What is High Shear Mixing?

High shear mixing is a process that employs a rotor–stator assembly rotating at tip speeds typically between 10–50 m/s to generate intense mechanical and hydraulic shear forces within a fluid. The narrow gap (0.1–0.5 mm) between the rotor and the precision-machined stator subjects the product to extreme shear rates of 20 000–100 000 s⁻¹, breaking down particles, droplets, and agglomerates far more efficiently than conventional impeller-based mixers.

How It Works

As the high-speed rotor draws material into the workhead, centrifugal force accelerates the product radially outward through the stator slots. This creates intense turbulence, cavitation, and impact forces at the rotor–stator interface. The result is rapid particle size reduction, de-agglomeration, and uniform distribution of immiscible phases — all in significantly shorter processing times compared to traditional methods. PVA Systems homogenizers utilise this principle to achieve sub-micron particle sizes and stable emulsions in a single pass.

Key Advantages

High shear mixers deliver repeatable results with narrow particle size distributions, reduced batch times (often 60–80 % shorter), lower energy consumption per unit of processed material, and the ability to create products that cannot be achieved with conventional agitation alone — such as nano-emulsions, fine dispersions, and highly stable creams.