Development of a High-Pressure Homogenizing Head for Dairy Processing

Project overview

HIGH-PRESSURE HOMOGENIZATION FOR DAIRY PRODUCTION

Industrial dairy homogenization requires precise control of fluid movement under high pressure. In this project, KVAZAR was tasked with developing a single-stage homogenizing head for an existing HPP Pump L-300/4, with a specified operating pressure of 1,200 bar.

THE ENGINEERING CHALLENGE

The main technical challenge was cavitation inside the homogenizing head. Under extreme operating conditions, cavitation can damage the valve surface, making component geometry and material selection critical design considerations.

ENGINEERING AND DEVELOPMENT

The project involved calculating fluid-flow behavior and cavitation conditions, developing the geometry of the valve and seat, selecting materials suitable for food-processing equipment, and preparing detailed manufacturing drawings.

The engineering solution was developed specifically for the required operating conditions rather than relying on a standard off-the-shelf homogenizing head.

PERFORMANCE AND RESULTS

The manufactured head demonstrated effective operation at 1,200 bar, with a throughput of 40 liters of homogeneous yogurt per minute.

The customer independently operated the head at increased pressures of 1,500 and 1,800 bar. Valve failures were recorded at 1,800 bar. These observations established an important distinction between the specified operating conditions and performance at pressures beyond the original requirement.

ENGINEERING CAPABILITIES

This project demonstrates KVAZAR's capabilities in high-pressure equipment design, fluid-flow analysis, precision mechanical engineering, material selection, and manufacturing documentation.

The challenge

Develop and manufacture a single-stage high-pressure homogenizing head for an HPP Pump L-300/4. The system was intended to produce a homogeneous dairy mixture and break down protein structures during yogurt processing. The required operating pressure was 1,200 bar.

Constraints

The primary engineering challenge was cavitation under extreme pressure. Cavitation occurring inside the homogenizing head can damage the valve surface and reduce component service life. The design required carefully calculated fluid-flow geometry, suitable valve and seat profiles, and materials compatible with food-processing applications.

Our solution

KVAZAR developed a custom single-stage homogenizing head designed for operation at 1,200 bar. Engineering work included analysis of fluid movement and cavitation, calculation and design of the valve and seat geometry, selection of suitable food-industry-compatible materials, and preparation of manufacturing drawings. The homogenizing head was manufactured according to the developed design.

Implementation

1. Analysis of operating requirements and pump specifications.
2. Calculation of fluid flow and cavitation conditions at 1,200 bar.
3. Development of the valve and seat geometry.
4. Selection of materials suitable for the operating conditions and food industry.
5. Preparation of engineering drawings and manufacturing documentation.
6. Manufacturing of the homogenizing head.
7. Evaluation of operating performance and analysis of results reported at higher pressures.

Technical details

Equipment: Single-stage high-pressure homogenizing head
Application: Dairy processing / yogurt homogenization
Operating pressure: 1,200 bar
Demonstrated throughput: 40 L/min
Pump: HPP Pump L-300/4
Pump maximum pressure: 2,800 bar
Pump specified flow rate: 45.3 L/min
Additional pressures applied by the customer: 1,500 and 1,800 bar
Observed limitation: Valve failures recorded at 1,800 bar

The result

The developed homogenizing head operated effectively at the specified pressure of 1,200 bar, delivering 40 liters of homogeneous yogurt per minute. The customer subsequently applied pressures of 1,500 and 1,800 bar independently. Valve failures were recorded at 1,800 bar, identifying a limitation beyond the original 1,200-bar operating requirement.

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