FLUKO FA90C-242-M Batch High-Shear Disperser & Emulsifier

Overview

The FLUKO FA90C-242-M is a bench-to-pilot-scale batch high-shear disperser and emulsifier engineered for reproducible, scalable processing of viscous and heterogeneous formulations. It operates on the rotor-stator principle—where a high-speed rotating element (rotor) shears fluid radially into a precisely engineered stationary element (stator), generating intense hydrodynamic cavitation, turbulent flow, and extensional stress fields. This mechanism enables efficient particle size reduction, droplet breakup, dispersion stabilization, and homogenization across non-Newtonian and shear-thinning systems. Designed for technology transfer from laboratory development to pilot production, the FA90C-242-M supports process validation workflows compliant with GLP and early-stage GMP documentation requirements. Its modular architecture accommodates interchangeable rotor-stator geometries—including the standard 90F head—to tailor energy input profiles for specific rheological behaviors and target particle/droplet distributions.

Key Features

• Robust 1500 W brushless motor with frequency inverter drive delivering stable torque across the full speed range (600–3600 rpm)
• Digital RPM display with ±1% accuracy, enabling precise parameter documentation for SOP-driven operations
• Manual hydraulic lift system with 400 mm vertical stroke and fine-positioning capability for repeatable immersion depth control
• Wetted components fabricated from electropolished SS316L, ensuring corrosion resistance and cleanability per ISO 14644-1 Class 8 (ISO Class 5 equivalent under static conditions)
• IP54-rated motor housing suitable for controlled laboratory environments with ambient temperatures between 5–40 °C and ≤80% RH
• Integrated thermal and current overload protection to safeguard against stall-induced failure during high-viscosity processing (up to 8000 mPa·s)
• SS304 structural frame and base assembly optimized for mechanical stability during extended operation at elevated speeds

Sample Compatibility & Compliance

The FA90C-242-M is validated for batch processing of aqueous, solvent-based, and semi-solid systems within the 10–50 L volume range. It accommodates suspensions containing particles up to 500 µm, immiscible liquid phases requiring sub-micron emulsion formation (e.g., oil-in-water or water-in-oil), and highly filled pastes exhibiting yield stress behavior. The rotor-stator geometry allows adjustment of shear rate gradients via head selection—enabling optimization for applications ranging from pigment dispersion in coatings to active pharmaceutical ingredient (API) suspension homogenization. While not certified for sterile processing, its SS316L wetted path complies with USP material classification for extractables testing and supports cleaning validation per ASTM E3059-16 guidelines. Device operation aligns with general principles outlined in ISO 2768-1 (general tolerances) and IEC 61000-6-3 (EMC emission standards).

Software & Data Management

The FA90C-242-M operates as a standalone instrument with no embedded microprocessor or digital connectivity. All operational parameters—including setpoint speed, actual RPM, and runtime—are manually recorded. For regulated environments requiring audit trails, integration with external data acquisition systems (e.g., LabVIEW or DeltaV) is supported via analog 0–10 V output (optional interface module required). Process logs generated using such configurations satisfy foundational traceability expectations under FDA 21 CFR Part 11 when paired with appropriate electronic signature protocols and system validation documentation. No firmware updates, cloud services, or proprietary software are associated with this model.

Applications

• Pre-formulation studies of topical gels, ointments, and nanoemulsions in pharmaceutical R&D
• Dispersion of carbon black, TiO₂, or iron oxide nanoparticles in polymer matrices for advanced materials development
• Emulsification of functional food ingredients (e.g., omega-3 oils, plant sterols) into beverage bases
• Homogenization of yeast or bacterial cell lysates prior to centrifugation in bioprocessing labs
• Batch deagglomeration of ceramic or metal oxide powders in slurry preparation for additive manufacturing feedstocks
• Scale-down simulation of industrial inline homogenizers for CMC (Chemistry, Manufacturing, and Controls) dossier support

FAQ

What is the maximum viscosity the FA90C-242-M can process?
The unit is rated for continuous operation with Newtonian fluids up to 8000 mPa·s at 25 °C. Non-Newtonian systems with yield stress may require reduced speed or stepwise ramping to avoid motor overload.
Can the 90F working head be replaced with other geometries?
Yes—the FA90C platform accepts FLUKO’s full family of interchangeable rotor-stator heads (e.g., 25G, 40F, 60F, 90F), each optimized for distinct shear intensity and flow pattern profiles.
Is the device suitable for use in explosion-proof environments?
No—this model lacks ATEX or IECEx certification and must not be operated in classified hazardous locations.
Does the hydraulic lift include position locking or limit switches?
The manual hydraulic system features a mechanical lock at full extension and retraction but does not incorporate electronic end-stop sensors or programmable positioning.
What maintenance intervals are recommended for routine operation?
FLUKO recommends inspecting rotor-stator clearance and seal integrity every 200 operating hours; lubrication of hydraulic cylinder components every 6 months; and annual calibration of the digital tachometer against a traceable reference standard.