ULTRASOUND BLENDING – THE BLENDTEK CONCEPT

Blendtek’s ultrasonic blending technology transforms how lubricants are produced. Unlike traditional methods that rely on heat and heavy mechanical stirring, our system blends at a molecular level using sound waves. The result: faster, cleaner, and more sustainable blending.

KEY FEATURES

• Heatless process – “Cold Boiling” technology.
• Molecular blending – no physical agitation needed.
• Unique ultrasound wave control – tailored to lubricants.
• Gentle on additives – no shearing or polymer degradation.
• Low energy requirements – typically over 90% less than traditional methods.
• Flexible production – no wasted heat or resources.
• Carbon-neutral ready – compatible with renewable energy.
• Retrofit design – fits into any existing plant.
• Fast product changeovers – easily flushable and no minimum batch size.
• Low maintenance – simple, reliable, user-friendly.

Sustainable blending has never been this efficient.

HOW DOES IT WORK?

Acoustic Cavitation

Unlike conventional methods that require heating, stirring and cooling, Blendtek blends oils and additives in continuous flow – instantly and efficiently. High-frequency sound waves create microscopic bubbles that collapse with incredible force. These micro-explosions generate powerful local jets that instantly disperse additives into base oils – without heat or mechanical stirring.

The Process

• Ultrasound waves cause bubbles to form and collapse within the fluid.
• The implosions release focused energy, dispersing additives at the molecular level.
• Most blending occurs in the first passes, breaking down clusters instantly.
• Later passes fine-tune the homogeneity until the blend is complete.

By harmonising the benefits of both micro- and macro-mixing, the Blendtek system combines the convenience of batch blending with the speed and efficiency of inline systems. The result is optimum homogeneity at record speed, seamlessly integrated into existing plant operations.

How “Blend as You Fill” Works

Traditional blending requires filling a tank with base oil and additives before starting a separate heating and mixing process. Blendtek works differently: it blends as you fill.

• Base oils and additives flow through the ultrasonic circuit as they enter the vessel.
• Ultrasonic energy is applied instantly, dispersing additives at a molecular level before they even reach the tank.
• This continuous inline approach saves time, energy, and resources.

Result: a perfectly uniform blend – achieved in a fraction of the time and with minimal energy input.

SYSTEM PARAMETERS

Blendtek units are engineered around three core factors:

• Total Volume Exchange (TVE): time for the full batch to pass once through the circuit.
• Vessel Fill Rate (VFR): time to input all components into the vessel.
• Residence Time Distribution (RTD): exposure time of fluid to ultrasound waves.
• Long service life / scalable
  

⚡ For maximum efficiency, TVE and VFR are balanced. If TVE rises and RTD falls, additional units can be added to maintain optimum performance.

WHY IT WORKS FOR LUBRICANTS

• Additives are dispersed instantly into a small volume of base oil, creating a master blend.
• As more base oil is added, the ultrasound circuit and flow turbulence complete the blending.
• Homogeneity is achieved quickly, with diminishing returns on later passes – proving the majority of the work is done at the start.

THE RESULT

We have validated both blend homogeneity and additive stability through a comprehensive study:

1. Homogeneity – On blend completion, samples were taken from both the top and bottom of the vessel. Results proved a complete and uniform mix.
2. Additive Integrity – The finished blend was circulated repeatedly through the ultrasound unit. Results showed no degradation of additive packs, even over extended exposure.

All sample results consistently fell within their test standard repeatability limits, confirming the stability and quality of the final product.

Bottom Line

• Faster blending cycles.
• Lower energy input.
• Homogeneous, high-quality blends.
• Flexible integration into existing plants.
  

Ready to Transform Your Blending Process?

Discover how Blendtek’s ultrasonic technology can cut your energy use, reduce your CO₂ footprint, and speed up your production.

👉 Contact us today to request a demo, discuss your plant requirements, or calculate your potential ROI.