂。作用的最终结果使脂肪球的直径减小到大约0.7 m，同时脂肪/浆液的表面积增加了4-6倍，新生成的脂肪球不再全被原来的膜覆盖，取代它们是从浆液相中吸附的蛋白质的混合物。均质效率根据斯托克斯定
2、律，粒子的上升速度可表示为：V=速度g=重力加速度P=粒子尺寸hp=液体的密度Ip=粒子的密度t=粘度或是V常数 p2，这样就可以看出，减小粒子的直径是减小上乳速度的有效方法。这样，减小牛乳中脂肪球的尺寸就可以减小稀奶油上浮的速度。脂肪颗粒上浮速度研究检测脂肪颗粒上浮速度的最古老的办法是取样后静置一定的时间，分析样品中不同层液中的脂肪含量。USPH法就是基于这一原理，取样1000ml，静置48h，之后测定顶部100ml 的脂肪含量以及其余奶液的脂肪含量，如果顶部脂肪含量的0.9 倍低于底部的脂肪含量，则认为均质是有效的。N120法也是基于同样的原理，用这种方法，取样25ml，在40以下以100
3、0rpm的速度，在半径为250mm的离心机中离心30min。用底部20ml 液体的脂肪含量除以全样品的脂肪含量，用比数乘以100，此结果称之为N120 值。巴氏杀菌乳的N120 值通常为50-80%。破碎前的细胞破碎前的细胞破碎后的细胞破碎后的细胞什么是高压均质技术什么是高压均质技术?破碎破碎物料通过均质阀物料通过均质阀Importance of Understanding MechanismThe energy imparted by the homogenizer to the liquid in the homogenizing valve is equivalent to 1000 k
4、W per milliliterLess than 0.1 percent of this energy is used to form the emulsion.The rest is converted to heat.More efficient use of this available energy will produce a better emulsion.紊流形态模拟紊流形态模拟显微镜下的视野显微镜下的视野Video根据流体虚拟程序得到的结论根据流体虚拟程序得到的结论Homogenization of emulsions is caused by intense turbule
5、nce;cavitation has an adverse effect on homogenization;droplet break-up occurs after discharge from the valve gap.A computer software platform was developed to link a Computational Fluid Dynamic program to the proprietary equations defining homogenization.This computer system is used to predict how
6、the geometry of a homogenizing valve will affect the mean droplet size and droplet size distribution of an emulsion while accounting for emulsion parameters.均质作用的原理均质作用的原理(乳化乳化)紊流 *)(空化)*)Localised pressure differences will tear apart the particles.The pressure differences are due to the random velo
7、city fluctuations of turbulent flow.高压均质应用于在细胞破碎上高压均质应用于在细胞破碎上大致作用原理大致作用原理高压均质应用于在细胞破碎上大致作用原理:紊流撞击(作用于撞击环)(空化)The mechanism of cell disruption is not completely defined.如何控制颗粒大小如何控制颗粒大小压力(P)一级均质/二级均质均质次数(N)均质阀类型温度(t)预混合缩小粒径并使粒径分布变得狭窄缩小粒径并使粒径分布变得狭窄Distribution:024681012020004000600080001000012000均质前均
8、质前均质后均质后Volume-%Diameter(Nanometer)Multiple Pass HomogenisationVolume Weighted Particle Size Distribution05101520253035Particle Diameter in nm(nanometer)(logaritmic scale)Volume-%1 pass (800 BAR)3 passes(800 BAR)5 passes(800 BAR)7 passes(800 BAR)101001000800Bar下下7次均质后次均质后Cell Disruption as a Functio
9、n of Pressure01020304050607080901000 BAR200 BAR 400 BAR 600 BAR 800 BAR1000BAR1200BARPressure(BAR)Yield(%)Percent Yield(Protein)1.Fermenter2.Separator3.Feed pump4.Plate cooler5.Pressure gauge6.Homogeniser7.Plate coolerCell Disruption ProductsMultiple Pass Homogenisation Techniques 1 1 2 24 4BA C2.4
10、T BAR 100=P:)1 =4.18,=(c WaterEx.)cmx g(Density =)Cx gx J(Heat Specific =c )BAR (liquid the in Pressure =P C)(etemperatur in Increase =T oo oo3-1-1-C)(x cx 9.9P =T能量转换能量转换Profitable Properties obtained by High Pressure HomogenisationReduction of the particle sizeImproved stabilityInfluence on the vi
11、scosity and consistencyImproved water-binding capacityGlossMinimisation or optimal use of emulsifying agent or stabilisersCell rupture/Release of important intercellular componentsImproved chemical reactionsEasier filtration Improved absorptionImproved penetrationReduction of the molecular weight均质机
12、均质机(机械部分机械部分)Gaulin&Rannie-Liquid EndExploded ViewHomogenising UnitValve HousingCylinder Arrangement均质单元均质单元一级调压一级调压阀体阀体柱塞单元柱塞单元液体端液体端动力端动力端 Oil pressure lubrication of crosshead and crank shaft Cooling water system with environmentally friendly 更节水 Max.revolutions for crankshaft 180 o/min.on large
13、machinesRannie 球阀球阀Gaulin-一体式气缸一体式气缸 Reliability of operation Service-friendly design Available with poppet or ball valves Hygienic design Aseptic design Reduced costs of spares Reduced maintenance costs Reduced downtime during service/maintenance Production flexibility Pressure range up to 600 barR
14、annie 三片式气缸三片式气缸 Reliability of operation Service-friendly design Available with poppet or ball valves Hygienic design Aseptic design Reduced costs of spares Reduced maintenance costs Reduced downtime during service/maintenance Production flexibility Pressure range up to 1500 barCylinder Arrangement
15、 Available with chromium coated or ceramic plungers Sanitary packings Special packings for special applications Available in aseptic design Min.expenses when converting to aseptic design调压系统调压系统 完整的调压系统必定与均质阀数量对应 可选 0-10 V/4-20 mA 信号 使用 H1 级油(食品级润滑油)油不可压缩 坚固耐用(非常强劲的系统)绝无污染产品的危险 油滴吸入对人体无害 液压调压液压调压 手动
16、控制手动控制330-10 V DC气动头液压站对应阀门放大器Potentiometer均质阀00液压调压液压调压 自动控制自动控制344-20mAPLC0-10 V DC100100气动头液压站对应阀门TransducerPressure终端计算机均质阀放大器发射台信号变频器均均 质质 阀阀普通均质阀普通均质阀-XFD XFD 所有物料只适用于二级均质 压力最高 600 Bar标配材质:斯泰利选配材质:钨碳合金专利产品专利产品-已过有效期已过有效期高效均质阀高效均质阀 LW LW 适用于无研磨性的物料只需一级均质压力最高 200 bar标配材质:不锈钢镀铬层保护专利产品专利产品专利产品专利产品
17、-尚在有效期尚在有效期高压均质阀高压均质阀-SEO SEO 耐研磨物料 需一级或二级均质压力超过 600 bar标配材质:陶瓷专利产品专利产品-已过有效期已过有效期微间隙均质阀微间隙均质阀 Micro Gap 专利产品专利产品专利产品专利产品-尚在有效期尚在有效期微间隙均质阀微间隙均质阀 Micro Gap Micro-Gap ValveThe patented Micro-Gap(MG)Valve was developed to provide optimal performance for milk processing.The MG requires less operating pr
18、essure to achieve desired particle size,delivering increased product stability and savings on energy and maintenance costs.专利产品专利产品专利产品专利产品-尚在有效期尚在有效期微间隙均质阀微间隙均质阀 Micro Gap 上表：微间隙均质阀与常规均质阀的均质效果比较微间隙均质阀微间隙均质阀 Micro Gap ProductProductHeat treat-Heat treat-ment,ment,StorageStorageConven-Conven-tionalti
19、onalValveValve(BAR)(BAR)Micro-GapMicro-GapValve(bar)Valve(bar)Pasteurised MilkPasteurised Milk(0.5%to 3.5%Fat)I.1-1110-15070-12020-35%Pasteurised Milk,Pasteurised Milk,PartialPartialHomogenisationHomogenisation(4.5%to 12%Fat)110-15070-12020-35%Chocolate Milk andChocolate Milk andother Flavoured Milk
20、other Flavoured Milk(0.5%to 3.5%Fat)I.1-10110-15070-12020-35%Abrasive Cocoa powderreduces the life of thevalvesLight CreamLight Cream(9%to 18%Fat)I.1-9110-15070-10035%CreamCream(18%to 30%)90-12060-8035%HeavyHeavyCream,WhippingCream,WhippingCreamCream(30%to 40%Fat)N/AN/AN/ANot normallyhomogenisedYogh
21、urtYoghurt(0.5%to 3.5%Fat)200-250130-20020%Sour CreamSour Cream(9%to 18%Fat)100-12080-10020-35%Ice Cream MixIce Cream MixFrozen140-17090-14020-35%Dissolve stabiliser,cocoaand whey at 38 C.for 20min.,20 to 30 bar on the2nd stageCommentsCommentsPasteurisation,Shorttermstorage,refrigeratedAvoid too hig
22、h pressuresProduct specificationsProduct specificationsAppl.Ab-Appl.Ab-stractstractRef.No.Ref.No.Total HomogenisingTotal HomogenisingPressurePressureSaving*)Saving*)withwithMicro-GapMicro-GapValveValve专利产品专利产品-尚在有效期尚在有效期微间隙均质阀微间隙均质阀 Micro Gap 她能为您做到：她能为您做到：显著的减少能耗，有效节能显著的减少能耗，有效节能 提高产品品质和稳定性提高产品品质和稳
23、定性 大幅提高单位时间处理量大幅提高单位时间处理量专利产品专利产品专利产品专利产品-尚在有效期尚在有效期压力计算压力计算总压力计算总压力计算4521005050200HydraulicOutletInlet2nd stage1st stage0Outlet50 bar150 bar200 bar200400250二级均质二级均质分散作用在含脂肪产品分散作用在含脂肪产品472nd stage一级之后二级之后P12000 psi3000 psi4000 psi5000 psi0.200.300.400.500.600.700.800.90Mean Droplet Size(um)0.100.200
24、.30P2/P10.00 Droplet Size(Oil/Water Emulsion)versus P2/P1P2=Second Stage Pressure(psi),P1=Total Pressure(psi)二级均质压力的效果二级均质压力的效果供料系统供料系统供料系统供料系统 离心泵离心泵50离心泵均质机产品罐供料系统供料系统 位移泵位移泵51位移泵均质机回路阀(弹簧式)By-pass flowapprox.10%产品罐Partial homogenisation52脂肪离心机均质机混合机1000 l/h3,5%Fat750 l/h-0,5%Fat250 l/h11,5%1000 l
25、/h LW-Valve max 13%fat =200 bar Saves energy up to 75%Reduces investment costs Smaller machine can be used预混合预混合Energy Level of MixersPremixHomogenized at 4000 psi0.60.8234567 8 92030Effect of Premix for 5%O/W EmulsionDroplet Diameter(um)1100246810Relative Percent of VolumeEffect of Premix-10.60.823
26、4567 8 92030PremixHomogenized at 4000 psiEffect of Premix for 5%O/W Emulsion0246810Relative Percent of Volume110Droplet Diameter(um)Effect of Premix-20.60.823468 9720305PremixHomogenized at 4000 psiEffect of Premix for 5%O/W Emulsion0.02.04.06.08.010.012.014.0Relative Percent of Volume110Droplet Diamter(um)Effect of Premix-3
