Case Study: Application of Medium-Speed High-Shear Emulsifiers in Emulsion Product Production
This case study records the application process of medium-speed high-shear emulsifiers in a production facility specializing in emulsion-based products, focusing on the pre-application challenges, equipment selection considerations, commissioning and parameter optimization, long-term operation effects, and maintenance practices. All content is based on actual production scenarios and technical data, aiming to provide practical reference for other practitioners in the same industry who are faced with similar production needs.
1. Background of the Production Scenario
The production facility involved in this case mainly produces three categories of emulsion products: low-viscosity hydrating gels (viscosity: 6000-12000 mPa·s), medium-viscosity facial lotions (viscosity: 15000-25000 mPa·s), and high-viscosity anti-aging creams (viscosity: 30000-40000 mPa·s). Before introducing medium-speed high-shear emulsifiers, the facility used traditional low-speed mixers (rotating speed: 200-300 rpm) and single-stage high-shear homogenizers for production. With the expansion of production scale and the improvement of product quality requirements, the original equipment gradually exposed a series of problems that affected production efficiency and product stability.
From the perspective of product quality, the emulsion products produced by the original equipment had obvious defects: the particle size of the low-viscosity hydrating gel was uneven (average particle size: 8-12 μm), resulting in poor transparency and slight graininess when applied; the medium-viscosity facial lotion was prone to stratification after 2-3 months of storage, with oil droplets floating on the surface; the high-viscosity anti-aging cream had uneven texture, with local agglomeration of functional ingredients (such as plant extracts and vitamins), which reduced the product's efficacy and user experience.
In terms of production efficiency, the original production process required multiple steps of mixing and homogenization: first, the low-speed mixer was used for preliminary mixing of raw materials (taking 40-60 minutes), then the single-stage high-shear homogenizer was used for secondary processing (taking 20-30 minutes), and finally, manual stirring was required to adjust the texture (taking 10-15 minutes). The total processing time for a single batch (100L) was 70-105 minutes, and the daily output was only 300-400 kg, which could not meet the increasing market demand. In addition, the original equipment had no automatic wall-scraping function, and a large amount of material adhered to the tank wall after each batch of production, resulting in material waste (waste rate: 3-5%) and increased manual cleaning workload (cleaning time per batch: 20-30 minutes).
In terms of equipment maintenance and operation, the single-stage high-shear homogenizer was prone to blockage when processing high-viscosity materials or materials containing solid particles, requiring frequent disassembly and cleaning (2-3 times a week), which not only increased the labor intensity of operators but also affected the continuity of production. At the same time, the low-speed mixer had poor temperature control accuracy (temperature fluctuation: ±2-3℃), which led to the inactivation of heat-sensitive ingredients (such as vitamins) in the production process, further reducing product quality.
2. Equipment Selection Considerations
To solve the above problems, the production facility decided to replace the original equipment with professional emulsification equipment. After in-depth research on the market and technical communication with equipment technicians, the facility finally selected two medium-speed high-shear emulsifiers (model: 100L and 200L) as the core production equipment. The selection process mainly considered the following factors, all of which were closely combined with the actual production needs and product characteristics of the facility:
First, the adaptability to product viscosity and particle size requirements. The facility's products cover low, medium, and high viscosity ranges, and the low-viscosity hydrating gel has high requirements for transparency (average particle size ≤ 1 μm). The selected medium-speed high-shear emulsifiers have adjustable homogenizing speed (3000-15000 rpm) and shear gap (0.02-0.06 mm), which can meet the particle size requirements of different products: high speed (12000-15000 rpm) and small shear gap (0.02-0.04 mm) for low-viscosity products, medium speed (9000-12000 rpm) and moderate shear gap (0.04-0.05 mm) for medium-viscosity products, and medium-low speed (8000-10000 rpm) and slightly larger shear gap (0.05-0.06 mm) for high-viscosity products. At the same time, the equipment is equipped with a frame-type mixing paddle (speed: 10-80 rpm) and a wall-scraping paddle (speed: 5-40 rpm), which can ensure uniform mixing of materials of different viscosities and avoid local agglomeration and material adhesion.
Second, production efficiency and automation level. The selected medium-speed high-shear emulsifiers integrate multiple functions such as mixing, homogenization, vacuum degassing, temperature control, and automatic wall scraping, which can complete the entire production process (from raw material feeding to finished product discharge) in one tank, eliminating the need for multiple transfers and secondary processing. The equipment is equipped with a PLC control system, which can store multiple sets of formula parameters and realize one-key start, reducing manual operation steps and improving production efficiency. In addition, the equipment's CIP in-place cleaning system can realize automatic cleaning of the tank body and components, greatly reducing manual cleaning time and labor intensity.
Third, temperature control accuracy and protection of functional ingredients. The facility's products contain a variety of heat-sensitive ingredients (such as vitamins, plant extracts, and peptides), which require strict control of emulsification temperature and cooling rate to avoid inactivation. The selected medium-speed high-shear emulsifiers adopt a jacketed temperature control structure, with a temperature control range of 20-90℃ and temperature control accuracy of ±0.5℃, which can accurately control the emulsification temperature (65-75℃ for medium and high viscosity products, 45-55℃ for low viscosity products). At the same time, the equipment's cooling system has an adjustable cooling rate (3-12℃/h), which can realize rapid cooling of heat-sensitive ingredients after emulsification, ensuring the activity of functional ingredients and the stability of product quality.
Fourth, equipment stability and maintenance convenience. The key components of the selected medium-speed high-shear emulsifiers (such as homogenizing head, frame paddle, and wall-scraping paddle) are made of 316L stainless steel, which has good corrosion resistance and wear resistance, and can adapt to the production of products containing acidic or alkaline ingredients. The equipment's sealing system adopts imported perfluoroelastomer sealing rings, which have good sealing performance and long service life, reducing the frequency of sealing ring replacement. In addition, the equipment's structure is designed to be easy to disassemble and assemble, which is convenient for daily maintenance and parts replacement, reducing the downtime caused by equipment maintenance.
Fifth, compliance with industry standards. The facility's products are sold in both domestic and international markets, so the production equipment must meet relevant compliance standards (such as GMP, FDA, and CE). The selected medium-speed high-shear emulsifiers have passed GMP certification, FDA food contact material certification, and CE certification. The materials of the parts in contact with materials meet the safety and hygiene requirements of the cosmetics and pharmaceutical industries, ensuring that the products meet the market access standards of various regions.
3. Equipment Commissioning and Parameter Optimization
After the medium-speed high-shear emulsifiers were delivered to the production facility, professional technicians from the equipment manufacturer and the facility's production and technical personnel jointly carried out commissioning and parameter optimization work. The entire process lasted 3 days, covering idle test, vacuum test, temperature control test, homogenization and mixing test, CIP cleaning test, and product simulation test. The key steps and parameter optimization results are as follows:
The first stage was equipment idle test (1 day). The technicians started each motor (homogenizing motor, frame paddle motor, wall-scraping motor, vacuum pump motor) separately and ran it for 30 minutes. During the test, the operation status of the equipment was observed, including noise (≤ 75 dB), vibration (≤ 0.1 mm/s), rotation direction, and speed stability (speed fluctuation ≤ 5 rpm). After the test, it was confirmed that all components of the equipment operated normally, and no abnormal noise or vibration occurred.
The second stage was functional test (1 day), including vacuum test, temperature control test, and CIP cleaning test. In the vacuum test, the tank cover was closed tightly, and the vacuum pump was started. The test results showed that the vacuum degree of the equipment could reach -0.098 MPa within 5 minutes, and the pressure drop within 10 minutes was ≤ 0.002 MPa, indicating that the equipment had good sealing performance and no air leakage. In the temperature control test, 50% of the effective volume of clean water was injected into the tank, and the heating temperature was set to 80℃. After 30 minutes of heat preservation, the temperature fluctuation was ≤ ±0.5℃, which met the temperature control accuracy requirement. Then, the cooling rate was set to 8℃/h, and the water temperature was cooled from 80℃ to 25℃. The actual cooling rate was consistent with the set value (error ≤ ±1℃/h). In the CIP cleaning test, the full-process cleaning (pre-rinsing for 5 minutes, detergent cleaning for 15 minutes, rinsing for 10 minutes, hot air drying for 10 minutes) was carried out. After cleaning, the conductivity of the tank inner wall was ≤ 10 μS/cm, and there was no cleaning dead corner or material residue, indicating that the CIP system operated normally.
The third stage was product simulation test and parameter optimization (1 day). The technical personnel used the facility's actual raw materials and formulas to carry out small-batch production simulation (batch volume: 50L for 100L model, 100L for 200L model) for the three categories of products, and optimized the equipment parameters according to the product quality test results. The specific parameter optimization process and final parameter settings are as follows:
For low-viscosity hydrating gel (main ingredients: aloe vera extract, hyaluronic acid, glycerin, etc.), the initial parameter settings were: homogenizing speed 10000 rpm, shear gap 0.03 mm, frame paddle speed 30 rpm, temperature 50℃, vacuum degree -0.095 MPa, cooling rate 8℃/h. After production simulation, the product particle size was tested (average particle size: 2.5 μm), and the transparency was not up to standard. The technical personnel adjusted the parameters: increased the homogenizing speed to 14000 rpm, reduced the shear gap to 0.02 mm, and increased the cooling rate to 10℃/h. After re-production, the product particle size was reduced to 0.8 μm, the transparency was significantly improved, and there was no graininess when applied. The final parameters were determined as: homogenizing speed 14000 rpm, shear gap 0.02 mm, frame paddle speed 30 rpm, temperature 50℃, vacuum degree -0.097 MPa, cooling rate 10℃/h.
For medium-viscosity facial lotion (main ingredients: squalane, vitamin E, glycerin, emulsifier, etc.), the initial parameter settings were: homogenizing speed 9000 rpm, shear gap 0.04 mm, frame paddle speed 40 rpm, temperature 70℃, vacuum degree -0.09 MPa, cooling rate 6℃/h. After production simulation, the product had slight stratification after 1 month of storage, and the texture was slightly uneven. The technical personnel adjusted the parameters: increased the homogenizing speed to 11000 rpm, adjusted the frame paddle speed to 50 rpm, and increased the vacuum degree to -0.093 MPa. After re-production, the product particle size was tested (average particle size: 1.5 μm), and no stratification occurred after 6 months of storage. The final parameters were determined as: homogenizing speed 11000 rpm, shear gap 0.04 mm, frame paddle speed 50 rpm, temperature 70℃, vacuum degree -0.093 MPa, cooling rate 6℃/h.
For high-viscosity anti-aging cream (main ingredients: collagen, retinol, shea butter, emulsifier, etc.), the initial parameter settings were: homogenizing speed 8000 rpm, shear gap 0.05 mm, frame paddle speed 50 rpm, temperature 75℃, vacuum degree -0.09 MPa, cooling rate 4℃/h. After production simulation, the product had local agglomeration, and the functional ingredient content was uneven. The technical personnel adjusted the parameters: increased the homogenizing speed to 9500 rpm, adjusted the frame paddle speed to 60 rpm, and set the wall-scraping paddle to independent operation (speed 35 rpm). After re-production, the product texture was uniform, no agglomeration occurred, and the functional ingredient content was evenly distributed. The final parameters were determined as: homogenizing speed 9500 rpm, shear gap 0.05 mm, frame paddle speed 60 rpm, wall-scraping paddle speed 35 rpm, temperature 75℃, vacuum degree -0.092 MPa, cooling rate 4℃/h.
After the parameter optimization was completed, the technical personnel carried out continuous production simulation for 3 batches of each product. The test results showed that the product quality was stable, and all indicators (particle size, transparency, texture, stability, functional ingredient activity) met the facility's quality standards. The equipment was officially put into production after passing the commissioning.
4. Long-Term Operation Effects and Benefits
The medium-speed high-shear emulsifiers have been in stable operation in the production facility for 18 months. During this period, the facility has established a complete equipment operation and maintenance system, and strictly implemented daily, weekly, monthly, quarterly, and annual maintenance work. The long-term operation effects and benefits of the equipment are reflected in the following aspects:
In terms of product quality improvement, the application of medium-speed high-shear emulsifiers has significantly solved the quality problems existing in the original production process. For low-viscosity hydrating gel, the average particle size is stably controlled at 0.6-1.0 μm, the transparency is significantly improved, and the product has a smooth and delicate texture when applied, which has been highly recognized by users. For medium-viscosity facial lotion, the particle size is controlled at 1.2-1.8 μm, and no stratification occurs after 12 months of storage (under normal storage conditions), which greatly improves the product's shelf life. For high-viscosity anti-aging cream, the texture is uniform and smooth, no local agglomeration occurs, and the functional ingredients (such as retinol and collagen) are evenly distributed, which effectively ensures the product's efficacy. According to the facility's quality inspection data, the qualified rate of products has increased from 92% (before equipment replacement) to 99.5% (after equipment replacement), and the customer complaint rate related to product quality has decreased from 5% to 0.3%.
In terms of production efficiency improvement, the integration of multiple functions of medium-speed high-shear emulsifiers has greatly shortened the production cycle. For a single batch of 100L products, the total production time (from raw material feeding to finished product discharge) has been reduced from 70-105 minutes (original equipment) to 35-45 minutes (new equipment), and the production efficiency has been increased by about 60%. At the same time, the equipment's automatic operation and CIP cleaning system have reduced the manual operation time and cleaning time. The daily output of the facility has increased from 300-400 kg (before equipment replacement) to 800-1000 kg (after equipment replacement), which can fully meet the market demand. In addition, the equipment's wall-scraping function has effectively reduced material adhesion, and the material waste rate has decreased from 3-5% (original equipment) to 0.8-1.2% (new equipment), which has saved a lot of raw material costs for the facility.
In terms of operation and maintenance cost control, the medium-speed high-shear emulsifiers have good stability and reliability, and the equipment failure rate is very low during long-term operation. According to the facility's maintenance records, the equipment has only experienced 2 minor faults (vacuum pipeline leakage and cooling water flow instability) in 18 months, and the fault handling time is within 2 hours, which has little impact on production. The daily maintenance of the equipment is simple and convenient, and the maintenance cost (including lubricating oil, sealing rings, and other consumables) is about 800-1000 yuan per month, which is lower than the maintenance cost of the original equipment (1500-2000 yuan per month). In addition, the equipment's energy consumption is more reasonable. For the same batch of products, the energy consumption of the new equipment is 20-30% lower than that of the original equipment, which has further reduced the production cost of the facility.
In terms of operator work intensity reduction, the medium-speed high-shear emulsifiers are equipped with a PLC control system, which can realize automatic control of the production process. Operators only need to set the formula parameters, start the equipment, and monitor the operation status of the equipment during production, which greatly reduces the manual labor intensity. The CIP in-place cleaning system of the equipment eliminates the need for manual cleaning of the tank body and components, and the cleaning time per batch is reduced from 20-30 minutes (original equipment) to 10-15 minutes (new equipment), which has significantly reduced the labor burden of operators. According to the survey of the facility's operators, the work intensity has been reduced by about 40% after the replacement of the new equipment, and the work efficiency and work satisfaction of operators have been significantly improved.
In terms of compliance with industry standards, the medium-speed high-shear emulsifiers have passed relevant international and domestic certifications, and the production process meets the GMP requirements. The facility has successfully passed the on-site inspection of domestic and foreign regulatory authorities many times after using the new equipment, and the products have smoothly entered the European and American markets. The stable operation of the equipment and the reliable product quality have laid a solid foundation for the facility's market expansion.
5. Maintenance Practices and Experience Summary
During the 18-month operation of the medium-speed high-shear emulsifiers, the production facility has accumulated rich equipment maintenance experience, and established a set of scientific and standardized maintenance system, which has effectively ensured the stable operation of the equipment and extended the service life of the equipment. The key maintenance practices and experience summary are as follows:
First, strictly implement daily maintenance work. After each batch of production, the facility's operators will carry out daily maintenance in accordance with the maintenance manual: run the CIP full-process cleaning to ensure that there is no material residue on the tank inner wall, homogenizing head, paddles, feeding port, and discharge port; check the oil level of each motor (between the upper and lower scales of the oil sight glass), and add lubricating oil in time if the oil level is insufficient; check the sealing rings of the tank cover, feeding port, and discharge port for wear, deformation, or leakage, and replace the sealing rings in time if any abnormality is found; check the cooling water pipeline, compressed air pipeline, and discharge pipeline for leakage, and tighten the pipeline connector or replace the damaged pipeline in time. Daily maintenance is the basis for ensuring the stable operation of the equipment, and can effectively prevent the occurrence of equipment faults.
Second, do a good job in regular maintenance work. The facility has formulated weekly, monthly, quarterly, and annual maintenance plans, and arranged professional maintenance personnel to carry out regular maintenance: every week, clean the filter screens of the feeding port, vacuum pipeline, and cooling water pipeline to remove impurities and avoid blockage; check the wear of the frame-type mixing paddle and wall-scraping paddle, and tighten the fixing bolt or replace the worn parts in time; add lubricating oil to the vacuum pump and calibrate the PLC touch screen. Every month, calibrate the PT100 temperature sensor and digital vacuum gauge to ensure the accuracy of parameter measurement; disassemble the homogenizing head to check the stator-rotor gap, and replace the stator or rotor if the gap exceeds the standard; add lithium-based grease to the motor bearings and clean the cooling water jacket of the tank body to remove scale. Every quarter, fully disassemble and clean the homogenizing head, replace the sealing rings of all parts, check the wiring of the control system, and maintain the CIP system. Every year, fully disassemble and inspect all components of the equipment, replace worn or aging components (such as motors, frequency converters, and pipelines), conduct a full-performance test of the equipment, and sort out the maintenance records of the whole year.
Third, pay attention to the maintenance of vulnerable parts. The vulnerable parts of the medium-speed high-shear emulsifiers mainly include sealing rings, PTFE scrapers, stator-rotor, and filter screens. The facility has prepared sufficient vulnerable parts in advance, and replaced them in accordance with the replacement cycle (sealing rings are replaced every quarter, PTFE scrapers are replaced every 6 months, stator-rotor are replaced every 2 years, and filter screens are replaced every month). At the same time, the facility has established a vulnerable part replacement record, which records the replacement time, model, and quantity of each vulnerable part, which is convenient for tracking and management.
Fourth, strengthen the training of operators and maintenance personnel. Before the equipment is put into use, the facility invites professional technicians from the equipment manufacturer to train the operators and maintenance personnel, including equipment structure, working principle, operation process, parameter adjustment, fault handling, and maintenance methods. After the training, the operators and maintenance personnel must pass the assessment before they can take up their posts. During the operation process, the facility regularly organizes technical exchange meetings to share the experience of equipment operation and maintenance, and continuously improves the professional level of operators and maintenance personnel. The professional quality of operators and maintenance personnel is an important guarantee for the stable operation of the equipment and the improvement of maintenance efficiency.
Fifth, record and analyze equipment operation data. The medium-speed high-shear emulsifiers are equipped with a data recording function, which can record the operation parameters (such as homogenizing speed, temperature, vacuum degree, and production time) of each batch of products. The facility's technical personnel will sort out and analyze these data regularly, summarize the operation rules of the equipment, and optimize the production parameters and maintenance plans. At the same time, if the equipment has a fault, the technical personnel will analyze the fault cause according to the operation data, and take targeted measures to handle the fault, which can effectively shorten the fault handling time and prevent the recurrence of similar faults.
6. Conclusion
The application of medium-speed high-shear emulsifiers in the production facility has effectively solved the problems of poor product quality, low production efficiency, high maintenance cost, and high operator work intensity existing in the original production process. Through scientific equipment selection, strict commissioning and parameter optimization, and standardized maintenance work, the equipment has been in stable operation for a long time, and has brought significant economic and social benefits to the facility: the product quality has been significantly improved, the production efficiency has been greatly increased, the production and maintenance costs have been effectively controlled, the work intensity of operators has been reduced, and the compliance of the production process has been improved.
This case shows that for production facilities specializing in emulsion-based products, choosing suitable emulsification equipment is crucial to improving product quality and production efficiency. Medium-speed high-shear emulsifiers have the advantages of strong adaptability, high automation level, high temperature control accuracy, good stability, and convenient maintenance, and are very suitable for the production of emulsion products with different viscosities and quality requirements. At the same time, scientific equipment maintenance and standardized operation management are important guarantees for giving full play to the performance of the equipment and extending the service life of the equipment.
For other production facilities in the same industry that are faced with similar production problems, they can learn from the experience of this case, combine their own production needs and product characteristics, select suitable emulsification equipment, establish scientific maintenance and operation management systems, and continuously improve product quality and production efficiency, so as to achieve sustainable development of the enterprise.
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