Master Plant MP

The IKA Master Plant homogenizing and emulsifying plant (Reactor) is a universal mixing system designed for the production of emulsions and suspensions, mainly in the pharmaceutical industry, but also in the food and beverage, cosmetic and chemical industries.   The installation complies with GMP standards and guarantees a high level of accuracy, safety and reproducibility of results.   The Master Plant mixing plant can operate under pressure and vacuum, directly feed dry and liquid components, mix and disperse the contents of the tank, and heat or cool the product.

The required level of homogenization and grinding of dry substances is achieved by circulating the mixture through the working chamber of the DBI disperser integrated into the base of the tank.   The patented, proven IKA DBI homogenizer consists of two stages:

• The specially designed rotor ensures suction and pumping of the contents of the working tank through the circulation circuit, as well as mixing at low shear rates.   At maximum speed, pressures of up to 4 bar and extremely high throughput are achieved, which is necessary for non-disassembly cleaning in place (CIP).
• The highly efficient generator, which has a rotor-stator design, creates high shear forces, which allows for the crushing of droplets and solid particles, and also promotes the rapid distribution of the dispersed phase in the dispersion medium in the production of stable ultrafine emulsions and suspensions.   Turbulent flows created by the rotation of the generator ensure the suction of components into the dispersion zone without creating a vacuum in the container.

Depending on the requirements of the technical specifications, by controlling the built-in valve, it is possible to (1) carefully feed the mixture only to the first stage of the DBI machine and pump it through without grinding, or (2) pass the product with or without suction of new ingredients through two stages of the machine with dispersion and grinding.

A special mixing device built into the lid of the working container, with the possibility of reversible rotation, evenly mixes the contents of the container, moving the product vertically and horizontally.   For products with relatively high viscosity - up to 100,000 mPas - it is recommended to use a countercurrent device consisting of an external and internal mixer.   The alternative spiral mixer made of tubular profiles with heating or cooling options is ideal for products with viscosities up to 30,000 mPas.   Additional flexible PTFE scrapers prevent deposits on the tank walls.

After the end of the periodic process, the finished product is completely unloaded.   There is no need to create additional pressure.   The process is controlled using a modern touch screen monitor.   Specially designed electric control - on request.

It is possible to manufacture the system in an explosion-proof version.

The Master Plant MP series of units is available in 9 sizes with capacities from 10 to 4,000 liters.

• Advantages of the Master Plant MP system:
  • Feeding of dry and liquid components without creating a vacuum in the working container
  • Fast and high-quality, lump-free mixing of solid dry components with liquid ones thanks to their feeding directly into the dispersion chamber.
  • Possibility of minimum loading up to 15% of the nominal working capacity
  • Choice of short or long circulation to minimize dead zones and material losses
  • Significant reduction in time to reach the required product temperature thanks to mixer heating/cooling
  • Non-disassembly cleaning in place (CIP), in which the DBI 2000 machine performs the pumping function and supplies cleaning liquid to the spray nozzles.
  • Interchangeable mixing tools
  • Ability to influence the quality of mixing and dispersion by setting the speed of rotation of the tools
  • Minimal maintenance
  • Reliable technology scaling from lab to production thanks to identical design across all Master Plant sizes
  • Optional steam sterilization without disassembly (SIP) of the unit
  • Optional equipment of the installation with a hot steam injection system
  • Possibility of supplying the system in explosion-proof design, also in accordance with directives 94/9 EG (ATEX 95)

Master Plant (Reactor) — professional solution in the Технологические установки category

Master Plant (Reactor) is a modern business-class equipment designed for daily operation in demanding conditions. The combination of reliability, accuracy and durability makes this product the optimal choice for companies seeking consistent process quality, predictable results and reduced operating costs. The purchase price is a reasonable investment in the development and scaling of the enterprise.

Why Master Plant (Reactor)

• Reliability and durability: industrial-grade design and materials withstand intense loads.
• Accuracy and repeatability: stable performance that reduces the risk of defects and downtime.
• Process efficiency: optimizing staff time and increasing productivity at every stage.
• Compliance with standards: manufactured taking into account current international requirements for the business segment.
• Ease of integration: Master Plant (Reactor) fits easily into existing process lines and IT infrastructure.

Areas of application Технологические установки

Технологические установки solutions are widely used in manufacturing, research laboratories, construction sites, energy and agricultural sectors, pharmaceutical and food industries. Implementing Master Plant (Reactor) allows you to increase productivity, ensure accuracy of operations and optimize resource utilization across the entire enterprise.

Key benefits for business

Technical highlights

• Industrial reliability of components and assemblies for long-term trouble-free operation.
• Stable parameters that ensure repeatability of results and product quality.
• Energy efficiency and optimized life cycle cost of ownership.
• Compatibility with related equipment and standard data exchange protocols.

Service and support

Together with Master Plant (Reactor) you receive professional advice on selection, commissioning and personnel training. We provide warranty and post-warranty service, prompt delivery of consumables and spare parts. Our team supports projects from the procurement stage to the stable operation of the complex so that your business receives the expected result every day.