Tech Team · Kintek Solution

Wiped film evaporators (WFEs) are highly efficient distillation systems widely used in industries requiring precise separation and purification of heat-sensitive materials. Their key advantages include reduced residence time, enhanced heat transfer, and the ability to handle high-viscosity and high-solids materials. These systems operate continuously, increasing productivity while maintaining product quality. Additionally, WFEs are cost-effective, customizable, and suitable for large-scale production, making them ideal for refining sensitive compounds like cannabinoids, essential oils, and pharmaceuticals. The technology ensures excellent heat transfer, material transport, and separation efficiency, resulting in high-quality distillates with minimal degradation.

Key Points Explained:

1. Reduced Residence Time:

   • Wiped film evaporators minimize the exposure of materials to high temperatures by reducing residence time to just 1-3 minutes.
   • This is particularly beneficial for heat-sensitive compounds, such as cannabinoids, essential oils, and pharmaceuticals, as it preserves their quality and prevents degradation.
   • The short residence time is achieved through the use of 45° diagonal grooved scrapers that create controlled, small active movements of the material, ensuring efficient mixing and evaporation.

2. Enhanced Heat Transfer:

   • The agitated thin film created by the scrapers generates a "bow wave," which significantly improves heat transfer efficiency.
   • This mechanism allows for rapid and uniform heating, even for high-viscosity or high-solids materials, ensuring consistent product quality.
   • The system uses temperature-controlled feed containers and outer jacketed wiped film bodies, along with refrigerated cooling for condensers and vacuum traps, to maintain precise thermal conditions.

3. Handling High-Viscosity and High-Solids Materials:

   • WFEs are uniquely capable of processing materials with high viscosity and solid content, which are challenging for traditional distillation methods.
   • The scrapers ensure even distribution and mixing of the material, preventing clogging and ensuring efficient separation.

4. Continuous Operation and High Productivity:

   • Wiped film evaporators operate in a continuous mode, eliminating the need for frequent changeovers and enabling large-scale production.
   • This continuous operation increases productivity and reduces downtime, making it ideal for industrial applications.
   • The system's ability to process large batches of liquids further enhances its efficiency.

5. Low Evaporation Temperatures and Vacuum Operation:

   • WFEs refine heat-sensitive and dirty materials using low evaporation temperatures and high vacuums, minimizing thermal degradation.
   • The use of robust turbo molecular pumps allows for achieving very low pressures, improving separation efficiency and yield.

6. Cost and Space Efficiency:

   • The compact design of wiped film evaporators reduces the need for extensive equipment and space.
   • By minimizing processing time and energy consumption, WFEs lower operational costs while maintaining high-quality output.

7. Customization and Control:

   • Operators can optimize material feed rates, vacuum levels, and temperatures to achieve the desired distillate composition.
   • The system's easy-to-use controls ensure repeatable processes, making it suitable for a wide range of applications.
   • Customization options allow for tailoring the equipment to specific production needs.

8. High-Quality End Product:

   • The combination of short residence time, precise temperature control, and efficient separation results in an extremely high-quality distillate.
   • Although two passes through the system are often required for optimal purity, the final product is exemplary, with minimal impurities and degradation.

In summary, wiped film evaporators offer a versatile and efficient solution for distillation processes, particularly for heat-sensitive and challenging materials. Their ability to operate continuously, handle high-viscosity substances, and produce high-quality distillates makes them a valuable tool in industries ranging from pharmaceuticals to essential oils and cannabinoid extraction.

Summary Table:

Advantage	Description
Reduced Residence Time	Minimizes material exposure to high temperatures, preserving quality.
Enhanced Heat Transfer	Rapid and uniform heating for high-viscosity and high-solids materials.
Continuous Operation	Increases productivity and reduces downtime for large-scale production.
Low Evaporation Temperatures	Refines heat-sensitive materials with minimal thermal degradation.
Cost and Space Efficiency	Compact design reduces equipment and energy costs.
Customization and Control	Operators can optimize feed rates, vacuum levels, and temperatures.
High-Quality End Product	Produces distillates with minimal impurities and degradation.

Ready to optimize your distillation process? Contact us today to learn more about wiped film evaporators!