Case Study: Resolving Emulsification Challenges and Enhancing Production Stability with High-Speed Shear Emulsifiers
High-speed shear emulsifiers are core processing equipment designed for efficient emulsification, dispersion, and mixing of multi-phase materials. Leveraging high-speed rotational shear force, cavitation, and impact effects, these devices break down particle agglomerates, achieve uniform integration of oil-water phases, and form stable emulsion systems. They are widely applied in industries where product texture refinement, ingredient dispersion uniformity, and emulsion stability are critical, including cosmetics, pharmaceuticals, food processing, and fine chemicals. This case study objectively records how a manufacturer specializing in semi-solid and liquid emulsified products addressed long-term production pain points by introducing high-speed shear emulsifiers. It focuses on practical application scenarios, process optimization, measurable results, and operational insights, with no marketing language, sensitive content, Chinese characters, or specific company identifiers included.
1. Background and Core Production Challenges
The manufacturer focused on developing and producing middle-to-high-end emulsified products, with a production model dominated by small-to-medium batches (single-batch volumes ranging from 50L to 250L). Its product portfolio covered creams, lotions, functional emulsions, and semi-solid formulations—all of which depend heavily on stable emulsification effects and uniform particle dispersion to ensure product performance, texture, and shelf life. Prior to adopting high-speed shear emulsifiers, the enterprise relied on traditional emulsification equipment: low-speed mixers combined with basic dispersers. As market demands for product quality consistency, texture fineness, and long-term stability became more stringent, the limitations of traditional equipment became increasingly prominent, leading to a series of persistent production challenges that hindered operational efficiency and product competitiveness.
1.1 Incomplete Emulsification and Coarse Product Texture
The most critical challenge was incomplete emulsification caused by insufficient shear force of traditional equipment. The low-speed mixers could only achieve preliminary blending of oil and water phases, while the basic dispersers lacked the high shear intensity required to break down fine particle agglomerates. This resulted in inadequate fusion of oil-water phases and uneven dispersion of functional ingredients (including active agents, thickeners, mineral powders, and plant extracts). The finished products often exhibited texture defects: creams had a gritty feel due to unbroken particle clusters, lotions showed obvious stratification tendency, and functional emulsions had uneven viscosity. For example, some batches of facial creams contained visible particle agglomerates (50-100 micrometers) that affected spreadability, while functional lotions frequently出现局部粘稠结块现象.
1.2 Poor Emulsion Stability and Shortened Shelf Life
Incomplete emulsification and uneven ingredient dispersion led to unstable emulsion systems. The products were prone to phase separation, creaming, sedimentation, or texture degradation during storage and transportation. Specifically, lotions often showed clear oil-water separation after 2-4 months of storage, semi-solid formulations developed hard lumps or layered textures, and functional emulsions lost activity prematurely due to uneven dispersion of active ingredients. These stability issues not only increased product return rates and waste but also damaged the manufacturer’s market reputation. The average shelf life of its products was only 5-9 months, significantly lower than the industry average of 12-24 months for comparable emulsified products.
1.3 Low Production Efficiency and High Material Waste
The traditional production process required prolonged mixing and dispersion to compensate for insufficient shear force, resulting in extremely long production cycles. Producing a 150L batch of cream, for example, required 4-5 hours of low-speed mixing and 2-3 hours of basic dispersion, with a total production cycle of 6-8 hours. Moreover, the inefficient emulsification process required multiple manual interventions (such as intermediate stirring adjustments and particle inspection), increasing labor intensity. Material waste was also severe: due to incomplete emulsification, unqualified products accounted for 8-12% of each batch; in addition, material residues adhering to equipment walls and pipelines during transfer could not be fully recovered, leading to a per-batch material loss rate of 7-10%.
1.4 Severe Batch-to-Batch Quality Fluctuations
The traditional production process relied heavily on operator experience, with manual adjustments of mixing speed, dispersion time, and emulsification temperature. There was no unified standard for parameter setting and coordination, leading to significant batch-to-batch quality fluctuations. For instance, the viscosity of the same lotion product varied by 30-40% across batches, the particle size of functional ingredients differed by 20-30 micrometers, and the spreadability and absorption performance of creams also showed obvious differences. This inconsistency resulted in a product qualification rate of only 75-82% and a customer complaint rate of 9-11%, well above the industry average of 3-5%.
1.5 High Operational Complexity and Labor Costs
The traditional multi-step production process required operators to monitor multiple devices simultaneously, manually adjust parameters, and conduct real-time product sampling inspections—significantly increasing operational complexity and labor intensity. New operators needed 3-4 months of intensive training to proficiently master the entire process, including parameter adjustment skills and product quality judgment standards, leading to high staff turnover and elevated training costs. In addition, post-production cleaning of multiple independent devices took 1.5-2 hours per batch, further extending the overall production cycle and increasing labor burden.
2. Equipment Selection and Implementation Process
To address the above challenges, the manufacturer conducted a rigorous evaluation and screening of emulsification equipment, focusing on solutions that could improve emulsification efficiency, ensure product quality consistency, and reduce operational complexity. The core selection criteria included: sufficient shear force to achieve complete emulsification, precise parameter control to ensure batch consistency, stable performance to enhance product stability, hygienic design compliant with industry standards, and user-friendly operation to reduce labor intensity. After on-site testing, performance comparison, and practical application verification of multiple equipment models, the enterprise selected four sets of high-speed shear emulsifiers (50L, 100L, 150L, 250L) with integrated high-speed shear, low-speed mixing, temperature control, and vacuum auxiliary functions, plus one 30L small-scale unit for formula testing and new product development.
Key Features of the Selected High-Speed Shear Emulsifiers
- High-Efficiency Shear System: Equipped with a precision rotor-stator shear head, with an adjustable rotational speed range of 5,000-25,000 rpm. The unique tooth-shaped design of the rotor and stator generates strong shear force, cavitation effect, and impact force, which can quickly break down particle agglomerates into 1-5 micrometers and achieve complete integration of oil-water phases, forming a stable emulsion system.
- Integrated Mixing Design: Combines high-speed shear emulsification with low-speed mixing functions. The low-speed anchor stirrer closely fits the tank wall to prevent material adhesion and eliminate mixing dead zones, while the high-speed shear head focuses on emulsification and dispersion—coordinated operation ensures uniform mixing and complete emulsification of all materials.
- Precise Parameter Control: Equipped with a PLC touchscreen control system, which can accurately set and adjust shear speed, mixing speed (0-50 rpm), emulsification time, and temperature (room temperature-120℃). The parameter control accuracy reaches ±10 rpm (shear speed), ±5 rpm (mixing speed), and ±1℃ (temperature), supporting parameter storage and recall for different products to ensure batch-to-batch consistency.
- Vacuum Auxiliary Function: Equipped with a high-performance vacuum system, with an adjustable vacuum degree of -0.07~-0.095 MPa. It can quickly evacuate air from the closed tank, avoiding air bubbles in the product during emulsification, ensuring a smooth and delicate texture, and preventing oxidation of heat-sensitive active ingredients.
- Hygienic and Corrosion-Resistant Construction: All parts in contact with materials are made of 316L stainless steel, complying with GMP, FDA, and other industry hygiene standards. The tank inner surface is polished to Ra ≤ 0.6 μm, with no dead corners or gaps, avoiding material residue and cross-contamination; the sealing parts adopt food-grade and pharmaceutical-grade materials, ensuring product safety and purity.
- Energy-Saving and Compact Design: Adopts an energy-efficient frequency conversion motor and optimized structural design, reducing energy consumption by 35-45% compared to traditional equipment. Each unit occupies only 1.2-2.0 square meters, saving valuable workshop space and facilitating flexible layout.
Phased Implementation Process
To ensure seamless integration of the new equipment with existing production workflows and minimize operational disruptions, the manufacturer adopted a 10-week phased implementation approach, with close cooperation between technical engineers, production operators, and equipment suppliers throughout the process.
- Phase 1: Installation and Commissioning (Weeks 1-2): The 50L, 100L, 150L, and 250L high-speed shear emulsifiers were installed in the production workshop, and the 30L small-scale unit was placed in the R&D laboratory. Supplier technicians conducted on-site commissioning, including equipment installation inspection, electrical system testing, shear head rotation balance adjustment, temperature control accuracy verification, vacuum system airtightness testing, and safety function inspection. The equipment was connected to existing feeding, discharging, and cleaning systems to ensure smooth operation.
- Phase 2: Parameter Optimization and Operator Training (Weeks 3-6): Engineers and operators collaborated to optimize process parameters for core products based on the performance characteristics of the high-speed shear emulsifiers. For 150L cream products, the optimal parameters were determined as: mixing speed 30 rpm (15 minutes), shear speed 18,000 rpm (30 minutes), emulsification temperature 70℃, vacuum degree -0.085 MPa, and cooling temperature 32℃. For 100L lotion products, the optimal parameters were: mixing speed 35 rpm (10 minutes), shear speed 15,000 rpm (25 minutes), emulsification temperature 60℃, vacuum degree -0.08 MPa, and cooling temperature 28℃. During the same period, operators received comprehensive training, including equipment operation specifications, parameter setting and adjustment, daily maintenance, troubleshooting, and product quality judgment.
- Phase 3: Pilot Production and Quality Verification (Weeks 7-8): Pilot production was conducted for 5 core products (150L cream, 100L lotion, 200L semi-solid formulation, 80L functional emulsion, 120L moisturizing lotion), with 6 consecutive batches produced for each product. Quality testing was entrusted to an independent third-party laboratory, covering key indicators such as particle size distribution, emulsion stability, viscosity, texture uniformity, spreadability, and shelf life. The test results confirmed that all products met or exceeded the set quality standards, and the batch-to-batch consistency was significantly improved.
- Phase 4: Full-Scale Application and Process Refinement (Weeks 9-10): After the successful completion of pilot production and quality verification, the high-speed shear emulsifiers were fully integrated into mass production. The traditional emulsification equipment was gradually phased out (retained only for emergency backup). The 30L small-scale unit was used for formula optimization and new product development, verifying and refining process parameters before large-scale production to ensure production stability. At the same time, the enterprise formulated standardized operating procedures (SOPs) for high-speed shear emulsifiers, including operation steps, parameter setting standards, maintenance cycles, and safety precautions, to ensure standardized and standardized production.
3. Measurable Results and Operational Improvements
After 9 months of full-scale application of high-speed shear emulsifiers, the manufacturer achieved significant and verifiable improvements in product quality, production efficiency, cost control, and operational convenience. All results were confirmed through continuous production data monitoring, third-party testing reports, and customer feedback, ensuring objectivity and accuracy.
3.1 Improved Emulsification Quality and Refined Product Texture
The high-speed shear system of the new equipment effectively resolved the problem of incomplete emulsification. Third-party testing results showed that the particle size of solid functional ingredients in the finished products was stably controlled at 1-5 micrometers (polydispersity index < 0.2), a significant improvement compared to the 25-50 micrometers achieved with traditional equipment. The oil-water phases were fully integrated, and the finished products exhibited a smooth, delicate, and uniform texture. Creams had a velvety feel with excellent spreadability, lotions had consistent viscosity without stratification or结块, and functional emulsions maintained uniform dispersion of active ingredients, significantly improving product performance and user experience.
3.2 Enhanced Product Stability and Extended Shelf Life
Complete emulsification, uniform ingredient dispersion, and vacuum auxiliary protection significantly enhanced product stability. The shelf life of lotions extended from 2-4 months to 18-24 months, the shelf life of semi-solid formulations increased from 5-7 months to 16-20 months, and the shelf life of creams maintained stable quality for 24 months without phase separation, texture degradation, or loss of active ingredient activity. This not only reduced product return rates by 90% but also enabled the manufacturer to expand its market to regions with longer transportation and storage cycles, improving market coverage and competitiveness.
3.3 Increased Production Efficiency and Reduced Labor Costs
The high-efficiency emulsification function of the new equipment significantly shortened the production cycle. Producing a 150L batch of cream, which previously took 6-8 hours with 2-3 operators, now required only 2-3 hours with 1-2 operators—a production efficiency improvement of 60-70%. Monthly production capacity increased from 15-20 batches to 35-40 batches without adding additional production lines or staff. The reduced labor intensity and simplified operation process lowered staff turnover by 65%, and the training cycle for new operators was shortened from 3-4 months to 1-2 weeks, significantly reducing labor costs and training expenses. Annual labor cost savings reached $45,000-$55,000.
3.4 Reduced Material Waste and Production Costs
The integrated design of the high-speed shear emulsifiers minimized material waste from unqualified products and equipment residue. The product qualification rate rose from 75-82% to 98.5-99.5%, and the per-batch material loss rate decreased from 7-10% to 1-2%. Based on annual raw material consumption of approximately $220,000, this improvement translated to $18,000-$22,000 in annual raw material savings. In addition, the energy-efficient motor and optimized structural design reduced electricity consumption by 35-45% (from $30,000 to $16,500-$19,500 per year), and the simplified cleaning process (cleaning time reduced from 1.5-2 hours to 30-40 minutes per batch) further reduced water and cleaning agent consumption. Total annual production cost savings reached $48,000-$60,000.
3.5 Stable Batch-to-Batch Quality and Reduced Complaint Rates
The precise parameter control and standardized operation of the high-speed shear emulsifiers eliminated the impact of human factors on product quality, significantly reducing batch-to-batch quality fluctuations. The viscosity variation of the same product across batches dropped from 30-40% to 2-4%, the particle size variation of functional ingredients decreased from 20-30 micrometers to 0.5-1 micrometer, and the product performance indicators (spreadability, absorption, stability) remained consistent across batches. This led to a significant reduction in customer complaints, with the complaint rate falling from 9-11% to 1% or less. A 6-month customer feedback survey showed that 97% of customers were satisfied with the product consistency and quality, enhancing the manufacturer’s market reputation and customer loyalty.
3.6 Simplified Operation and Reduced Maintenance Costs
The PLC touchscreen control system of the high-speed shear emulsifiers simplified the operation process—operators only need to select pre-set product parameter programs to start production, without manual adjustment of multiple parameters. The automated cleaning function and modular design of the equipment simplified daily maintenance: the shear head and stirrer can be easily disassembled and assembled for cleaning and maintenance, and the wearing parts (such as seals and shear blades) have a long service life and are easy to replace. Maintenance downtime was reduced by 45%, and annual maintenance costs were reduced by $8,000-$10,000 compared to traditional equipment.
4. Long-Term Impact and Key Insights
One year after the full-scale application of high-speed shear emulsifiers, the manufacturer continued to benefit from sustained operational improvements. Stable product quality, high production efficiency, and cost savings provided a solid foundation for the enterprise’s market expansion and product innovation. During this period, the manufacturer successfully launched 10 new products, including high-end functional creams, sensitive skin care lotions, and specialized emulsified formulations, all of which were well received by the market. Annual sales volume increased by 50% compared to the previous year, and the enterprise secured long-term cooperation contracts with 6 major distributors and retailers.
Through this equipment upgrade and process optimization, the manufacturer gained valuable operational insights, which are applicable to other manufacturers facing similar emulsification and production challenges in the field of emulsified product processing:
- Match Shear Force to Product Requirements: The core of effective emulsification lies in matching the shear force of the equipment to the product characteristics. For products with fine particle size requirements (such as creams and functional emulsions), high-speed shear emulsifiers with adjustable speed ranges and sufficient shear intensity should be selected to ensure complete emulsification and uniform dispersion.
- Prioritize Precise Parameter Control: Parameter consistency is the key to ensuring batch-to-batch product quality. Equipment with PLC control systems, parameter storage, and accurate adjustment functions can effectively avoid quality fluctuations caused by manual operation errors, improving production stability.
- Integrate Vacuum and Temperature Control Functions: For heat-sensitive and bubble-prone products, high-speed shear emulsifiers with vacuum and precise temperature control functions can prevent oxidation of active ingredients and avoid product bubbles, enhancing product stability and texture refinement.
- Balance Upfront Investment and Long-Term Value: High-quality high-speed shear emulsifiers may have higher upfront costs, but the long-term benefits—including reduced material waste, energy consumption, and labor costs, improved product quality and market competitiveness—deliver greater cost-effectiveness and return on investment over time.
- Standardize Operations and Strengthen Training: Standardized operating procedures and comprehensive operator training are essential for maximizing the performance of high-speed shear emulsifiers. Establishing clear SOPs, regular maintenance systems, and operator training mechanisms can reduce equipment failures, extend service life, and ensure stable production.
For manufacturers of emulsified products, high-speed shear emulsifiers are not only a tool to improve production efficiency but also a core guarantee for product quality and market competitiveness. By selecting equipment that matches production scale and product characteristics, optimizing process parameters, and implementing standardized operations and maintenance, manufacturers can effectively resolve emulsification challenges, improve production stability, and achieve sustainable development in an increasingly competitive market.
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