IKA UTL 25 digital Inline ULTRA-TURRAX® Dispersing Emulsifying System

Overview

The IKA UTL 25 digital Inline ULTRA-TURRAX® is a high-performance, inline dispersing and emulsifying system engineered for precise, scalable fluid processing in laboratory and pilot-scale environments. Unlike batch-type rotor-stator homogenizers, the UTL 25 operates on a continuous-flow principle—fluid is actively drawn through its precision-machined stator-rotor chamber where intense hydrodynamic shear, cavitation, and turbulent mixing occur. This inline architecture enables real-time control over dispersion stability, particle size distribution, and phase homogeneity—critical parameters in formulation development for pharmaceutical suspensions, nanoemulsions, pigment dispersions, and functional food matrices. Designed to ISO 9001-compliant manufacturing standards in Staufen, Germany, the system integrates seamlessly into closed-loop or semi-closed processing workflows, supporting both vacuum-assisted degassing (down to 1 mbar) and pressure-rated operation (up to 6 bar), making it suitable for sterile, oxygen-sensitive, or high-viscosity applications when paired with compatible feed pumps.

Key Features

• Digitally controlled speed regulation from 3000 to 25,000 rpm with real-time LED RPM display—enabling reproducible shear rate modulation across viscosity ranges.
• Modular, compact benchtop design (450 × 120 × 100 mm) with low footprint; mountable on stands or integrated directly into tubing manifolds.
• Stainless-steel wetted parts and autoclavable components (including stator housing and extension arm) compliant with DIN 13095-1 for steam sterilization at 121 °C / 2 bar.
• Robust 300 W output motor coupled with optimized thermal management—sustains stable performance during extended operation under load.
• Configurable flow path: open-outlet delivery (4.4–11.6 L/min) or pressure-regulated output via inline valves; optional integration with peristaltic or diaphragm feed pumps for viscous (>5,000 mPa·s) or non-self-priming media.
• IP20-rated enclosure ensures operator safety and electrical integrity in standard laboratory environments (IEC 60529); CE-marked per Machinery Directive 2006/42/EC and EMC Directive 2014/30/EU.

Sample Compatibility & Compliance

The UTL 25 supports aqueous, organic, and high-solids slurries with viscosities up to 10,000 mPa·s when used with auxiliary pumping. Its 26 mL process chamber accommodates rapid optimization of emulsification kinetics, nanoparticle deagglomeration, and polymer dispersion without batch-to-batch variability. The system complies with GLP documentation requirements when operated with validated SOPs and audit-trail-enabled data loggers. While not intrinsically rated for ATEX zones, its non-sparking motor design and grounded chassis meet general-purpose lab safety protocols outlined in DIN VDE 0100-410. For regulated biopharmaceutical use, the inline configuration facilitates compliance with FDA 21 CFR Part 11 when interfaced with compliant SCADA or LIMS platforms for electronic record retention.

Software & Data Management

The UTL 25 digital model features a built-in microprocessor controller with non-volatile memory for storing up to 5 user-defined operating profiles—including speed ramping, dwell time, and total runtime. Though standalone (no PC interface), all operational parameters—including actual RPM, run duration, and thermal status—are logged locally and displayed in real time. When connected to external data acquisition systems via analog 0–10 V or 4–20 mA outputs (optional module), speed and motor load signals can be synchronized with particle size analyzers (e.g., Mastersizer) or rheometers for closed-loop process correlation studies. All firmware updates are performed via secure USB port under IKA’s certified calibration traceability chain.

Applications

• Preparation of stable oil-in-water and water-in-oil emulsions for topical formulations and nutraceutical delivery systems.
• Deagglomeration of nanocellulose, carbon black, or metal oxide pigments in coating and ink R&D.
• In-line homogenization of bacterial lysates prior to chromatographic purification (reducing clogging risk in FPLC systems).
• Vacuum-assisted removal of entrained air from silicone elastomer precursors or dental impression materials.
• Continuous-phase inversion of microemulsion templates for mesoporous silica synthesis.
• Shear-controlled disintegration of lyophilized protein cakes into uniform reconstituted suspensions.

FAQ

Is the UTL 25 self-priming?
No. It requires an external feed pump or gravity-driven inlet head ≥0.5 m for reliable fluid introduction—especially for viscosities above 1,000 mPa·s.
Can it be used for sterile processing?
Yes—provided all wetted surfaces are sterilized via autoclaving (121 °C, 20 min) and the system is installed within a laminar flow hood or isolator using aseptic tubing connections.
What is the minimum achievable droplet or particle size?
Size reduction depends on formulation, surfactant system, and residence time; typical D90 values of 100–500 nm are attainable in optimized oil-in-water emulsions after two inline passes.
Does it support GMP documentation?
While the base unit lacks electronic signature capability, its operational consistency, traceable calibration certificates, and compatibility with third-party 21 CFR Part 11-compliant data loggers enable full GMP alignment in quality-controlled labs.
Is DK 25.11 the only compatible dispersing head?
The UTL 25 is specifically engineered for the DK 25.11 inline stator-rotor assembly; alternative geometries (e.g., DK 25.10) are not mechanically or hydraulically interchangeable.