Technik und Innovation

Agitators

The anchor agitator - conventional agitation system for all standard applications.

Features of the anchor agitator:
  • Outstanding mixing results and short mixing times
  • Very good horizontal and vertical product flow
  • Particularly suited for low and medium viscosity ranges
  • Consisting mixing results for all batch sizes
  • Optimum heat transfer from the vessel wall
  • Flexible and efficient
  • Large and variable range of speeds
  • 100% scalability

As an alternative for the toughest demands in mixing- and process flexibility, symex offers the coaxial agitator!
The coaxial agitator: agitation system with two agitators, independent of each other, for complex mixing requirements!

Features of the coaxial agitator:
  • Unparalleled in flexibility, effectiveness and productivity
  • Scraper- and central agitator driven independently of each other
  • Counter rotating system with infinitely variable range of speeds
  • Optimum mixing results and shortest mixing times
  • Controllable horizontal and vertical product flow
  • Particularly suited for high viscosity ranges (up to 2,000,000 cP)
  • Constant efficiency at all speed ranges
  • Consisting mixing results for all batch sizes
  • Optimum heat transfer from the vessel wall
  • Excellent temperature distribution even at maximum viscosity
  • No mixing shadows / without fixed installations
  • Extremely good and fast cleaning
  • Extremely flexible and efficient
  • Definable energy input
  • 100% scalability

The symex coaxial agitator – the agitation system for the highest demands on mixing technology!

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Homogenizers

The rotor-stator homogenizer - conventional homogenization technology for all standard applications.

Features of the rotor-stator homogenizer:
  • Two shearing zones for maximum energy input
  • 3-30 m/s shear speed / 60,000 s-1shear rate
  • Additional pumping stage for maximum pressure build-up
  • Very high pump performance even for high viscosity
  • Homogenization via external product circulation
  • “First in, first out” homogenization
  • Long and short product circulation
  • Batch size flexibility between 15% and 110%
  • Induction of powders and liquids directly into the homogenizer
  • 100% scalability

“All in one system” – homogenizer, CIP- and discharge pump and discharge pump all in one unit
Co-Twister - the patented rotor-rotor homogenizer.

Limitless flexibility thanks to independent control of shearing and pump capacity. Co-Twister features:
  • Independent control of pump output and shearing input
  • “Dynamic stator” driven independently of rotor
  • Up to 85% savings in time for homogenization and cleaning
  • 100% repeatability of the process
  • 0-60 m/s shear speed / 120,000 s-1shear rate
  • Two shearing zones for maximum energy input
  • Additional pumping stage for maximum build-up of pressure
  • Very high pump performance even at maximum viscosity (up to 2,000,000 cP)
  • Homogenization via external pruduct circulation
  • “First in, first out” homogenization
  • Long and short circulation loop
  • Batch size flexibility between 15% and 110%
  • Induction of powders and liquids directly into the homogenizer
  • 100% scalability
  • Pressure- and flow rate-controlled CIP cleaning

Operating modes and applications Click here for more information


Co-Twister – the “All in one solution” for toughest demands and highest flexibility!
The Sybot - the recirculation pump system for the phase tank with unparalleled advantages

Sybot features:
  • Minor investment costs
  • Extremely fast melting of solids (flakes, granulate, chips, etc.)
  • Not sensitive to larger solids
  • 3-30 m/s circumferential speed
  • Very high pump capacity even at maximum viscosity
  • Homogenization via external “short circulation” recirculation pipe
  • “First in, first out” homogenization
  • Batch size flexibility between 15% and 110%
  • Induction of powders and liquids directly into the Sybot
  • Easily converted to rotor-stator homogenizer
  • 100% scalability
  • “All in one system” – agitator, homogenizer, transfer- as well as CIP- and discharge pump all in one unit

Sybot – more flexible, more effective and more efficient than any other bottom agitator!

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Temperature control systems

Standard system for the temperature control of the mixing vessel via direct steam-  and cooling water supplied to the double jacket. 

Features of the standard system:
  • Temperature control system for all standard applications
  • Heating via direct steam supplied to the double jacket
  • Cooling via direct cooling water supplied to the jacket
  • Compact unit incl. all components
  • One central media connection point
  • Two product temperature sensors in the mixing system
  • Intelligent temperature control

For the highest requirements of thermal process management and control accuracy, symex alternatively offers the TA-W2 secondary water circuit system!
The symex TA-W2 secondary circuit system offers the highest level of flexibility and control accuracy  for demanding thermal process management.

Features of the secondary circuit system:
  • Temperature control system with secondary circuit
  • Heating via direct steam supplied to the heat exchangers
  • Cooling via direct cooling water supplied to the heat exchangers
  • Compact unit incl. circulating pump and heat exchangers
  • One central media connection point
  • Two product temperature sensors in the mixing system
  • Highest control accuracy (+/- 0.5°C product temperature)
  • Extremely rapid switching from heating to cooling
  • Absolutely homogeneous temperature distribution in jacket
  • Intelligent temperature control
    • Fast mode without performance restriction compared to direct systems
    • Parametrisable inlet temperature controls
    • Ramp function with controlled heating- and cooling speed
    • Delta-T-function for jacket- and product temperature
  • Cost-effective investment
  • Effective use of resources (without losses)
  • No “hot spots” and “cold spots” in jacket
  • No effect on load cells (jacket permanently filled with water)
  • No steam hammers (as no steam is supplied directly into the jacket)

Secondary circuit systems - more control and accuracy without performance restriction

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Raw material dosing systems

The symex raw material dosing concept guarantees secure and 100% repeatable dosing of raw materials with maximum accuracy.

Features of the raw material dosing system:

  • Raw material feed under vacuum, atmosphere and even against pressure
  • Induction of pre-weighed powders and liquids under vacuum
  • Parameterable induction intervals with 100% repeatability
  • Extremely rapid induction of hydrogenating and agglomerating powders
  • All inductions and dosages 100% repeatable
  • Induction system completely CIP/SIP integrated
  • Dosings from permanently connected storage systems
  • Maximum dosing accuracy even without load cells

 

Special solutions for:

  • HOT/COLD emulsification for all emulsion types
  • Induction of prefabricated waxes (flakes, pellets, granulate, chips, etc.)
  • Secure and rapid feeding and melting of wax blocks
  • Fluidising funnel for bridging powder raw materials

 

“Everything through the manhole” was yesterday - the symex raw material dosing concept brings the process under control!

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CIP - /SIP Advanced

Fully automatic cleaning, sterilisation and drying to perfection

Features of the CIP- / SIP Advanced System:

  • Fully automatic procedure without system operator
  • Shortest cleaning times with minimal requirement for energy, water and purifier
  • Simple and safe operation
  • Maximum flexibility when creating recipes
  • Process stages can be freely configured
    • Melting
    • Pre-rinsing
    • Pre-washing
    • Main-washing
    • Final-rinsing
    • Sterilising/ sanitization
    • Drying
  • Automatic water- and additive dosing with highest accuracy
  • Preconfigured recipes for various product types
  • No manual cleaning stages
  • 100% reproducible cleaning results
  • Individual cleaning programs for every product type

 

CIP- / SIP Advanced – secure, fast and effective!

CIP advanced
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Transfer systems

Highly efficient transfer systems as a link between premix-phase vessel and mixing system

Features of symex transfer systems:

  • Parameterable transfer rates 100% reproducible
  • Various transfer options
    • Continuous transfer via pressure difference (vacuum)
    • Mass flow-controlled transfer via transfer pump
    • Dynamic transfer rate adaption (HOT/COLD)
  • HOT/COLD transfer for all emulsion types
    (with parameterable phase concentration in the mixing zone)
  • Secure and complete residual drainage
  • Heat tracing concept for the entire transfer system
  • Transfer system completely CIP/SIP integrated

 

Symex transfer systems - innovative technology for the highest demands in efficiency and process technology!

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Controls

Innovative control- and operating designs for high-efficiency mixing systems.

Features of symex operating designs:

  • Operation via two 19” operating panels (16:9)
  • Intuitive operating design for maximum security and comfort
  • Dynamic process visualisation
  • Integrated help desk system for functions and procedures
  • Real-time process data trending inc. archive function
  • Locking-, warning- and alarm system with history
  • In-house project management thanks to symex automation engineers
  • Explosion-proof versions (ATEX and NEC)

 

Technical versions:

  • SIEMENS, ROCKWELL and WONDERWARE as standard
  • GAMP, FDA, VDE, UL, CSA, NEMA-compliant versions
  • FDA-compliant user management
  • FDA-compliant processing data recording (21 CFR part 11)
  • Integrated remote maintenance system for control and visualisation
  • Secured service mode for maintenance work
  • Open programming
  • Frequency converter for agitators and homogenizers
  • Standard protocols such as ProfibusDP/PA, EtherNet, ControlNet, etc

 

symex automation – new standards for fully automatic mixing systems!

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system architecture
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Batch systems

Fully automatic recipe management and process control at the highest level

Features of symex batch systems:

  • “Electronic operator” without potential for error
  • 100% repeatable process flows and product quality
  • 100% plannable process times
  • Verification of introduced raw materials via scan function
  • Animated process flow and visual process control
  • Simple and intuitive to operate without special skills
  • Integrated recipe- and production management system
  • Revision management with audit trail
  • S88 and FDA conformity
  • FDA-compliant user management
  • FDA-compliant processing data recording (21 CFR part 11)
  • Guaranteed process validation
  • Simple to create recipes without size limitation
  • Customer-specific batch reports with all process data
  • Interface to main control systems (SAP, WERUM, etc.)

 

 

The versions:

  • symex Batch 3.0
    Unbeatable value for money and no licence fees
  • Wonderware InBatch
    Wonderware standard solution for InTouch visualisations
  • Rockwell FactoryTalk Batch
    Rockwell standard solution for Rockwell automated systems

 

symex batch systems – bespoke designs for mixing- and homogenizing systems!

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Batch system