Advanced Manufacturing Processes for Semi-Solid Products

In cosmetics, pharmaceuticals and food production, as economic manufacturing, flexibility and hygiene standards continue to increase, process technicians bear a special responsibility in optimizing production processes.

The report below on cosmetic production explains the likelihood of manufacturing facilities meeting the standards mentioned above.

For example, high-value cosmetic products found in beauty institutes where professional cosmetic recommendations are prioritized, beauty and spa centers. It goes without saying that these products have proven properties, contain a skin-friendly pH value, are made from natural ingredients of plant origin as much as possible, and have been developed according to the latest scientific findings. These high product quality standards require the same standards for manufacturing facilities. In this context, it should be considered that various cosmetic products require frequent production changes in different batch sizes. Therefore, the machine must guarantee maximum flexibility, short production and cleaning times. For the reasons mentioned above, it was first decided to separate the fat phase preparation process from the homogenization process. It is true that this created an additional investment cost for the premix tank. However, production times have been significantly reduced. This is because while products are fed into the premix tank and the mixture reaches the process temperature, other work can be done in the homogenizer mixer.

Circulation mixers were used instead of conventional propeller mixers for the mixing operation in the premix tank. These circulation mixers have the following advantages:

• In addition to providing good mixing, the prepared mixture can be transferred to the mixer via the circulation mixer. This particularly prevents air intake or foaming during the discharge of the tank in surfactant manufacturing and hot-cold processes. • Installation at the lowest point of the tank bottom allows operation with the smallest batch sizes and guarantees easy cleaning since there is no piece extending from the top of the tank into the tank. • Liquids or powders can be sucked into the circulation flow under vacuum. • Short product heating times are achieved through uniform edge flow along the heated tank wall. • Due to the high pumping capacity of the circulation mixer, no additional pump is required for CIP cleaning (cleaning in place) of the tank and all product lines. In general, the combination of the fat phase and cold water phase in the homogenizer mixer should be done under the highest possible vacuum (just below the product's evaporation point). This requires a homogenizer that guarantees good homogenization properties and high efficiency even under such critical production conditions to obtain the best possible, uniform particle size and distribution without air voids. When selecting a homogenizer, focus should be on limits, efficiency and capacity reserve to prevent permanent material wear for products that may require higher shear forces in the future. Drive power alone is not decisive in this respect, but exceeding the maximum tip speed of the rotor causes cavitation in homogenization. The rotor guard offered as an option for the homogenizer has proven useful. Its function is to prevent foreign materials that accidentally enter the mixer from getting between the rotor stator teeth and causing damage. The design of the anchor-type mixer is particularly important for ensuring good vertical mixing especially during cooling, as well as for continuously providing reliable homogenization during cooling and heating processes and maintaining it through good scraping of the tank wall. This must be ensured for both directions of rotation of the mixer.

In addition to the features mentioned above, cleaning the machine is of special importance, as it must be carried out as quickly and completely as possible.

The speed and reliability of the cleaning process can be ensured if the following points are observed: • High pumping capacity of the homogenizer (= pressurization). • Accessibility of the cleaning liquid to seals in contact with the product. • No sharp corners on all internal components in the product area. • No screws, pins, etc. in the product area if possible. By separating the premix tank from the mixer, this tank can be cleaned during the mixer's cooling process. While the mixer is in its final operation, the CIP cycle, a separation in the control system enables the start of a new batch number with water and oil premix in the premix tank. Thus, different operations can be produced and documented under different batch numbers.     Daniel Gimpel Sales Engineer Netzsch Makine Sanayi ve Tic. Ldt. Şti.