ASA emulsification plants
ASA is a highly reactive, hydrophobic sizing agent whose dispersion in water or starch size is stable for only a limited time. This makes preparation technically demanding and time-critical. In addition to the emulsifying machine, the chemistry—concentration, pH and emulsifier—and operating conditions such as emulsification time, temperature and pressure are decisive.
An ASA emulsification plant coordinates these requirements in a defined process. It combines a closed system, control valves, temperature, pressure and flow measurement with the ASA emulsifying machine at its core.
Reliable ASA preparation requires chemistry, equipment and process control to be matched. Cavitron therefore supplies both emulsifying machines for integration into existing systems and complete ASA emulsification plants.
Plant configuration
- Compact, closed design: modular equipment for continuous operation.
- Inline emulsification: preparation without batch holding stages in the emulsification section.
- Multi-ply dosing: emulsion distribution configured for the required paper plies.
- Flushing circuits and CIP capability: cleaning provision for ASA residues that can adhere and polymerise.
- Drainable pipework with minimised dead spaces: designed to limit deposits.
- ASA metering pump: controlled feed rate.
- Starch-size flow measurement: coordination of the ASA ratio, typically 0.5–2% according to the application.
- Wetted stainless-steel components: for example grades 1.4301 or 1.4571, selected for the formulation.
- Compatible seals and hoses: for example PTFE or FKM, selected for ASA service.
- Closed handling: containment of the reactive sizing agent.
- Temperature monitoring: elevated temperatures, particularly above 50 °C, accelerate hydrolysis.
- Integrated control: semi-automatic or fully automatic emulsion preparation according to the plant configuration.
Plant engineering for intensive mixing processes
Cavitron designs and builds processing plants around its own rotor-stator machines. A detailed analysis of the materials and required quantities is the first step in selecting the machine and arranging the process.
In addition to the high-shear mixer, Cavitron can integrate modules to support efficient and safe operation. Storage and feeding equipment, including big-bag stations, silos and screw conveyors, provides a continuous, uniform raw-material supply where required.
Gravimetric and volumetric metering systems support accurate formulation. Magnetic separators help protect the process from metallic contamination. Further modules can be included for liquid handling or automation of individual processing steps.
