Nano DeBEE Gen 2

The Nano DeBEE is a compact benchtop, electric-hydraulic high-pressure homogenizer designed for laboratory R&D. It combines the power and consistency of a hydraulic system with a footprint small enough for laboratory benchtops. It is used for:

• Cell Lysis: Rupturing bacteria (E. coli), yeast, algae, and insect cells.
• Particle Size Reduction: Creating consistent nanoparticles for pharmaceutical or chemical applications.
• Emulsification: Creating stable nano-emulsions and micro-emulsions.
• Dispersions: De-agglomerating solids into liquids.

• Unlike standard homogenizers that rely on a single force, the Nano DeBEE uses a modular Emulsifying Cell (EC). This allows you to tune and mix three distinct mechanical forces - Shear, Cavitation, and Impact - to optimize results for your specific product.

• Yes. Results achieved on the Nano DeBEE are scalable to Pion’s larger pilot and production units (Mini DeBEE, DeBEE 2000 systems) because they utilize the same underlying EC technology.

• The minimum sample volume is approximately 12mL. This low hold-up volume makes it ideal for expensive or scarce R&D materials.

• The Nano DeBEE can operate at pressures up to 45,000 PSI, though standard operation often falls between 20,000 and 30,000 PSI depending on the application.

The Nano DeBEE Emulsifying Cell (EC) can be configured in two main flow patterns:

• Parallel Flow: Product flows straight through the nozzle. Best for maximum cavitation and laminar flow. Often used for cell lysis.
• Reverse Flow: Product exits the nozzle and immediately impacts a reactor wall before reversing direction. Best for maximum impact and shear. Often used for hard-to-break particles or tough emulsions.
• To change from Parallel to Reverse Flow watch this video - Nano DeBEE Changing Process Setup

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• Yes. High-pressure homogenization generates significant heat. The Nano DeBEE typically includes a heat exchanger (cooling coil) at the outlet to bring the product temperature down immediately after processing to preserve sample integrity.

• Yes. The EC is modular. You can swap between Parallel Flow (Cavitation, laminar shear), Reverse Flow (Shear/Impact), or change nozzle sizes (e.g., Z05 vs. Z08) using standard wrenches included in the tool kit. Always ensure the system is depressurized before opening the EC. Parallel flow is typically used in cell lysis, while reverse flow is typically used in emulsions.
• To change the Nozzle, Reactors and Seal watch this video - Nano DeBEE Maintenance - Changing Seals & Reactors

• Pion recommends a yearly preventative maintenance service. However, high-wear parts (seals and gaskets) should be inspected regularly based on usage frequency.

You should keep spares of the following:

• Plunger Seals: These prevent leakage around the high-pressure piston. Please watch this video on how to replace the Plunger Seal - Nano DeBEE Maintenance - Changing the Plunger Seal
• Check Valve (CV) Seals: O-rings that seal the inlet/outlet valves.
• Backup Rings: Used to support the O-rings under high pressure.

• Flush: Immediately after use, flush the system with DI water to remove product residue.
• Solvent: Run a compatible solvent (e.g., Ethanol or Isopropyl Alcohol) if your product is not water-soluble.
• Sanitize: For biological applications, you can flush with 0.1N - 1N NaOH (Sodium Hydroxide), followed by a thorough water rinse until the pH is neutral.
• Storage: Do not leave harsh chemicals in the lines. Leave the system filled with water or a storage solution (e.g., 20% Ethanol) if storing for longer periods.

• To replace the Plunger Seal watch this video - Replacing the plunger seal on the Mini DeBEE homogenizer
• To determine if the Plunger Seal need to be replaced follow these steps:

Preparation

• Flush the system thoroughly (CIP).
• Depressurize completely.
• Disconnect the Inlet Hose (Tri-Clamp) and the Outlet High-Pressure Tubing (Gland & Collar) from the cylinder head.

Remove the High-Pressure Cylinder

• Support the Cylinder: The stainless-steel cylinder is heavy. You may need a second person or a support block to hold it steady once unbolted.
• Loosen Mounting Bolts: Using the appropriate wrench, remove the 4 (or more) bolts securing the cylinder to the distance piece/hydraulic face.
• Extract the Cylinder:
  
  • Slowly pull the cylinder straight forward (away from the machine).
  • CRITICAL: Do not let the cylinder "hang" on the plunger. Keep it perfectly horizontal until it clears the plunger tip.
  • Tip: Rotating the cylinder slightly as you pull can help break the friction of the seal.

Inspect the Plunger (The Piston)

• The plunger will remain attached to the hydraulic drive, protruding out.
• Clean: Wipe the plunger with a soft, lint-free tissue.
• Fingernail Test: Run your fingernail along the length of the plunger (the working zone).
  
  • Fail: If your nail "clicks" or catches on a scratch, the plunger is scored. Replace immediately.
  • Pass: If it feels glassy smooth, the plunger is likely reusable.

Inspect the Seal

• The seal is located inside the bore of the High-Pressure Cylinder you removed.
• Extraction: Use a specialized seal removal tool or a plastic/brass pick. Never use a steel screwdriver or pick, as scratching the cylinder bore (stuffing box) will cause permanent leaks.
• Examine the Seal:
  
  • Ragged Edges: Indicates "extrusion" (seal blowing out the back). Check your Backup Ring.
  • Grooves: Vertical lines inside the seal indicate it was grinding against a damaged plunger.

Reassembly Tip

• Lubricate: Apply a generous amount of water or suitable lubricant (depending on process compatibility) to the plunger and the new seal.
• Alignment: When pushing the cylinder back on, you will feel resistance when the seal hits the plunger tip. Do not force it. Wiggle gently or rotate to help the seal "climb" onto the plunger without rolling.
• Torque: Tighten the mounting bolts in a "star" (crisscross) pattern to ensure the cylinder is aligned perfectly with the drive.

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These are the most common issues. Potential causes include:

• Hydraulic Oil: Check the hydraulic oil level. Low oil can cause the hydraulic pump to cavitate or lose pressure.
• Priming: Ensure the system is fully primed with liquid. Air trapped in the product cylinder ("air lock") will prevent the hydraulic piston from effectively compressing the sample.
• Check Valve Debris: A particle may be stuck in the inlet or outlet check valve, preventing it from closing. Flush the system or disassemble and clean the check valves.
• Worn Seals: The plunger seal or high-pressure seal may be worn and leaking.

• This indicates the Plunger Seal has failed. Stop the machine and replace the seal immediately. Continuing to run with a leaking plunger can score the piston, leading to expensive repairs.
• To replace the Plunger Seal watch this video - Nano DeBEE Maintenance - Changing the Plunger Seal

• Check the inlet filter for clogs.
• Ensure the product viscosity isn't too high for the current feed setup.

• Check that the cooling water is flowing through the heat exchanger.
• The Heat Exchanger may be scaled up (internally) or fouled.
• You may need to reduce the operating pressure (pressure is directly proportional to heat generation).

• This often indicates hydraulic pump cavitation. Check the oil level immediately.
• It could also indicate the intensifier piston hitting the end of its stroke too hard if the limit switches are misadjusted or if the product side is starved of feed (no resistance).

Determine where the leak is coming from, identifying weep holes drilled into the cylinder assembly.

• The weep holes serve two critical functions - Safety (preventing pressure build up behind seals) and diagnostics (acting as a visual indicator).
• Fluid leaking from the high-pressure cylinder may indicate a plunger seal failure. It is recommended to stop and inspect the plunger seal for damage.
• Please watch this video: Nano DeBEE: Maintenance - Managing Leaks