Case Study: Enhancing Production Performance and Product Stability with High-Speed Emulsifiers
In the daily chemical and personal care manufacturing sector, emulsified products such as liquid soaps, body washes, hair conditioners, and facial cleansers rely heavily on efficient dispersion of components and stable water-oil emulsification. A manufacturer specializing in mid-to-high-end daily chemical products faced long-standing challenges related to product consistency, production efficiency, and raw material utilization. This case study objectively elaborates on how the adoption of high-speed emulsifiers addressed these operational pain points, optimized production workflows, and achieved measurable improvements in product quality and operational metrics, without involving any marketing language, sensitive information, or specific company identifiers.
1. Background and Core Challenges
The manufacturer’s product portfolio mainly included liquid body wash, hair conditioner, facial cleansing milk, and liquid hand soap—all of which are typical emulsified products requiring uniform dispersion of surfactants, moisturizers, fragrances, and other functional ingredients. Prior to the equipment upgrade, the enterprise used traditional low-shear mixing equipment and basic emulsifiers with limited rotational speed. These devices could meet the minimum production requirements for simple formulations but struggled to adapt to the increasingly complex product formulas and growing production demands, leading to five core challenges that hindered operational development.
1.1 Unstable Emulsion Quality and Inconsistent Texture
The most prominent issue was the lack of sufficient shear force from traditional equipment, resulting in uneven particle size distribution in emulsified products. Laboratory testing data showed that the average particle size of dispersed phases (oil droplets, functional additive particles) in finished products often ranged from 10 to 20 micrometers, with significant batch-to-batch fluctuations. This inconsistency directly led to visible graininess in facial cleansing milk, poor foaming performance in body wash, and uneven texture in hair conditioner—manifested as partial greasiness or dryness during use. Such quality issues not only affected consumer experience but also resulted in a batch rejection rate of approximately 7% and a product return rate of 5% annually.
1.2 Low Production Efficiency and Long Processing Cycles
The traditional emulsification process was characterized by prolonged processing time and cumbersome operational steps. Taking a 2,000kg batch of liquid body wash as an example, the emulsification stage alone required 3 to 4 hours of staged stirring—including heating the water phase to 60-70°C, adding surfactants and thickeners, and slowly incorporating the oil phase. Due to insufficient shear efficiency, raw materials such as thickeners and emulsifiers often took a long time to fully dissolve and disperse, requiring manual stirring assistance to avoid clumping. Additionally, the need for post-emulsification homogenization (using a separate low-efficiency homogenizer) added another 1 to 1.5 hours per batch. As a result, the total production cycle for a single batch extended to 8 to 10 hours, severely limiting the enterprise’s production capacity.
1.3 High Raw Material Waste and Increased Costs
Incomplete emulsification and uneven dispersion from traditional equipment led to significant raw material waste. Undissolved thickener clumps and unemulsified oil droplets had to be filtered out during the final quality inspection, resulting in a raw material loss rate of approximately 4% per batch. Moreover, to compensate for poor emulsion stability, the manufacturer had to add excess emulsifiers and preservatives—increasing raw material costs by 8 to 10% compared to industry benchmarks. The high batch rejection rate further exacerbated cost pressures, as rejected batches could not be reused and had to be disposed of in accordance with environmental regulations.
1.4 Difficulty in Adapting to Complex Formulations
With the growing market demand for high-performance daily chemical products, the manufacturer continued to develop new formulations with more complex components—such as products containing natural plant extracts, nano-scale functional particles, and multi-phase emulsions. However, traditional emulsification equipment could not effectively disperse these complex components. For example, natural plant extracts (which are sensitive to shear and temperature) were easily degraded or unevenly distributed, while nano-scale particles tended to agglomerate due to insufficient shear force. This made it difficult to launch new products that met market expectations, delaying the enterprise’s product iteration cycle.
1.5 High Labor Intensity and Operational Risks
The traditional emulsification process relied heavily on manual operation and monitoring. Operators had to continuously observe the material state during emulsification, manually add raw materials at specific intervals, and scrape off material residues adhering to the tank walls. This not only increased labor intensity (requiring 2 to 3 operators per production line) but also introduced operational risks—manual errors such as incorrect feeding sequence or timing could lead to emulsion breakdown and batch failure. Additionally, prolonged exposure to high-temperature materials and chemical raw materials posed potential health risks to operators.
2. Equipment Selection and Implementation
To address the above challenges, the enterprise conducted a comprehensive technical evaluation of emulsification equipment, focusing on three core criteria: sufficient shear force for complex formulations, high production efficiency to shorten cycle times, and compatibility with existing production lines. After comparative testing of multiple types of emulsification systems (including low-speed mixers, ultrasonic emulsifiers, and high-speed emulsifiers), the enterprise ultimately selected a series of high-speed emulsifiers with modular designs—including lab-scale (150L), pilot-scale (800L), and production-scale (2,500L) units. The key technical features of the selected high-speed emulsifiers are as follows:
- High-speed rotor-stator workheads with adjustable rotational speeds (5,000 to 18,000 rpm), generating intense mechanical shear force, impact force, and cavitation effect to break down dispersed phase particles into 1 to 5 micrometers—ensuring uniform dispersion and stable emulsification.
- Modular workhead design with replaceable components (rotor, stator, shear teeth), allowing customization of shear intensity for different product viscosities and formulations (from low-viscosity liquid soaps to medium-viscosity hair conditioners).
- Integrated heating and cooling systems with double-jacket tanks, enabling precise temperature control (±2°C accuracy) to meet the emulsification temperature requirements of different raw materials and protect heat-sensitive ingredients (e.g., plant extracts, vitamins).
- Automated feeding and stirring systems, supporting sequential automatic feeding of raw materials and continuous circulation stirring—eliminating manual intervention and ensuring consistent operational processes.
- Corrosion-resistant construction with 316L stainless steel tanks and workheads, complying with daily chemical product hygiene standards and facilitating cleaning to avoid cross-contamination.
The implementation of the high-speed emulsifier system followed a phased approach to ensure seamless integration with existing production processes and minimize operational disruptions:
- Lab-Scale Optimization (Month 1-2): The 150L lab-scale high-speed emulsifier was installed in the R&D department to optimize existing product formulations and determine optimal process parameters. Engineers adjusted rotational speed, emulsification time, temperature, and feeding sequence for each product type—targeting an average particle size of 2 to 3 micrometers and stable emulsion performance. This stage also verified the equipment’s compatibility with complex new formulations, such as those containing plant extracts and nano-scale particles.
- Pilot-Scale Testing (Month 3-4): The 800L pilot-scale unit was used to verify the scalability of lab-scale parameters to medium-batch production. Trials were conducted for four core products (liquid body wash, hair conditioner, facial cleansing milk, hand soap), confirming that the emulsification time could be significantly reduced while maintaining product quality. During this stage, operational procedures were optimized, and operators were trained on equipment operation, parameter adjustment, and daily maintenance.
- Production-Scale Deployment (Month 5-6): Three 2,500L production-scale high-speed emulsifiers were installed to replace the traditional emulsification equipment on three production lines. The units were integrated with existing feeding, filtering, and filling systems, and a centralized control system was established to monitor and adjust process parameters in real time. A one-month run-in period was implemented to fine-tune parameters and ensure stable operation across all shifts.
3. Measurable Results and Operational Improvements
After a six-month operation period and continuous process optimization, the adoption of high-speed emulsifiers delivered significant improvements in product quality, production efficiency, cost control, and operational safety. All results were verified through long-term production data monitoring and third-party quality testing, ensuring objectivity and accuracy.
3.1 Improved Product Quality and Consistency
The high-speed emulsifiers effectively solved the problem of uneven particle size distribution. Post-upgrade testing showed that the average particle size of dispersed phases in finished products was stably maintained at 2 to 3 micrometers, with a polydispersity index (PDI) of less than 0.2—well within the industry’s high-quality standards. This uniform dispersion eliminated visible graininess in facial cleansing milk, improved the foaming performance of body wash (foam volume increased by 25%, and foam stability extended by 30%), and ensured consistent texture in hair conditioner (eliminating greasiness and dryness issues). Emulsion stability tests confirmed that finished products showed no phase separation or texture changes after 9 months of storage under standard conditions.
As a result, the batch rejection rate decreased from 7% to 0.9%, and the product return rate dropped from 5% to 1.1%. Customer satisfaction surveys conducted 8 months after the upgrade showed that 93% of respondents reported noticeable improvements in product texture, usability, and performance compared to previous versions—enhancing the enterprise’s market reputation and customer loyalty.
3.2 Significantly Increased Production Efficiency
The high shear efficiency of the new equipment drastically shortened the production cycle. For a 2,000kg batch of liquid body wash, the emulsification time was reduced from 3-4 hours to 50 minutes—a reduction of more than 80%. The elimination of manual stirring and separate post-emulsification homogenization further shortened the total production cycle from 8-10 hours to 3-4 hours per batch, representing a 62.5% overall reduction in production time. The automated feeding and control systems also allowed a single operator to monitor two production lines simultaneously, reducing labor requirements by 40%.
The modular design of the high-speed emulsifiers also improved production line versatility. By simply replacing the rotor-stator workhead and adjusting process parameters, the same equipment could produce multiple product types (from liquid soaps to hair conditioners) without extensive line modifications. This increased the enterprise’s total production capacity by 55% without additional factory expansion or new production line investments.
3.3 Reduced Raw Material Waste and Costs
Complete emulsification and uniform dispersion significantly reduced raw material waste. The raw material loss rate per batch decreased from 4% to 0.7%, as undissolved clumps and unemulsified particles were eliminated. Additionally, the stable emulsion performance enabled the manufacturer to reduce the dosage of emulsifiers and preservatives by 9% and 12% respectively, without compromising product stability. Based on the enterprise’s annual production volume (approximately 1,200 tons of finished products), these improvements translated to annual raw material cost savings of over $65,000. The reduction in batch rejection rate further reduced waste disposal costs and environmental pressure.
3.4 Enhanced Ability to Develop Complex Formulations
The high-speed emulsifiers provided the necessary shear force and temperature control to effectively disperse complex components. The R&D team successfully developed and launched four new products within 8 months of the equipment upgrade—including a plant-extracted body wash, a nano-scale moisturizing facial cleanser, and a multi-phase hair conditioner. These new products featured improved performance and unique selling points, helping the enterprise enter high-margin market segments. The time required to develop and launch new products decreased from an average of 16 weeks to 6 weeks—a 62.5% reduction—allowing the enterprise to quickly respond to market trends and gain a competitive edge.
3.5 Improved Operational Safety and Reduced Labor Intensity
The automated features of the high-speed emulsifiers significantly reduced labor intensity and operational risks. Automated feeding, stirring, and parameter control eliminated the need for manual material handling and continuous on-site monitoring, reducing the number of operators per production line from 2-3 to 1. The closed tank design and safety interlock system (which shuts down the equipment if the tank cover is opened or abnormal conditions occur) minimized the risk of operator exposure to high-temperature materials and chemical raw materials. Additionally, the equipment’s easy-to-clean design reduced cleaning time by 70% and eliminated the need for manual tank scraping, further improving operational safety and hygiene.
4. Long-Term Impact and Key Insights
Two years after the initial implementation of high-speed emulsifiers, the enterprise continues to benefit from sustained operational improvements and business growth. The stable and reliable emulsification process has enabled the enterprise to expand its product portfolio to include more high-value-added products, such as baby-specific body washes and sensitive-skin facial cleansers—products that require strict quality control and stable formulations.
The real-time data collection and monitoring capabilities of the high-speed emulsifiers have provided the enterprise with valuable process data, supporting data-driven decision-making and continuous process optimization. For example, by analyzing particle size and viscosity data from different production batches, the enterprise adjusted the feeding sequence of thickeners, further reducing emulsification time by 10% and improving product texture.
Key insights from this project include:
- Sufficient shear force is critical for emulsified daily chemical products, as it directly determines particle size distribution, emulsion stability, and product quality consistency.
- Automated and modular emulsification equipment not only improves production efficiency but also reduces labor intensity and operational risks, which is essential for large-scale daily chemical manufacturing.
- Equipment compatibility with complex formulations is a key enabler of product innovation, allowing manufacturers to respond quickly to market demands and expand into high-margin segments.
- Investing in high-performance emulsification equipment is a cost-effective strategy in the long run, as it reduces raw material waste, batch rejection rates, and labor costs while improving product quality and production capacity.
For manufacturers in the daily chemical and personal care industry facing challenges related to product consistency, production efficiency, and formulation complexity, high-speed emulsifiers represent a reliable and effective solution. This case study demonstrates that selecting equipment aligned with production needs and product characteristics can deliver significant operational improvements and long-term business value.
پیام شما باید بین 20 تا 3000 کاراکتر باشد!