Koflo 316 Stainless Steel Helical Static Mixer

Overview

The Koflo 316 Stainless Steel Helical Static Mixer is an in-line, passive mixing device engineered for continuous, shear-sensitive blending of high-viscosity Newtonian and non-Newtonian fluids under laminar flow conditions. Unlike dynamic agitators, this mixer operates without moving parts—relying instead on precisely wound helical elements to induce controlled fluid division, radial reorientation, and axial recombination. Its geometry follows the principle of split-and-recombine static mixing, where each helical turn divides the incoming stream into discrete sub-layers, rotates them 180° around the central axis, and re-stacks them in reversed order. This mechanism ensures progressive homogenization without turbulence, minimizing energy input, heat generation, or product degradation. Designed specifically for sanitary process environments, the unit meets ASME BPE-2022 dimensional and surface finish requirements, with an electropolished interior (Ra ≤ 0.8 µm) and full traceability of material certification per ASTM A276 Type 316.

Key Features

• Construction from fully certified ASTM A276 Type 316 stainless steel—resistant to chloride-induced pitting and corrosion in acidic, saline, or dairy-based media
• Helical element geometry optimized for Reynolds numbers below 2000, ensuring predictable performance in viscous, low-velocity streams (e.g., 0.1–5 ft/s)
• Tri-Clamp end connections (0.5″ standard for model 1/2-SA-3-12RH-11) enabling rapid installation, cleaning-in-place (CIP), and sterilization-in-place (SIP) compatibility
• Twelve-element configuration provides ≥95% compositional uniformity after 8–10 pipe diameters of residence length—validated per ISO 11437 for static mixer efficiency testing
• No internal seals, bearings, or shafts—eliminating maintenance intervals, lubricant contamination risk, and failure modes associated with rotating equipment
• Validated for use in FDA-regulated food, pharmaceutical, and personal care manufacturing lines; documentation supports 21 CFR Part 11 audit readiness when integrated with compliant SCADA systems

Sample Compatibility & Compliance

This static mixer demonstrates consistent performance across a defined viscosity range of 1,500–50,000 cP at process temperatures from 4°C to 80°C. It is routinely deployed in the homogenization of thermally labile emulsions—including cultured dairy products (yogurt, sour cream), oil-in-water dressings (mayonnaise, ranch), frozen dessert bases (ice cream mix), and hydrocolloid-thickened suspensions (pectin gels, xanthan blends). All wetted surfaces comply with USP Class VI biocompatibility standards and meet EC 1935/2004 requirements for food contact materials. Pressure rating is validated to 150 psig at 25°C per ASME B31.3 process piping guidelines. Optional surface passivation per ASTM A967 Nitric Acid Method is available upon request for enhanced oxide layer stability.

Software & Data Management

As a purely mechanical device, the Koflo 316 Helical Static Mixer requires no embedded firmware, power supply, or digital interface. However, its performance is quantifiably integrated into process control architectures via upstream/downstream instrumentation. When paired with inline viscometers (e.g., RheoStream series), mass flow meters, or conductivity sensors, mixing efficacy can be monitored in real time using industry-standard protocols (Modbus TCP, HART 7). Batch records generated by supervisory systems may include mixer-specific metadata—such as installation date, calibration history of adjacent sensors, and CIP cycle logs—to support GLP/GMP traceability. Full documentation packages include material test reports (MTRs), surface roughness verification data, and ASME BPE conformance statements for regulatory submission.

Applications

• Continuous blending of acidified milk proteins with stabilizer premixes prior to HTST pasteurization
• In-line homogenization of egg yolk lecithin into vegetable oil phases during mayonnaise manufacturing
• Uniform dispersion of cocoa solids and sweeteners into ice cream base streams pre-freezing
• Controlled dilution of concentrated flavor emulsions into low-viscosity carrier liquids
• Mixing of pharmaceutical ointment bases with active pharmaceutical ingredients (APIs) under GMP Annex 1 conditions
• Integration into single-use bioprocessing skids for buffer conditioning in downstream purification

FAQ

What flow regimes are appropriate for this static mixer?
It is specifically designed for laminar flow (Re < 2000), where viscous forces dominate inertial forces—ideal for high-viscosity, low-velocity applications.
Can it handle particulates or suspended solids?
Yes—provided particle size remains below 20% of the internal diameter and concentration does not exceed 15% w/w to avoid element fouling.
Is validation support provided for pharmaceutical use?
Koflo supplies IQ/OQ protocol templates, material certifications, and surface finish verification reports aligned with EU GMP Annex 15 and FDA Process Validation Guidance.
How is cleaning verified after CIP cycles?
Residue detection is performed via ATP bioluminescence assays or rinse water conductivity profiling; mixer geometry enables full drainability with ≤0.5 mL hold-up volume.
Are custom lengths or connection types available?
Yes—standard configurations span 0.5″ to 2″ Tri-Clamp; custom flanged, welded, or sanitary clamp variants can be engineered per ASME BPE-2022 dimensional annexes.