Cream Emulsifier Equipment Application Case
In the field of daily chemical production, the stability and uniformity of cream products have always been core factors affecting product quality and market acceptance. A manufacturer engaged in the research and development and production of skin care creams once faced a series of production bottlenecks, which were ultimately resolved with the introduction of professional cream emulsifier equipment, achieving a comprehensive upgrade of production efficiency and product quality.
Background of Production Difficulties
Before purchasing the emulsifier equipment, the manufacturer mainly relied on traditional mixing equipment for cream production. The technical team found that there were prominent problems in the production process. First, the mixing uniformity of raw materials was insufficient. The oil phase and water phase raw materials could not be fully fused, resulting in the presence of small particle precipitates in the finished cream, which affected the texture and user experience of the product. Second, the emulsification time was too long. A single batch of cream products took more than 3 hours from raw material feeding to the completion of emulsification, which restricted the overall production capacity and could not meet the growing market demand.
In addition, the traditional equipment had poor temperature control accuracy during the production process. The temperature fluctuation range often exceeded ±5℃, which easily led to the inactivation of some active ingredients in the cream, reducing the efficacy of the product. The high rate of unqualified products also increased the production cost of the enterprise, and the after-sales complaints related to product texture gradually increased, bringing certain pressure to the brand reputation.
Selection and Introduction of Cream Emulsifier Equipment
After conducting market research and technical verification for many times, the manufacturer decided to introduce a set of fully automatic vacuum cream emulsifier equipment. The equipment was selected based on multiple dimensions such as technical parameters, production capacity and after-sales service. It was equipped with a high-shear emulsification head, a precise temperature control system and a closed vacuum operation environment, which could effectively solve the existing production problems.
Before the formal put into use, the equipment supplier sent professional technical personnel to the manufacturer's production workshop for on-site installation and debugging. The technical team of the manufacturer also conducted systematic training, mastering the operation process, parameter setting and daily maintenance skills of the equipment. After a week of trial operation and parameter optimization, the equipment officially entered the mass production stage.
Application Effect and Production Improvement
1. Optimization of Product Quality
After using the new cream emulsifier equipment, the most obvious change was the significant improvement of product uniformity. The high-shear emulsification head of the equipment could break the oil-water interface at a high speed of 3000r/min, making the oil phase and water phase raw materials fully emulsified and mixed. The detection data showed that the particle size distribution of the finished cream was more concentrated, and the particle diameter was controlled within 5μm, which was far lower than the 20μm standard of traditional equipment products. The finished product was delicate and smooth, without any granular feeling, and the qualified rate of products in each batch increased from 82% to 99.5%, and the after-sales complaints related to product texture decreased by more than 90% within half a year.
At the same time, the vacuum operation environment of the equipment avoided the contact between the materials and air during the production process, effectively reducing the oxidation of active ingredients. The precise temperature control system controlled the temperature fluctuation range within ±1℃, ensuring that the active ingredients in the cream were in a stable environment during the emulsification process, and the efficacy of the product was more stable. The third-party testing report showed that the retention rate of the core active ingredients of the product increased by about 25% compared with the past.
2. Improvement of Production Efficiency
The high-efficiency emulsification capacity of the equipment greatly shortened the production cycle of a single batch of products. The emulsification time of a single batch of cream was reduced from the original 3 hours to 45 minutes, and the production cycle of the whole batch was shortened by more than 70%. The daily production capacity of the enterprise increased from 5 batches to 18 batches, and the monthly output increased from 12 tons to 40 tons, fully meeting the market demand and even having the capacity to undertake customized production orders.
In addition, the automatic control system of the equipment realized the linkage of feeding, emulsification, temperature control and discharging, reducing the manual operation links. The number of operators in a single production line was reduced from 5 to 2, which not only saved labor costs, but also reduced the product quality deviation caused by manual operation errors, further improving the stability of the production process.
3. Reduction of Production Cost
The improvement of product qualification rate directly reduced the loss of raw materials. The waste of raw materials per batch was reduced from 8% to less than 1%, which saved a lot of raw material costs for the enterprise every month. The energy consumption of the new equipment was also lower than that of the traditional equipment. The power consumption per ton of products was reduced by about 30%, and the daily water consumption was also reduced due to the closed circulation system, realizing the goal of energy conservation and emission reduction in the production process.
In terms of maintenance, the equipment has a modular design, and the wearing parts can be quickly replaced. The failure rate is less than 2% per month, which is much lower than the 15% failure rate of traditional equipment, reducing the maintenance cost and downtime loss of the enterprise.
Long-term Value and Development Significance
The application of cream emulsifier equipment has not only solved the immediate production problems of the enterprise, but also laid a solid foundation for its long-term development. The improvement of product quality has enhanced the competitiveness of the enterprise's products in the market, and the sales volume of cream products has increased by 40% within a year of equipment use. The improvement of production capacity has also enabled the enterprise to expand its product line and successfully launch three new types of functional cream products, further opening up the market space.
In addition, the standardized and automated production mode brought by the equipment has helped the enterprise pass the higher-level production management system certification, improving the overall management level of the production workshop. The stable product quality and sufficient supply capacity have also established a good cooperative relationship with more downstream distributors, enhancing the brand influence of the enterprise in the industry.
Conclusion
The successful application of cream emulsifier equipment in this manufacturer proves that professional production equipment is an important driving force for the transformation and upgrading of the daily chemical production industry. By targeting the pain points of production, selecting suitable equipment and carrying out standardized application and management, enterprises can achieve the dual improvement of product quality and production efficiency, and obtain sustainable development momentum in the fierce market competition. For enterprises engaged in cream production, the rational allocation of emulsifier equipment is not only a technical upgrade, but also a strategic layout for long-term development.
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