Vacuum Film Evaporizer for High Viscosity Liquids

Product Overview

The Vacuum Film Evaporizer for High Viscosity Liquids represents a breakthrough in thermal separation technology, specifically engineered to handle challenging high-viscosity materials up to 100,000 cP. Utilizing mechanical vapor recompression (MVR) technology and a falling film design, this evaporator achieves efficient solvent removal or concentration under vacuum conditions (-96 kPa), operating at moderate temperatures (37-40°C) to preserve heat-sensitive components. With an exceptional energy efficiency rating of 0.05-0.07 kWh/L for water evaporation, it outperforms traditional evaporators by 70% in energy savings. The compact design features a vertical heating column with precision-engineered distribution plates that ensure uniform liquid film formation, critical for consistent evaporation rates in viscous applications. Available in processing capacities from 50L/h to 5,000L/h, this equipment serves industries ranging from food processing to specialty chemicals where gentle yet efficient concentration is essential.

Product Features

Energy-Efficient MVR Technology

The integrated mechanical vapor recompression system recovers latent heat from evaporated vapors, reducing energy consumption to 0.05-0.07 kWh per liter of distillate – a fraction of the 0.5-0.8 kWh/L required by conventional steam-heated evaporators. This translates to annual energy savings exceeding €25,000 for a 500L/h system operating 8,000 hours/year.

Advanced Process Control

PLC-based control system with HMI touchscreen interface

Real-time monitoring of vacuum level, temperature, and flow rates

Automatic feed rate adjustment based on viscosity measurements

Remote diagnostics capability via Ethernet connection

Sanitary & Industrial Configurations

Food-grade models feature 316L stainless steel construction with Ra 1.6μm polished surfaces, meeting EU 2025/351 regulations. Industrial versions offer Hastelloy C-276 options for corrosive applications, with pressure ratings up to 0.6MPa for high-boiling solvents.

Applications

Food & Pharmaceutical Industries

Fruit juice concentration (preserving vitamin C content by 30% vs. traditional methods)

Natural extract purification (herbal extracts, essential oils)

Pharmaceutical API concentration (temperature-sensitive compounds)

Dairy product processing (whey protein concentration to 30-40% solids)

Chemical & Industrial Applications

Polymer solution concentration (adhesives, coatings)

Wastewater treatment (zero liquid discharge systems with 99.9% COD removal efficiency)

Specialty chemical purification (removing volatile organic compounds)

Biofuel production (biodiesel purification and water removal)

The evaporator's low-temperature operation is particularly valuable for heat-sensitive materials, maintaining product integrity while achieving concentration ratios up to 10:1 in a single pass.

FAQ

What viscosity range can it handle?

The evaporator efficiently processes materials from 1,000 to 100,000 cP. For ultra-high viscosity materials (>50,000 cP), optional high-torque distribution pumps and heated feed lines are available.

How does it achieve energy savings?

By recompressing water vapor through a mechanical compressor, the system recovers >90% of the latent heat that would otherwise be lost, reducing primary energy requirements dramatically compared to steam-heated systems.

What maintenance is required?

Scheduled maintenance includes weekly inspection of wiper blades, monthly filter changes, and quarterly compressor oil analysis. The design allows 95% of components to be accessed without full system disassembly.

Is it suitable for food contact applications?

Yes, food-grade models meet FDA CFR 21 Part 177 and EU 10/2011 (2025 update) requirements, with all contact surfaces made from 316L stainless steel and designed for full CIP compatibility.

What is the typical payback period?

Based on average energy costs (€0.15/kWh), the energy savings typically result in a payback period of 18-24 months for continuous operation systems.