Author: joomir

Shampoos are a combination of surfactants, softeners and many other materials in a water solution. In addition to shampoos that are used only for hair washing, there are also shampoos that are used for two purposes. Also products that have properties such as dandruff treatment; Shampoos are used to protect the effect of ultraviolet or for hair washing hair (although ordinary shampoos are also used to wash colored hair) or have medicinal properties.

Shampoo production process

A conventional production process is as follows:

• The water temperature inside the process tank is measured. This water is heated to 50-60 ° C to help dilute and dispersion other materials.
• The first material added to the solution is surfactant because other additives, especially those that affect viscosity, can make it more difficult to dilute surfactant.
• The softener and other materials are added.
• The PH of the solution is adjusted to the required amount.
• Sodium chloride or other viscosity modifiers are finally added with color and aroma.

Challenges of the production process

When using regular mixers you have a number of problems:

Aeration (air mixing with the product) should be avoided, as this will cause transparent shampoos and instead of the product, it takes part of the product packaging.

• Silicones are impermeable with water and are chemically incompatible with some surfactants. As a result, it makes the emulsion or suspension very difficult.
• Ordinary mixers cannot create enough shear amounts for silicones to get them as needed, so emulsion or sustained suspension is not achieved. These mixers further increase aeration and bubble.
• Many viscosity ingredients are much higher than water. When mixing with mixer, higher viscosity materials form bullets that are spread to the solution without dilution and dispersion.
• Concentrated materials such as carbomers and cellulose -based products may require high shear mixing to activate.
• As viscosity increases, the addition of sodium chloride becomes increasingly difficult.
• To overcome these problems, shear mixer (hemorrhoider) is needed at high speed, as it is used by conventional mixers of air bubbles in the product.

Solution provided by ArkanFelez Company

These problems can be resolved by the use of a hemocent mixer under the vacuum of the metal company.

• A vacuum -based homogenizer mixer can quickly mix liquids with different viscosity.
• Under the vacuum, the mixer forms a closed system and prevents air from penetrating into the tank and the formation of the bubble.
• A dramatic decrease in the mix time results.
• It significantly increases the performance of thickening materials compared to traditional methods.
• Enhances the quality and recurrence of the product.
• Due to the vacuum of the mixer, it is possible to perform the dearabation process.

Medications for the treatment of conditions such as skin diseases, skin irritation, bite, fungal infections, etc. are typically produced as cream or ointment because it is an effective way to deliver the drug directly to the body.

The raw materials needed can be as water emulsions in oil or oil in water, consisting of waxes, softeners and lubricants in an oil phase or in a water phase containing emulsifying, stabilizing, thickening materials, materials Prepare and in some cases color. The active ingredients are scattered at each stage or are added when the emulsion is formed.

Production process

The ingredients, formulations and viscosity of the products are widely different, however, a conventional production process is divided into four separate operations:

Preparation of oil phase. Powder ingredients, which sometimes dry before the process begins, are scattered in mineral oil or silicone oil. Heating may be needed to melt some materials.

Scattering of water phase ingredients. Concentrates and stabilizers are dissolved in a separate container in water. Heating may be necessary to accelerate the process.

Emulsion formation. Two phases are mixed with high speed hemorrhoids to form emulsion.

Distribution of active substance. The active ingredient often forms only a small portion of the formulation. To maximize the efficiency and effectiveness of the product, it must be properly scattered.

Production challenges

Using regular mixers you will have a number of problems:

• By adding water, thickening, stabilizing and emulsifying materials can form pellets that mixers cannot break down.
• Similarly, the oil phase ingredients can form masses that require stress for dispersion.
• The ingredients to obtain the viscosity needed and the development of performance must be completely hydrated.
• The materials that are not completely dissolved are attached to the tank wall and parts of the mixer.
• Mixers cannot reduce the particle size enough to stabilize the emulsion.
• Active material can be temperature -sensitive. The cooling of the product before adding active ingredients increases the process time.
• Poor dispersal of active ingredients disrupts the effectiveness of the product.
• To obtain a uniform and sustainable end product, additional time and equipment are required.

Solution provided by ArkanFelez Company

The vacuum of the metal -based hemorgic compound can quickly dissolve solids in liquids, break down thickening, stabilizing and bullets, and completely reduce the size of the particles to make emulsion and suspension stable. The mixing time decreases dramatically, while the uniformity and consistency of the product improve greatly.

• Sustainable emulsion
• Mix without bubbles
• Reduces the mixture of the mix dramatically.
• The performance of the raw materials as thickening materials maximizes and other materials are completely scattered.
• The initial mixing stage of the powder material can be removed.
• The water phase can be produced at ambient temperature and reduced heating costs. It also accelerates the cooling of the mix and reduces time and cost of the process.
• The quality and repeat of the product

 

Cosmetic creams and lotions are used for a variety of purposes, including cleansing and moisturizing the skin. The ingredients will therefore vary depending on the intended application, however, the basic manufacturing process is largely the same.

Manufacturing process

Products can be in the form of oil-in-water or water-in-oil emulsions, consisting of emollients and lubricants dispersed in an oil phase and having a water phase containing emulsifiers and thickeners, fragrances, colors, and preservatives. The active ingredients are dispersed at each stage, depending on the raw materials and the desired properties of the final product. A typical manufacturing process would be as follows:

• Powder ingredients, such as cetyl alcohol and stearic acid, which are sometimes pre-dried, are dispersed in the oil phase. Heating may be required to melt some ingredients.
• The active ingredients are dispersed in the appropriate phase.
• The water phase, containing emulsifiers and stabilizers such as wigam or carbopol, is prepared separately.
• Both phases are mixed to form an emulsion. This is done at a temperature between 45°C and 85°C depending on the formulation and viscosity.
• The mixing process continues until the final product is homogeneous.

 

Production challenges

Using regular mixers you will have a number of problems:

• Some ingredients can form pellets that conventional mixers are unable to break down.
• Scattering of thickening materials and suspension is one of the hardest things in the hemorrhage process. The bubbles are easily formed and some of the materials needed to create the desired properties require high speed cut.
• When adding powdered ingredients to the mixer tank, materials that are not properly dissolved can stick to the tank wall and parts of the mixer.
• Even if oil and water phases are heated, mixers cannot easily form stable emulsions.
• Often required to achieve a homogeneous product, long period of time and extra equipment.

Solution provided by ArkanFelez Company

The additional steps of production can be eliminated, improved product quality, and the process time can be dramatically reduced by using a vacuum -borne mixer under the vacuum.

• Continuous product quality and recurrence
• Bubble -free mix
• Sustainable emulsion
• Quick mix time
• Maximizing the yield of raw materials used as thickening materials and other materials are completely scattered.

 

Toothpastes are usually either white abrasive pastes or clear gels. Although the formulation varies, many of their ingredients are common. These may vary from country to country, depending on the laws regarding the use of ingredients, etc.

Manufacturing process

• The processing methods vary depending on the type of product and the ingredients used. A typical process can be described as follows:
• First, the base liquid is prepared – water, sorbitol/glycerin and other liquid ingredients
• Rheology modifiers may be pre-mixed with a non-aqueous liquid such as glycerin or flavoring oil or mixed with other powdered ingredients to aid dispersion.
• The active ingredient, sweetener and preservative are added and dispersed.
• Abrasive/filler is added, which may be prepared as a water slurry or pre-mixed with water to make it compatible with the liquid base.
• Flavoring, color and essence are added.
• In the last step, the detergent is gradually added with slow, rapid mixing to minimize foaming. This step is typically done in solid form, so avoid adding water to the formulation at this stage.

 

Process Challenges

Bubbling is a major problem in toothpaste production. All powders contain a certain amount of air and detergents can exacerbate the problem. To overcome this, mixing is usually done under vacuum. Other problems that can be seen include:

• Rheology modifiers cause lumps to form that are difficult to break up with a mixer.
• Adding the compound to other liquid or powder ingredients increases process time and costs.
• Some rheology modifiers require high shear stress to achieve maximum efficiency.
• Some ingredients, such as hydrated silica, have low densities and are very difficult to mix and wet.
• Conventional mixers, especially when mixing powders, introduce air into the mix.
• Abrasives such as calcium carbonate can be supplied as a slurry and the mixing equipment must be able to break them apart.

Solution provided by Arkan Felez Company

Manufacturing of all types of toothpaste can be done using Arkan Felez Company’s vacuum homogenizer mixer. The high viscosity and abrasiveness of toothpaste make it necessary to use high-power homogenizers as well as high-speed lump breaker mixers manufactured by Arkan Felez Company.

Key points

• Prepare the liquid base before adding fillers and abrasives.
• Before adding detergents and thickeners, mix the mix thoroughly, especially in cases where fillers such as calcium carbonate are used as water dough.

Advantages of using a vacuum homogenizer mixer

• Manufacturing time is significantly reduced.
• Rapid mixing and wetting of powders.
• Product quality and stability are greatly improved.
• With the vacuum operation of the homogenizer mixer, the possibility of product bubbling can be minimized.
• At the end of the process, deaeration of the process components is possible.

Tomato sauce is used in many food products, including frozen foods, pasta sauces, sandwiches, pizzas, and as one of the most common food condiments. A tomato sauce is usually made entirely from tomatoes or from tomato paste. It also contains water, sugar, vinegar, salt, and seasonings. The desired viscosity is usually achieved by using starch-based thickeners.

Ketchup is a type of condiment made from similar ingredients, although tomato paste is used in its production instead of tomatoes. Highly concentrated ketchup sauces obtain their viscous content from a combination of water trapped in the fibrous strands in the tomato paste and the gel-like effect of the pectin substance present in the tomatoes. A homogenizer is used to obtain the desired viscosity. This is common with lower concentration ketchups, which may also contain starch-based thickeners.

Ketchup and tomato sauce manufacturing process

The process recipe and the appropriate viscosity for ketchup and tomato sauce can vary depending on the intended use of the final product, but typical process requirements are as follows:

The mixing equipment must be capable of completely dissolving the powdered ingredients in the water so that the product does not clump.

If the product is made entirely from tomatoes, it must be thoroughly ground before being added to the mix.

Insoluble particles in the tomatoes must be thoroughly dispersed and ground to achieve a smooth, uniform texture.

The carotene pigments in the tomatoes must also be thoroughly dispersed to provide the proper color.

To increase the water-holding capacity, the fibrous strands in the tomatoes must be thoroughly dispersed, which increases the viscosity.

After mixing, the product may be passed through a homogenizer to achieve the required consistency.

Production Challenges

Manufacturers face challenges when using conventional mixers and agitators:

Additives added to the product to increase the consistency of the product become lumpy when dissolved, and conventional mixers are unable to disperse them.

Incompletely dissolved materials may stick to the walls of the tank or mixer.

It takes a long time to achieve the final mix and complete the production process.

Dissolving tomato paste in water takes a long time, because conventional mixers cannot mix liquids of different viscosities.

To pass the mix through the homogenizer, the product particles must be completely dispersed. Conventional mixers are not able to do this process.

Several operations may be performed through the homogenizer to obtain the desired product.

Excessively long mixing time destroys the texture of the product and damages the water holding capacity, resulting in the desired color not being achieved.

The homogenization and mixing process can damage the texture of the final ketchup sauce product.

The mixing process of products that are completely made from tomatoes may cause the final product to become bitter.

The solution provided by Arkan Felez Company

The Arkan Felez Company’s vacuum homogenizer mixer can solve these problems and eliminate the need for additional processes such as crushing, defoaming, and some additional homogenization steps. The vacuum homogenizer mixer can be used in all stages of the production of tomato sauces and ketchup. Some of the advantages of using these mixers are listed below:

It significantly reduces the process time.

Rapid dispersion of thickeners and stabilizers and prevention of their caking

Improved performance of the raw ingredients

Smooth and uniform texture and improved product consistency

Improved color

The product fed to the homogenizer is uniform and uniform and its particle size is small, allowing for faster processing through the homogenizer.

Since the entire manufacturing process is under vacuum, the baking process takes place at a lower temperature than atmospheric mixers, so the final product has a better color.

Mayonnaise is an oil-in-water emulsion that can contain up to 80% oil. Starch-based thickeners are used in low-fat products to replace the viscosity and bulking effect of the oil and ensure a stable emulsion.

This process is often carried out semi-automatically and under vacuum. There are many applications for mayonnaise. It is very common to use mayonnaise in large volumes for the production of salad dressings and in small volumes for manufacturers of ready meals, salads and sandwiches. Therefore, mayonnaise must be produced in a way that allows for much greater flexibility.

Mayonnaise production process

In the first stage of production, eggs, which are used in liquid or powder form, are dissolved in water, which acts as an emulsifier.

The ingredients of the aqueous phase are added and dissolved in the water.
Oil is then added, which significantly increases the viscosity of the product by forming an emulsion.

Manufacturing Challenges

The water phase ingredients are only a small part of the total formulation, but they perform critical functions in the process. The mixing equipment must be able to disperse and homogenize these ingredients well in a relatively small volume of water. If the eggs and other emulsifiers are not properly dispersed and homogenized, the emulsion can easily break during the oil addition stage.
Dispersing and homogenizing stabilizers and thickeners is one of the most difficult operations in the mixing process. To complete this process, the solution is to run the dispersion operation for a longer period of time. Bubbles can easily form and cannot be removed by stirring alone.
Because of the high oil content in the mayonnaise recipe, the emulsion can break if the oil is not added to the water phase correctly. This is very difficult to control when adding oil manually.
The oil droplets must be as small as possible to maximize the oil level in the water phase to ensure a stable emulsion. This is not easily achieved without specialized equipment.
To maximize product shelf life, the amount of bubbles in the product must be minimized or completely eliminated.

Solution provided by Arkan Felez Company

Arkan Felez Company offers a vacuum homogenizer mixer to produce mayonnaise for the market and solve production challenges. This unit is capable of performing the entire process including rapid preparation of the mix, dispersion of thickening and stabilizing agents, and preparation of the final oil-in-water emulsion.

Ideal for small volumes intended for immediate use.
Due to the fact that the mixer is under vacuum, it prevents the formation of bubbles in the mix and its deterioration.
The fully automatic PLC system virtually eliminates operator errors.
The consistency and stability of the mayonnaise produced in the factory without spending high costs puts it in the top mayonnaise producers in Iran (most of them use mixers manufactured by Arkan Felez Company).
The performance of the raw materials is maximized, as the thickening agents are fully hydrated and other ingredients are properly dispersed.
Vacuum homogenizer mixer is designed to achieve high viscosity products without the need for additional pumps or auxiliary equipment.
Easily adapts to changes in product type and recipe.

Vacuum bubbler is a vacuum system for bubble removal of liquid, semi-liquid or paste products

VD series vacuum bubbler designed by Chroma Germany

Vacuum bubbler is a vacuum system for bubble removal of liquid, semi-liquid or paste products.

Applications

Food industry: All kinds of hot and cold sauces, pastry cream, cake gel, baby food, flavorings, food supplements, vitamins, juice

Cosmetic industry: Cosmetic powder, cosmetic pancake, lipstick, mascara, hair glue, mask, hair dye, varnish, creams, color pigments, lotions, toothpaste, shampoo

Pharmaceutical industry: Medical creams, gels and ointments, eye medicines and skin products

Chemical industry: Adhesives, ink and grease, varnish, microsilica gels in the construction industry, hard hydrocarbon homogenate, fertilizers, shoe polish, car wax, plant pesticides and agricultural pesticides

Bubbling at the highest standard

This device is used in quality assurance and production optimization in many sectors. In addition, it requires minimal supervision in its use and is also convenient and easy to clean in terms of maintenance. The machine offers different levels of automation and its interchangeable filter geometry allows it to be adapted to different products. The system is also fully CIP compatible.

Benefits at a glance

Prevention of oxidative effects such as discoloration and/or odor and taste changes, especially in the case of fats and oils
Consistently smooth, foamy and shiny surface for the product
Increased long-term stability (chemical stability and shelf life)
Optimum compatibility with the specific product
Increased dosing accuracy in downstream filling systems
Reduced packaging volume through increased specific gravity

Working principle

The product is spread as a thin layer on a rotating disc through a valve. Centrifugal force spins it through the filter cap onto the inner wall of the container, which is located underneath. Air or gas bubbles are released in this process and can be removed by a vacuum pump. A discharge pump transfers the product without bubbles to the next machine in the production line.

Standard design

Vacuum container with safety device
Thin film distributor with filter cap
Powerful vacuum system
Discharge pump
Simple operating control system

Options

Rising tube for foaming heavy products
Double-walled and insulated jacket
CIP cleaning system
Automatic level control
Lifting system for opening the container
Various filter caps
More options on request

In the production process of semi-thick liquids and high-viscosity products, bubbles of air (or other gases) are unintentionally formed in the product. This not only causes undesirable effects such as oxidation (spoiling of oil and fat inside the product), changes in aroma, taste, color and shortening of the product’s expiration date, but also creates numerous problems in weight packaging (especially tube packaging) due to the low density of the product.

The vacuum bubble trap designed by Chroma Germany is an ideal solution for eliminating trapped bubbles in high viscosity products.

This device, like a very precise filter, separates all bubbles from the product and improves the quality and texture of semi-solid products (various creams, sauces, hair dyes, ointments, lotions, toothpaste, etc.).

According to Chroma Germany’s recommendation, the most suitable place to install this device is immediately after the mixer or just before the filling machine.

Equipped with a pneumatic door, sight glass, independent vacuum pump with automatic vacuum control mechanism and speed adjustment by inverter.