IKA UTL 25 digital Inline ULTRA-TURRAX, continuous-flow disperser, 0010006856

Process reliability in continuous operation: The IKA UTL 25 digital Inline ULTRA-TURRAX

The IKA UTL 25 digital (MPN 0010006856) represents a specialised class of high-performance laboratory dispersers. Whilst conventional batch dispersers (immersion units) are held directly in an open beaker, the UTL 25 digital operates on the inline principle (continuous flow). This makes it an indispensable tool for simulating industrial-scale processes, for producing ultra-fine emulsions without air entrapment, and for the safe processing of critical substances in closed systems. With a speed range of up to 25,000 min⁻¹ and proven rotor-stator technology, this unit bridges the gap between laboratory experiments and pilot-scale operations.

The inline principle: Why continuous flow rather than batch?

The IKA UTL 25 digital differs fundamentally from conventional agitators. In inline dispersion, the medium is not swirled in an open vessel but is pumped through a closed working chamber (or conveyed by the suction effect of the rotor). This offers decisive advantages for demanding applications:

1. Prevention of air ingress: In open vessels, a ‘Trombe’ (vortex) often forms, drawing air into the product. This is undesirable in the case of creams, lotions or oxidation-sensitive substances. The UTL 25’s closed system effectively prevents this.
2. Controlled shearing: In batch operation, some particles pass through the shearing zone frequently, whilst others do so rarely. In inline operation, every particle must pass through the rotor-stator gap before leaving the outlet. This guarantees an extremely homogeneous particle size distribution and reproducibility.
3. Safety: As the system is sealed by hose connections, no vapours or aerosols escape. This is essential when working with toxic or volatile solvents.

Performance and digital control

At the heart of the IKA UTL 25 digital is a powerful drive with a power consumption of 500 watts. It enables speeds ranging from 3,000 to 25,000 rpm. The high circumferential speed of the rotor tips generates enormous shear forces, which reliably break down droplets and particles to the micro- or even nano-scale. The ‘digital’ designation stands for ease of use and process monitoring:

• LED display: The speed is clearly displayed, enabling the precise setting of experimental parameters.
• Timer function: You can set process times to carry out standardised test series (SOPs).
• Interface: The device can be controlled and monitored via USB (using the optional labworldsoft software ®) to document speed-time profiles.

Scalability: From the laboratory to production

A key area of application for the IKA UTL 25 digital is ‘upscaling’. In the chemical and pharmaceutical industries, products are often manufactured in large-scale inline machines (e.g. the IKA 2000 series). If you carry out development work in the laboratory using a simple beaker stirrer, the results often cannot be transferred to large-scale production. The UTL 25 digital simulates the fluid dynamics and shear conditions of large-scale machines on a laboratory scale. A formulation successfully developed here is highly likely to scale up to production plants without any problems. This saves time and costs in process development.

Flexibility in configuration: recirculation vs. single-pass

The unit offers maximum flexibility when conducting tests:

• Recirculation (loop): The outlet is reconnected to the inlet vessel via a hose. The product passes through the shear zone multiple times (‘multipass’). Ideal for achieving very narrow particle size distributions.
• Single-pass (through-flow): The product is conveyed once from a feed vessel through the machine into a collection vessel. Ideal for continuous processes or where shear sensitivity is a critical factor.

The rotor’s pumping capacity is often sufficient to draw in low-viscosity media automatically. For higher-viscosity media, an upstream pump may be necessary to ensure flow.

Durability and Cleaning

The working chamber and the dispersing tool are made of high-quality stainless steel and are chemically resistant. Cleaning is extremely simple: it is often sufficient to rinse the system whilst it is closed using a suitable solvent or cleaning agent (CIP – Cleaning in Place). However, the dispersion chamber can also be dismantled for thorough cleaning or sterilisation. An optional temperature sensor (PT 1000) can be connected directly to the unit to monitor the product temperature at the outlet – an important feature, as high shear forces always generate heat.

Application examples

• Cosmetics: Production of ultra-fine emulsions for creams and lotions without air pockets.
• Food: Homogenisation of dairy products, juices or sauces.
• Chemicals: Dispersing pigments in varnishes or paints in a continuous flow.
• Pharmaceuticals: Cell disruption or the production of active ingredient suspensions.

In summary, the IKA UTL 25 digital is the professional solution for laboratories that need to go beyond simple stirring. It brings the benefits of industrial in-line production to your laboratory bench.

Technical data

• Motor power input/output: 500 W / 300 W
• Speed range: 3,000 – 25,000 rpm
• Max. viscosity: 5,000 mPas
• Flow rate (H₂O): 4.4 – 11.6 l/min (depending on the tool/setup)
• Display: LED
• Timer: Yes
• Volume range (circulation): unlimited (depending on the container)
• Interface: USB
• Connection for external temperature sensor: Yes (PT 1000)
• Dimensions (W x H x D): 87 x 271 x 106 mm
• Weight: 2.5 kg
• Protection class: IP 20

Contents

• 1 x IKA UTL 25 digital (drive unit)
• 1 x dispersion chamber (DK 25.11 generator)
• 1 x tripod pole
• 1 x USB cable
• 1 x User manual

Individual requirements & accessories

To set up a complete recirculation system, you will need tubing, stand components and, if necessary, a suitable container. Adapters for batch operation are also available. Please contact our procurement service for advice on the appropriate setup.