Author: joomir

Introduction

Vacuum homogenizer mixer is one of the important equipment in the pharmaceutical industry, which is used to produce pharmaceutical solutions, suspensions, creams and gels. This device mixes pharmaceutical compounds with high precision by creating a continuous homogenization process and ensures the quality of the final product. One of the most important advantages of this device is to increase the uniformity and stability of pharmaceutical compounds. Vacuum homogenizer mixer uses advanced mechanisms such as high shear and ultrasonic force to break particles and create a completely homogeneous mixture. This feature increases the effectiveness of drugs and improves their absorption in the body.

In addition, reducing production time is another important advantage of this device. Unlike discontinuous homogenization methods that require more time, the high-efficiency vacuum model speeds up the production process and reduces operating costs. This method also requires less human intervention, which increases safety and reduces human error in the production process. Ultimately, the use of a vacuum homogenizer mixer increases quality, optimizes production, and reduces pharmaceutical waste, which plays an important role in the development of the pharmaceutical industry.

Vacuum homogenizer mixer speed

The speed of a vacuum homogenizer mixer in the pharmaceutical industry plays a vital role in optimizing the production process and increasing the quality of products. This device uses high shear force and advanced technologies to mix pharmaceutical compounds uniformly and homogeneously in a short period of time. The high speed of this mixer reduces processing time and increases production efficiency, which ultimately leads to reduced operating costs and energy consumption. This feature also enables the production of large volumes of drugs in a short period of time and improves market demand. Precise speed control in this device prevents the formation of heterogeneous particles and instability in the pharmaceutical formulation, which increases the quality and effectiveness of the final product. In addition, adjusting the mixer speed based on the type of material and the desired formulation creates high flexibility in the production process and allows the processing of different types of liquid, semi-solid and suspension drugs. As a result, the high speed of the vacuum homogenizer mixer, in addition to reducing production time and improving quality, increases the stability of pharmaceutical compounds and improves the level of pharmaceutical standards, which is of great importance in the production of safe and effective drugs.

Multipurpose

Vacuum homogenizer mixer is one of the important equipment in the pharmaceutical industry that has wide applications due to its multipurpose features. This device is designed to produce pharmaceutical products with uniformity and high quality and performs the mixing, emulsification and homogenization process continuously. One of the most important advantages of the vacuum homogenizer mixer is its ability to process a wide range of formulations. From the production of pharmaceutical syrups and suspensions to creams, gels and lotions, this device can uniformly combine materials with different viscosities. It also plays an important role in the preparation of pharmaceutical emulsions such as liposomal injectable drugs or nanostructures.

The ability to adjust the speed and cutting intensity in this device allows for precise control of the mixing process, increasing productivity and reducing production time. In addition, the use of a vacuum homogenizer mixer helps reduce the waste of raw materials and optimize energy consumption. Other applications of this device in the pharmaceutical industry include the production of oral solutions, pharmaceutical sprays, and injectable formulations. This device also plays an effective role in biological processes such as the production of vaccines and therapeutic proteins. Overall, the vacuum homogenizer mixer has become one of the essential equipment in the pharmaceutical industry due to its high efficiency, flexibility in the production of various products, and the ability to optimize pharmaceutical processes.

No contact of the product with air

In the pharmaceutical industry, one of the important challenges in the production process is to prevent the product from coming into contact with air. Contact of pharmaceutical materials with oxygen and moisture in the air can cause oxidation, decrease stability, change in physical and chemical properties, and ultimately reduce product quality. The vacuum homogenizer mixer, with its advanced design, solves this problem and provides production conditions in a fully controlled environment. One of the important features of this device is the use of sealed systems and vacuum chambers or inert environments such as nitrogen. This design prevents the product from being exposed to oxygen during homogenization and prevents the destruction of air-sensitive components. This feature is especially important in the production of biological drugs, injectable emulsions, creams, gels and other pharmaceutical formulations that contain unstable compounds.

In addition to maintaining the stability of the materials, the lack of contact with air also improves the physical properties of the product. For example, in the production of pharmaceutical creams and lotions, preventing air bubbles from entering the formulation increases uniformity, reduces the possibility of phase separation and increases the quality of the final product texture. Also, in the production of injectable solutions and sterile drugs, maintaining airless conditions prevents possible contamination and meets GMP standards. Overall, the vacuum homogenizer mixer helps improve the quality, stability, and safety of drugs by eliminating product contact with air, and plays an important role in the production of advanced pharmaceutical products.

Pumping materials

In the drug production process, uniform and vacuum transfer of materials is one of the key factors for achieving high quality and increasing productivity. Due to its advanced design, the vacuum homogenizer mixer uses powerful pumping systems that allow continuous movement and mixing of materials. This feature is especially important in the pharmaceutical industry, which requires high accuracy in mixing materials. One of the most important advantages of using internal pumps in a vacuum homogenizer mixer is the ability to transport materials with different viscosities. This device is capable of uniformly transporting a variety of liquid, semi-solid and even suspension formulations. In this process, the pumps are designed to provide the right pressure for the movement of the materials and prevent excessive turbulence or foaming in the product.

In addition, the pumps used in these mixers are usually of the lobe pump, peristaltic pump or gear pump type, which allow for precise control of the flow of materials. This reduces the waste of raw materials, optimizes energy consumption and increases the final quality of the product. Also, due to the hygienic design of these pumps, the risk of contamination is reduced and GMP and FDA standards are well respected. Overall, pumping materials in a vacuum homogenizer mixer plays an important role in controlling the production process, increasing the uniformity of the composition and improving the quality of pharmaceutical products, and is considered one of the important factors in the sustainable and efficient production of drugs.

Low Energy Consumption

One of the important advantages of the vacuum homogenizer mixer in the pharmaceutical industry is its low energy consumption compared to traditional homogenization methods. With its advanced design and use of modern technologies, this device is able to perform the mixing process with minimal energy consumption and maximum efficiency. In old methods, achieving the desired uniformity required a long time and high energy consumption, but in vacuum models, optimal power transfer and precise process control reduce energy waste. The vacuum homogenizer mixer uses efficient motors and low-energy pumps that help reduce operating costs and increase productivity. In addition, automatic settings and intelligent control of the device allow the amount of energy consumed to be adjusted according to the type and amount of materials, which prevents unnecessary electricity consumption. This feature is not only effective in reducing production costs, but is also environmentally important because carbon emissions and environmental impacts caused by high energy consumption are reduced. As a result, the low energy consumption of this device reduces costs, increases environmental sustainability and optimizes the drug production process, which is an important competitive advantage for the pharmaceutical industry.

Ability to be installed on all production lines

One of the key advantages of the vacuum homogenizer mixer in the pharmaceutical industry is the ability to be installed and integrated with all production lines. This feature allows manufacturers to use this device in various processes without the need for extensive changes to the factory infrastructure. The modular and flexible design of this mixer makes it suitable for integration with the production lines of pharmaceutical solutions, suspensions, creams and emulsions. The vacuum homogenizer mixer has industry standard connections that allow connection to other equipment such as reactors, storage tanks, pumping systems and filling machines. This feature allows the production process to be carried out without interruption and with minimal changes to the factory structure. Also, the ability to adjust speed and pressure in this device allows it to be used in production lines with different capacities. The easy and integrated installation of this device, in addition to reducing installation and maintenance costs, increases productivity, reduces production time and optimizes pharmaceutical processes. As a result, the ability to install on all production lines makes this mixer an ideal choice for modern pharmaceutical factories.

Introduction

A homogenizer is an important tool in various industries such as the food, pharmaceutical, chemical and cosmetic industries, which is used to create a uniform mixture of liquids or different materials. The main function of this device is to create high pressure on the materials, which causes the division of large particles into fine and homogeneous particles. This process causes the materials to be evenly distributed among each other and improves the quality of the final product.

Homogenizers come in different types, but they are mostly divided into two categories: mechanical homogenizers and ultrasonic homogenizers. In mechanical homogenizers, a high-pressure pump is usually used to pass the liquid through tiny holes or nozzles, which causes the particles to break and divide. In the ultrasonic type, high-frequency sound waves are used to create pressure and tension in liquids.

The homogenizer is especially used in the production of products such as milk, cosmetic creams, sauces and medicines. In the food industry, a homogenizer improves the taste and consistency of products. In the pharmaceutical industry, this device can help improve the breakdown and absorption of suspended drugs. In addition, the use of a homogenizer in the production process of chemicals and dyes also plays an important role in the quality and durability of products. Homogenizers help increase production speed and reduce operating costs and are recognized as an essential tool in many industries.

Application of the homogenizer device

The homogenizer device has numerous applications in various industries that improve the quality and efficiency of products. This device is mainly used to create a uniform mixture of liquids or suspended substances in liquids and plays a fundamental role in the food, pharmaceutical, chemical, cosmetic and health industries and even in some environmental industries.

In the food industry, a homogenizer is used to produce products such as milk, sauces, jams, various drinks and even ice cream. This device improves the taste, consistency, and stability of food products by creating finer and more uniform particles. For example, in milk production, a homogenizer makes the fat and liquid mixture in milk uniform, which prevents the separation of fat from the liquid and increases the shelf life of the product.

In the pharmaceutical industry, a homogenizer is used to produce suspended drugs and suspensions. This device causes the drug particles to be evenly distributed in the liquid, thus improving the effectiveness of the drug. Also, in the production of skin drugs, creams, and ointments, a homogenizer creates a soft and uniform texture that is better absorbed by the skin.

In the chemical industry, homogenizers are used to produce dyes, resins, and detergents. These devices divide the raw material particles into appropriate sizes so that the final product is of higher quality and more stable. Homogenizers are also used in the cosmetic and health care industries to produce creams, lotions, shampoos, and other skin and hair care products. The use of a homogenizer in this industry creates a uniform and effective texture in the products that perform better in skin and hair care.

Types of Homogenizers

Types of homogenizers include ultrasonic homogenizers, high-pressure homogenizers, bead mill homogenizers, and rotor-stator homogenizers, which are explained below:

Ultrasonic Homogenizer

Ultrasonic homogenizers are a type of homogenizer used to break down and disperse particles in liquids. They operate by using very high-frequency sound waves (usually above 20 kHz). The sound waves generated by a transducer are transmitted into the liquid and create pressure and tension in it. This pressure and tension causes the large particles to break down into smaller, more uniform particles, which improves the quality of the final product.

This process uses a phenomenon called bubble reduction. When ultrasonic waves enter a liquid, bubbles are formed inside the liquid, which release a lot of energy when the bubbles burst. This explosion of bubbles causes large particles to break into smaller, more dispersed particles. This technique produces excellent results, especially in short times and with less energy consumption than other methods.

Ultrasonic homogenizers are used in many industries. In the food industry, this device helps to improve the composition of materials such as sauces, drinks and ice creams. Also, in the pharmaceutical industry, for the production of suspensions and suspended drugs, ultrasonic homogenizers play an important role in the uniformity and effectiveness of drugs. In the chemical and cosmetic industries, this device is also used to produce high-quality products with uniform textures. This type of homogenizer also has advantages such as reduced process time and low maintenance requirements, which make it an efficient and economical choice for many industries.

 

High Pressure Homogenizer

A high pressure homogenizer is one of the important types of homogenizer devices used in various industries to create a uniform mixture and divide particles into smaller particles. In this type of device, liquid passes through small nozzles or special filters under very high pressure. This high pressure causes large particles to break and become smaller and more uniform particles, which improves the quality and stability of the final product.

The homogenization process in these devices is that the liquid first enters the device and is subjected to high pressure. Then the liquid passes through nozzles with very small holes. This passage through the nozzles creates fast and powerful currents in the liquid, and in the same way, particles and substances suspended in the liquid are divided into smaller sizes. In this way, the composition of the materials in the liquid becomes uniform and no particles of the material are separated from other materials.

High pressure homogenizers are widely used in the food industry. For example, in milk production, a homogenizer homogenizes the fat in milk to prevent its separation and improve the shelf life and quality of the product. In the pharmaceutical industry, this device is also used to produce suspensions and suspended drugs so that the drug is evenly distributed in the liquid and its effectiveness is maximized. In the chemical and cosmetic industries, high-pressure homogenizers are also used to produce paints, resins, detergents, and cosmetic and hygiene products. These devices have a great impact on improving the performance and durability of products by providing a uniform and high-quality product.

Bead mill homogenizer

Bead mill homogenizer is a type of homogenizer used to crush and homogenize particles in liquids. This device is mainly used in the chemical, pharmaceutical, food and cosmetic industries. In a bead mill homogenizer, the homogenization process is carried out using small balls, usually made of glass, ceramic or stainless steel, which are placed inside a chamber containing liquid. These balls move back and forth, converting larger particles into smaller particles, creating a uniform mixture.

The operation of a bead mill is such that the liquid enters the chamber along with solid particles or suspended materials. Then the small balls move inside the chamber and, by colliding with larger particles, crush them and convert them into smaller sizes. This process is carried out by the force of friction and impact between the balls and the particles. In this way, the particles are dispersed uniformly and very finely in the liquid.

The beet mill is widely used in various industries due to its ability to crush particles to very fine sizes. In the food industry, it is used to produce sauces, jams, suspended drinks and ice cream. In the pharmaceutical industry, the beet mill is used to produce suspensions and suspended drugs that require uniform dispersion. Also, in the cosmetic and health industries, the beet mill is used to produce creams, lotions and skin and hair care products. This type of homogenizer is effective in producing high-quality products with uniformity in texture and composition of materials due to its high ability to crush particles.

Rotor Stator Homogenizer

Rotor Stator Homogenizer is a type of homogenizer used to create uniform mixtures of different materials in liquids. This device is widely used in the food, pharmaceutical, chemical and cosmetic industries. The principle of operation of this device is based on the use of a rotating rotor and a fixed stator, which together produce a strong shear force to crush and homogenize particles of suspended materials in the liquid.

In this device, the liquid enters a chamber that includes a rotor and a stator. The rotor, which usually rotates at high speed, draws the liquid into the stator. The stator, which is fixed in place, creates shear and tensile forces by colliding with the liquid flow and its particles, which causes the particles to be crushed and dispersed evenly. This process leads to a reduction in particle size and better mixing of materials.

Rotor-stator homogenizers are used in many manufacturing and industrial processes due to their simple and efficient design. In the food industry, this device is used to produce products such as sauces, drinks, jams and ice cream to evenly disperse fat particles and other substances in the liquid. In the pharmaceutical industry, this type of homogenizer is also used to produce suspensions and suspended drugs that require uniformity. One of the advantages of the rotor-stator homogenizer is the high speed of the homogenization process and its ease of use and maintenance. This device is usually suitable for small to medium volumes and has a lower cost than other types of homogenizers.

Different Parts of a Homogenizer

A homogenizer device is made up of different parts, each of which plays a specific role in the homogenization process and the production of the final product. Here are the most important parts of a homogenizer:

Inlet Pump: This part is responsible for transporting the liquid or material into the homogenizer. The inlet pump is usually designed to introduce the liquid flow into the system at the appropriate pressure so that the homogenization process can begin properly.

Rotor and Stator System: One of the main parts of the homogenizer is the one that performs the actual homogenization process. The rotor (which rotates) directs the liquid towards the stator (which is stationary). The stator creates high shear force to crush large particles and convert them into finer, more uniform particles.

Nozzles: Nozzles are used in the homogenizer to force the liquid under pressure through tiny holes. This process breaks the particles and mixes them better. In some models, the nozzles are designed in multiples to create better homogenization.

Chamber: The chamber or tank is where the liquid or raw materials enter and the homogenization process takes place inside it. In this tank, the liquid is subjected to high pressure and shear force to reduce the particles to smaller sizes.

Pressure Control System: This system is designed to regulate the pressure required for the homogenization process. The appropriate pressure is different for each type of material and this system ensures that the pressure remains within a certain range to achieve the best result.

Outlet: After the liquid has undergone the homogenization process, it is discharged through the outlet of the device. This homogenized liquid is ready to be used in the next stages of production.

All of these departments work together to ensure the homogenization process is carried out in the best possible way and to produce a final product with high quality and excellent uniformity.

How does a homogenizer work?

The homogenizer works by applying high pressure and shear to break up and disperse large particles in liquids. It is mainly used in the food, pharmaceutical, chemical and cosmetic industries to produce high-quality, uniform products. But how exactly does this process work?

First, the raw materials, which can be liquids or suspended solids, are fed into the machine through an inlet pump. The pump directs the liquid into the homogenizer chamber and puts it under high pressure. The liquid then enters the rotor and stator sections. In this section, the rotating rotor directs the liquid towards the stationary stator. The stator creates a strong shear force that breaks large particles into smaller particles. This shear force creates a uniform and dense mixture of liquid and particles. In some types of homogenizers, the liquid passes through fine nozzles. These nozzles exert high pressure on the liquid, and thus, the particles are divided into smaller and more uniform sizes. In ultrasonic homogenizers, high-frequency sound waves are used to create pressure and tension in liquids, which also helps in the breakdown and dispersion of particles.

After the materials have undergone the homogenization process, the liquid is removed from the device and is ready for use or packaging. At this stage, the particles have become small enough that they no longer separate or precipitate, and the final product is uniform and of high quality. As a result, the homogenizer uses high pressure and shear force to crush the material particles, creating a uniform and stable mixture that is required in many industries.

How to work with a homogenizer

How to work with a homogenizer generally includes specific steps that must be followed carefully to achieve the desired result in the homogenization process. These steps include preparing the device, setting the parameters, loading the materials, and performing the homogenization process. The first step in working with a homogenizer is preparing the device. Before starting work, the device must be thoroughly cleaned to prevent any contamination or residue from previous materials. After that, all parts of the device such as the pump, rotor, stator, nozzles, and pressure system must be checked and their health must be ensured.

In the next step, the raw materials, which can include liquids or materials suspended in liquids, are introduced into the device. Usually, liquids are transferred into the homogenizer chamber through a pump. The pressure and speed of the pump must be carefully adjusted to achieve the desired result in the homogenization process. To adjust these parameters, the appropriate pressure and speed must be selected according to the type of material to be homogenized.

After the settings, the homogenization process begins. In this step, the liquid passes through the fine nozzles or the rotor and stator system under high pressure. This passage causes the material particles to be divided into smaller sizes and dispersed evenly in the liquid. Depending on the type of homogenizer, such as high-pressure, ultrasonic or rotor-stator homogenizer, this process can be carried out in different ways. After the process is complete, the homogenized liquid is discharged from the device. Finally, the final product is ready for use or packaging. To ensure quality, tests may be required to check the uniformity and size of the particles. Also, after each use, the device must be thoroughly cleaned and ready for reuse.

Homogenizer Uses in Dairy Industries

Homogenizers are very important in dairy industries and play a key role in improving the quality of dairy products. One of the main uses of homogenizers in this industry is the process of homogenizing milk. This process means making the fat and liquid composition of milk uniform to prevent fat from separating from milk. In the homogenization process, milk passes through fine nozzles under high pressure, which causes the fat particles to be divided into smaller and more uniform particles. This action makes the milk homogeneous and uniform and prevents the formation of fat layers on the surface of the milk. Homogenizers are also used in the production of other dairy products such as butter, yogurt, cheese and ice cream. In butter production, the homogenizer helps reduce the size of fat particles so that the process of separating butter from curd is easier and more effective. In yogurt production, the homogenizer helps to evenly distribute beneficial bacteria inside the milk, leading to improved taste and texture of the final product.

In ice cream production, a homogenizer helps to evenly distribute fat and liquids among other ingredients such as milk, cream, and sugar, which helps improve the soft and creamy texture of ice cream. The homogenizer also reduces the size of ice crystals in ice cream, which helps improve the taste and prevent unpleasant texture in ice cream. Finally, using a homogenizer in the dairy industry, in addition to improving the quality and taste of products, increases their shelf life and stability. These devices also help increase productivity and reduce material waste.

Important points when using a homogenizer

When using a homogenizer, observing some important points can help increase the efficiency of the device, improve the quality of the final product, and prevent technical problems. Below are some basic points that should be considered when using a homogenizer:

Correctly adjust the pressure and speed: One of the most important points is adjusting the pressure and speed of the device. Excessive pressure can damage the machine or produce particles that are too fine, while low pressure will cause incomplete homogenization. Also, the appropriate speed setting for the rotor and stator is different for each type of material.

Raw material preparation: Raw materials such as milk, liquids or suspended materials must be properly prepared before the homogenization process begins. For example, the materials must reach the appropriate temperature for effective homogenization.

Machine cleanliness: The homogenizer must be thoroughly cleaned after each use. Residual materials from the previous process can affect the quality of the final product. Proper cleaning of the machine from contaminants and material residues extends the life of the machine and prevents cross-contamination.

Machine health check: All parts of the machine such as pumps, nozzles, rotor and stator should be checked before starting to ensure that there is no damage or failure. In particular, the nozzles must be clean and unclogged so that the homogenization process can be carried out optimally.

Temperature control: In some cases, an increase in temperature during homogenization can lead to the decomposition of sensitive substances or change the taste and texture of the final product. Therefore, temperature control and the use of cooling systems when necessary are of great importance.

Follow production instructions: Each type of homogenizer may have its own instructions for best performance. Following these instructions, including the appropriate time and pressure for the process, will help achieve better results.

Following these tips when using a homogenizer will not only help improve the quality of the final product but also extend the useful life of the device.

In which industries is a homogenizer used?

A homogenizer is used in many industries to improve the quality and uniformity of products. This device divides material particles into smaller sizes by creating high shear force and pressure and causes them to be uniformly mixed in liquids. Here are some important industries that use a homogenizer:

Food industries: One of the main applications of a homogenizer is in the food industry. In the production of products such as milk, sauces, jams, ice cream, beverages and other liquid foods, a homogenizer is used to prevent the separation of substances and fats. The homogenizer causes fat particles in liquids to be divided into smaller sizes and the final product is uniform and of high quality.

Pharmaceutical industry: Homogenizers play a vital role in the production of liquid medicines and suspensions. This device helps to evenly distribute active pharmaceutical ingredients in liquids and improves the effectiveness and stability of the drug. Homogenizers are also used in the production of pharmaceutical emulsions and creams.

Chemical industry: In the production of paints, resins, detergents and other chemical compounds, a homogenizer is used to ensure the uniformity and stability of products. This device is important for the uniform dispersion of material particles in liquids and preventing their sedimentation.

Cosmetics and health industry: In the production of creams, lotions, gels and other skin care products, a homogenizer is used to obtain a uniform texture and long-term shelf life. This device helps in the uniform distribution of active ingredients and oils in the products.

Oil and gas industry: In some refining and production processes of petroleum products, a homogenizer is used to mix various materials such as additives and liquids. This increases the quality and stability of petroleum products.

Agricultural industry: In the production of pesticides and liquid fertilizers, a homogenizer is used to evenly distribute chemicals in the liquid. This helps increase the efficiency and performance of agricultural products.

Overall, homogenizers are used in various industries that require uniformity in liquid materials and have a great impact on improving the quality and stability of final products.

Introduction

Starting a cosmetics production line is one of the most profitable and popular businesses in the beauty industry. These production lines include several processes from the preparation of raw materials to the final packaging of the product. To produce high-quality cosmetics, it is necessary to use standard raw materials and advanced equipment. Production lines can produce a variety of products such as moisturizers, lipsticks, mascaras, lotions, and skin and hair care products. One of the most important points in starting a cosmetics production line is to comply with health standards and obtain the necessary permits from the relevant authorities. The required equipment such as mixer tanks, filling machines, sealers, and packaging must be carefully selected to ensure the quality and safety of the product. In addition, attractive packaging design and attention to branding also play an important role in the success of the production line.

Cosmetic Cream Production Line Equipment

Cosmetic cream production line equipment includes a set of equipment for manufacturing, mixing, and packaging creams. One of the most important devices is the homogenizer mixer, which is used to uniformly mix raw materials and create a cream texture. These devices, by precisely controlling temperature and speed, enable the production of creams with the right consistency and quality. In addition to the mixer, filling and sealing devices also play an important role in the production process. The filling device carefully fills the produced cream into the desired containers, and the sealing device seals the containers to prevent leakage and increase the shelf life of the product. Finally, labeling devices are used to insert product and brand information on the packaging. For optimal and economical production, it is essential to use advanced equipment with automatic adjustment capabilities and comply with GMP standards.

Licenses required to set up a cosmetics production line

To set up a cosmetics production line, it is necessary to obtain legal and health licenses. The first step is to obtain a license from the Food and Drug Administration, which requires the submission of documents such as a feasibility study, a list of equipment, and product ingredients. In addition, obtaining an operating license from the Ministry of Industry, Mines, and Trade is mandatory. Other licenses include standard certificates, environmental permits for waste management, and GMP (Good Manufacturing Practices) certificates. Compliance with these requirements guarantees the quality and safety of the products.

Types of Cosmetic and Health Products Production Lines

Cosmetic and Health Products Production Lines include a wide range of equipment and processes for the production of various products. These production lines are divided into different categories according to the type of product:

Cream and Lotion Production Line: These lines are designed to produce a variety of moisturizing creams, sunscreens, and lotions. The main equipment includes a homogenizer mixer, a filling and sealing machine. These devices allow for precise mixing of ingredients and standardized packaging of products.

Color Cosmetics Production Line: This category includes products such as lipsticks, mascaras, and eye shadows. The production process includes precise mixing of pigments and base materials, shaping, and packaging. Molding machines, advanced mixers and automatic filling equipment are key tools in these lines.

Shampoo and liquid soap production line: Production lines for hygiene products such as shampoo and liquid soap are based on the combination of surfactants and additives that enhance the product’s performance. These lines operate with devices such as liquid mixers, automatic fillers and packaging systems.

Nail polish production line: These lines include special mixers for mixing pigments, resins and solvents and small filling machines for nail polish bottles. Capping and brushing machines are also used to complete the product.

Choosing the right equipment, complying with hygiene standards and using modern technologies are important factors for success in any type of cosmetic and hygiene production line.

Introduction to the detergent production line and how it works

The detergent production line is one of the most widely used production lines in the health industry, designed to produce products such as dishwashing liquid, shampoo, hand sanitizer, and detergent powders. This line includes various stages from mixing raw materials to final packaging and, using modern equipment, allows for fast and optimal production. Initially, raw materials including surfactants, aromatic essential oils, softeners, and other additives are fed into industrial mixers. These devices mix the materials uniformly by precisely controlling the temperature and speed. Then, the prepared mixture is transferred to filling machines, which fill the detergent into appropriate containers with high precision. After filling the containers, they are transferred to sealing and capping machines to prevent leakage and contamination. Finally, the labeling process is carried out, which includes inserting information such as brand, ingredients, production date, and expiration date. To maintain quality and standards, detergent production lines must operate under GMP and HACCP standards. The use of advanced technologies and strict quality control plays an important role in the success of these products.

Varnish production

The varnish production line includes processes such as mixing resins, pigments and solvents. First, the raw materials are mixed in special mixers to achieve a uniform mixture. Then the product is transferred to filling machines and packaged in varnish jars. Brushing and capping machines are also used to complete the process. Compliance with quality standards and the selection of high-quality raw materials are of particular importance in varnish production.

Tissue production line

The tissue production line is one of the most popular lines in the hygiene products industry, which includes a variety of processes from the preparation of raw materials to the packaging of the final product. This production line is designed to produce a variety of box, roll and pocket tissues and, using modern technologies, allows for high-capacity production. The production process begins with the preparation of raw paper. Rolls of raw or mother paper are transferred to cutting and converting machines. These machines cut the paper into different sizes and shapes depending on the type of product. If necessary, special designs or logos are also applied to the paper using printing machines. Then, folding or rolling machines form the paper into folded or rolled tissues. The tissues then enter packaging machines, where they are packaged in boxes, plastic or paper and ready to be released to the market. Quality control is of particular importance at every stage of production, from the selection of raw paper to packaging. The use of modern equipment and compliance with hygiene standards guarantees the production of high-quality and competitive tissue in the market.

Ketchup Sauce Production Line

Ketchup sauce production line is one of the most widely used production lines in the food industry, which includes various processes from the preparation of raw materials to the packaging of the finished product. This production line is specifically designed to produce a sauce with a uniform taste, appropriate concentration and high shelf life. The ketchup sauce production process begins with the selection and preparation of raw materials such as tomatoes, vinegar, sugar, salt and spices. First, the tomatoes are washed and transferred to shredders. Then the shredded materials are fed into cooking machines, where they are pasteurized at a controlled temperature to ensure the preservation of the taste and shelf life of the product. After cooking, the mixture is fed into homogenizer mixers to create a uniform consistency and texture. Then the sauce is transferred to filling machines and filled into bottles or other packages. In the next step, capping and labeling machines are used to complete the packaging. Quality control at every stage, from raw material selection to packaging, ensures the production of high-standard ketchup. The use of modern technologies and compliance with hygiene standards play an important role in the success of this production line.

Mayonnaise Production Line (Industrial)

Mayonnaise production line in the food industry is designed to produce high-quality sauces with a uniform texture and good taste. This process includes various steps from the preparation of raw materials to the packaging of the finished product. The main raw materials of mayonnaise include oil, eggs or alternative emulsifiers, vinegar, salt and flavor additives. First, the ingredients are combined in advanced mixers. The mixer-homogenizer device plays an important role in creating a stable and uniform emulsion. This device prevents the separation of oil and water layers by adjusting the temperature and speed and produces a sauce with a uniform texture. After the sauce mixture is prepared, it is transferred to filling machines, where it is accurately filled into various containers or bottles. In the next step, the packaged containers are sealed by sealing and capping machines to maintain the quality and shelf life of the product. Quality control is of great importance at every stage of production, from the selection of raw materials to packaging. Compliance with health standards and the use of modern equipment in industrial mayonnaise production lines guarantee the quality and health of the product.

Cost of setting up a sauce production line

The cost of setting up a sauce production line depends on several factors and can vary according to the production capacity and type of equipment. The main costs include the purchase of production and packaging equipment, the cost of raw materials, renting or purchasing workshop space, and legal permits. The main devices required include mixers, homogenizers, fillers, sealers, cappers, and labeling. The price of this equipment varies depending on the model and production capacity. For industrial-scale production, the cost of equipment can vary from several hundred million tomans to several billion tomans. In addition to equipment, costs related to facilities such as electricity, water, and proper ventilation must also be considered. Also, obtaining health permits and relevant standards from the Food and Drug Administration and other legal authorities requires additional costs. Running costs such as purchasing raw materials such as oil, eggs, spices and preservatives, employee salaries and equipment maintenance also form part of the overall budget. Accurate cost estimates, preparing a proper business plan and selecting quality equipment are essential for setting up a sauce production line and succeeding in this business.

Mayonnaise Production Plant

A mayonnaise production plant produces a sauce with a uniform taste and texture using modern equipment and quality raw materials. The production process involves mixing oil, eggs or alternative emulsifiers, vinegar, salt and additives in homogenizer mixers, which ensures product uniformity and stability. After preparation, the sauce is transferred to filling machines and filled into various packages such as plastic, glass bottles or small sachets. The sealing, capping and labeling steps increase the quality and shelf life of the product. Compliance with hygiene standards and quality control at all stages is a requirement for these factories.

Types of Sauce Packaging

Sauce packaging plays an important role in maintaining quality and attracting customers. Packaging comes in a variety of forms, including plastic and glass bottles, single-serving sachets, and lidded containers. Plastic packaging such as squeeze bottles are very common for sauces such as mayonnaise and ketchup. This type of packaging provides ease of use and high safety. Glass packaging is mostly used for luxury or export products. Small sachet packaging is also popular for restaurants and fast food due to its easy transport and single-use consumption. Compliance with hygiene standards and attractive packaging design are key factors in successful sales.

Shampoo Production Line

The shampoo production line includes advanced processes for mixing raw materials, packaging and preparing the final product. Raw materials include surfactants, softeners, essential oils and care additives. In the first stage, the materials are mixed in industrial mixers and a uniform solution is formed. Then the prepared mixture is transferred to filling machines and filled into various bottles or containers. Sealing and capping steps are performed to prevent leakage and maintain quality. Shampoo production lines must comply with health and quality standards such as GMP. The use of advanced equipment and precise formulation guarantees product quality.

Cost of starting a detergent production line

The cost of starting a detergent production line depends on various factors, including the type and capacity of production, the equipment required and the location of the factory. The main costs include the purchase of mixers, fillers, packaging machines and quality control systems. The costs of raw materials such as surfactants, essential oils, and other additives must also be considered. In addition, costs related to facilities, renting or purchasing workshop space, and legal permits must also be calculated. In general, the cost of setting up a detergent production line can vary from several hundred million to several billion Tomans.

Raw materials for detergent production

Raw materials for detergent production are obtained from a combination of chemical and natural compounds that are used to create specific properties such as cleaning, foaming, and antibacterial properties. One of the most important components of detergents is surfactants, which have the ability to reduce the surface tension of water and help clean surfaces. Water is used as the main solvent in many detergents. Emollients such as glycerin and polymers help maintain moisture and softness of the skin in detergent products such as soaps and toilet liquid. Essential oils are also added to create a pleasant smell in the products. Preservatives are added to the formulations to prevent spoilage and increase the shelf life of the products. Finally, acids and bases are used to adjust the pH level and create optimal conditions for the activity of surfactants. Combining these materials carefully and in compliance with health standards makes it possible to produce effective, safe and high-quality detergents.

Sunscreen Production Line

The sunscreen production line includes several stages to create a product with a suitable formulation, high efficiency and long shelf life. Initially, raw materials such as chemical and mineral filters such as zinc oxide and titanium dioxide are added to the base formulations to protect the skin from UV rays. Then these materials are mixed in homogenizer mixers to become uniform and uniform. After preparing the cream, this mixture is transferred to filling machines to be filled into various containers such as tubes or pumps. The next stage includes sealing and capping to maintain quality and prevent contamination. Finally, labeling is done with product information. In this production line, it is very important to comply with hygiene standards and conduct quality control tests to check the SPF capability, pH, and shelf life of the product. These processes ensure that the sunscreen is effective and safe on the skin.

 

What is an oxidant?

An oxidant is a chemical used in various processes such as bleaching and coloring hair. This substance is actually a mixture of hydrogen peroxide that has the ability to open the hair cuticle and allow the colors to penetrate the deeper layers of the hair. Oxidants are available in different percentages such as 10, 20, 30 and 40, each of which is used for specific applications. When using an oxidant, its strength depends on the active percentage of hydrogen peroxide. For regular colors, 10 and 20 percent oxidants are usually used, but for bleaching or lighter colors, 30 and 40 percent oxidants are used. This substance also helps to create the oxidation process in the colors and stabilizes the color and makes it last longer on the hair. Due to its strong chemical properties, care should be taken when using oxidants and avoid contact with the skin and eyes.

Oxidant Production Line

The oxidant production line consists of several complex process steps designed to produce a quality and safe product. The first step involves the selection and preparation of raw materials such as hydrogen peroxide, distilled water and stabilizers that are used to maintain stability and prevent premature decomposition. In the next step, these materials are carefully mixed in industrial mixers and subjected to specific temperature and pressure conditions to achieve a uniform composition. Special care must be taken at this stage to maintain the correct percentage of hydrogen peroxide and other ingredients. After preparing the oxidant mixture, it is transferred to filling machines and filled into various packages such as plastic and glass bottles. After filling, the capping machines and sealing of the packages are carried out to protect the final product from contamination. Finally, to ensure quality and safety, all products are checked for hydrogen peroxide percentage, pH and stability and then released to the market.

Introduction

Industrial mixers are devices used to mix different materials in various industries. These mixers are divided into different types depending on the need and type of materials. Below, we have examined some of the most important types of industrial mixers:

Vertical Mixers: These types of mixers are used to mix powdered and granular materials. The movement of materials in a vertical direction ensures uniform mixing. These devices are especially used in the animal feed and chemical industries.

Horizontal Mixers: Horizontal mixers are used to mix large volumes of materials. These types of mixers are usually used in the feed, pharmaceutical and food industries.

Powder Mixers: These mixers are designed to combine powdered and granular materials. They are usually used in the food, pharmaceutical and chemical industries and can mix different types of powders uniformly.

Homogenizer Mixers: These devices are used to mix materials with precise and uniform composition. They are especially used in the pharmaceutical and chemical industries to produce high-quality materials.

Industrial mixers play a key role in various industries, especially in the production of food, medicine, chemicals and even in the construction industry.

Homogenizer Mixer

A homogenizer mixer is one of the important devices in various industries that is used to mix materials in such a way that a uniform and homogeneous composition is obtained. This device is especially used in the food, pharmaceutical, chemical and cosmetic industries and is used for processes such as emulsification, mixing and reducing the particle size of materials. The operation of the homogenizer mixer is based on the compression and spraying of materials under high pressure. In this process, the materials pass through a nozzle at high speed and pressure and become very fine and uniform particles. This improves the quality of the final product and increases its shelf life.

The homogenizer mixer is used in the production of products such as sauces, medicinal creams, sweets, medicinal powders, paints and cosmetics. This device also helps to improve the texture and uniformity of products and plays an important role in preventing the separation of materials in liquid mixtures. By using the homogenizer mixer, the production process can be optimized, production time can be reduced and the quality of products can be improved. This device is one of the essential tools for producing high-quality products with a long shelf life.

Shampoo Homogenizer Mixer

Shampoo homogenizer mixer is used to produce shampoos with a uniform and high-quality composition. This device uses high pressure and a homogenization process to convert the various ingredients in the shampoo formulation into fine and uniform particles and helps prevent the separation of materials. The operation of the shampoo homogenizer mixer is such that the combination of shampoo raw materials such as water, surfactants, oils, fragrances and dyes passes through a series of nozzles under high pressure. This process causes the particles in the shampoo to mix evenly and a smooth and uniform final product is obtained.

The homogenizer mixer is very important in the production of shampoos that require stable emulsions. This device helps prevent the separation of various ingredients and create the appropriate foam and concentration. Also, using this device increases the quality, improves the texture, increases the shelf life and optimizes the shampoo production process. Ultimately, the shampoo homogenizer mixer is an essential tool in the health product manufacturing industry that helps produce high-quality and better-performing shampoos.

Laboratory Homogenizer Mixer

A laboratory homogenizer mixer is a device used to create uniform mixtures and reduce particle size on a small scale. These devices are especially useful in laboratories, scientific research, and manufacturing industries that require testing and producing small quantities of products. The function of a laboratory homogenizer mixer is similar to industrial devices, except that its design and capacity are optimized for use on a laboratory scale. The materials pass through special nozzles under high pressure, and this process converts large particles into fine and uniform particles.

These devices are used in various fields such as the pharmaceutical, food, cosmetic, and chemical industries. For example, in the production of creams, lotions, suspensions or emulsions, a laboratory homogenizer mixer helps to create a uniform and high-quality mixture. A laboratory homogenizer mixer allows scientists and researchers to test different formulations and evaluate the final quality of products before large-scale production. This device is also very effective in increasing the accuracy and speed of experiments and reducing waste.

Laboratory Mixer

A laboratory mixer is a device used to mix and blend materials on a small scale. These devices are used in laboratories and scientific research and help produce uniform and homogeneous mixtures. Laboratory mixers can mix liquid, powder and granular materials. These devices are used in various industries including pharmaceutical, food, chemical and cosmetic. Laboratory mixers are usually designed in different sizes and with adjustable mixing speed and time to meet different experimental needs.

What is a homogenizer?

A homogenizer is a specialized tool designed to produce uniform mixtures of liquids and semi-solid materials in various industries. This device uses high pressure to pass the materials through one or more nozzles, which reduces the particle size and creates a homogeneous mixture. Homogenizers are used in the food, pharmaceutical, cosmetic and chemical industries to produce products such as sauces, creams, ointments and beverages.

These devices help improve the quality of products and prevent the separation of materials and the formation of layers in liquids. Also, by reducing the size of particles, the absorption and effectiveness of materials in the final products are improved. Homogenizers help increase the shelf life and stability of products and at the same time speed up the production process. As a result, the homogenizer is one of the important tools for producing high-quality and uniform products, which is especially important in industries sensitive to uniform mixing and quality control.

Vacuum Homogenizer Mixer Device

The vacuum homogenizer mixer device is an advanced tool designed to mix materials uniformly and under vacuum conditions. This device uses negative pressure inside the mixer chamber to bring particles and molecules together, reducing the size of particles and creating a uniform mixture. The vacuum process in this mixer is especially effective for the production of products that need to maintain air-sensitive properties, such as creams, emulsions and pharmaceutical products.

The main advantage of using a vacuum homogenizer mixer is to prevent air from entering the mixture and reduce the possibility of unwanted chemical reactions. This device also helps to remove air bubbles and dissolved gases in the materials, which can be effective in producing quality and long-lasting products. These features make the vacuum homogenizer mixer used in industries such as pharmaceuticals, food and cosmetics, where maintaining the quality and properties of the final product is of great importance. Using this device helps to improve the texture, increase stability and optimize the production process and is also effective in reducing waste. The vacuum homogenizer mixer is especially vital in the production of products with complex and sensitive compositions.

Thousand Island Sauce Mixer

The Thousand Island Sauce Mixer is a device used to combine and mix the ingredients of Thousand Island Sauce. This mixer combines various ingredients such as mayonnaise, ketchup, vinegar, spices and vegetables together with fast and uniform performance, uniformly and without breaking. Using this mixer in the production of industrial sauces increases the quality, speed of production and reduces waste. This device is widely used in the food production industry, especially in factories and restaurants to produce high-quality sauces.

Toothpaste Mixer

A toothpaste mixer is an important device in the toothpaste manufacturing industry that is used to uniformly mix the various ingredients in the toothpaste formulation. This device uses mechanical movements, often a combination of pressure and rotation, to uniformly mix various ingredients such as fluoride, glycerin, surfactants, water, and other additives.

The function of a toothpaste mixer is to use different ingredients at specific temperatures and conditions to ensure that all ingredients are thoroughly mixed and the final product has a high level of uniformity. These mixers usually perform this process at high speed and in a short period of time, which helps improve production speed and reduce waste.

Using a toothpaste mixer in the production of this product improves quality, creates the right texture, and maintains the chemical properties of the ingredients. These devices also help to remove air bubbles from the toothpaste and prevent the separation of various ingredients over time. For this reason, toothpaste mixers are essential in industrial toothpaste production lines to achieve a high-quality and long-lasting product.

Food mixers

A food mixer is a device used to combine and mix various raw materials in the food industry. These devices are usually used in the production of products such as sauces, drinks, yogurts, soups and pastes. Food mixers mix various materials evenly by creating appropriate movement and pressure. These devices are designed in different types such as horizontal and vertical mixers and can effectively combine powdered, liquid and granular materials. The use of food mixers improves the quality and speed of production in the food industry.

Shampoo Mixer

A shampoo mixer is a device used to mix various ingredients in the production of shampoo. This device is especially used in the health and cosmetic industries to mix raw materials such as surfactants, water, moisturizers and fragrances. A shampoo mixer uses mechanical movement and pressure to mix ingredients evenly and prevent material separation. This device is effective in producing high-quality, uniform and stable shampoos and helps to increase production speed and reduce waste in the production process.

Oxidant Mixer

An oxidant mixer is a device used to uniformly mix oxidants and other materials in the color and beauty industry. This device is usually used in the production of hair dyes and related products. An oxidant mixer uses mechanical systems and proper rotation to mix materials thoroughly and evenly and prevents lumps or separation of materials. This process helps to ensure the quality of the final product and create hair colors with a stable composition and high durability. The use of an oxidant mixer in production increases the speed and efficiency of the process.

Vaseline mixer

A Vaseline mixer is a device used for uniform and optimal mixing of materials in the production of Vaseline. This device mixes raw materials such as oils, waxes and Vaseline uniformly by creating appropriate movement and pressure. Vaseline mixer is especially used in the pharmaceutical and cosmetic industries for the production of creams, ointments and skin care products. This device helps to prevent the separation of materials and maintain the physical and chemical properties of the final product. Vaseline mixer plays an effective role in speeding up the production process and improving the quality of products.

Pressure mixer

A pressure mixer is a device designed to mix materials under high pressure. This mixer is commonly used in the chemical, pharmaceutical and food industries, where there is a need to mix materials under specific conditions and with controlled temperature and pressure. The pressure mixer uses high pressure to mix different materials uniformly and prevent separation or unwanted reactions. This device is used in processes such as the production of emulsions, suspensions and the mixing of pressure-sensitive materials and improves the quality of the final product.

Industrial Homogenizer

An industrial homogenizer is one of the important devices in various production processes that is used to combine and mix materials uniformly and with fine and uniform particles. These devices are commonly used in the food, pharmaceutical, chemical and cosmetic industries to improve the quality and production processes. The operation of an industrial homogenizer is such that materials pass through one or more nozzles under very high pressure. This process causes the material particles to turn into finer particles and a uniform mixture of different materials is obtained. This feature is very important in the production of products such as sauces, creams, ointments, paints and drinks.

Industrial homogenizers are used in the food industry to produce products such as milk, yogurt, drinks, sauces and jams. In the pharmaceutical industry, these devices are also essential for the production of pharmaceutical solutions, creams and emulsions. In addition, industrial homogenizers are used in the production of cosmetics and chemicals to improve the texture and quality of products. In addition to improving the quality and uniformity of products, these devices help reduce production time, increase productivity and reduce waste. The use of industrial homogenizers in various productions guarantees high-quality products with a long shelf life.

What is a lobe pump?

A lobe pump is a type of positive displacement pump used to transfer viscous (thick) liquids and chemicals. This pump uses two lobe-shaped rotors that rotate simultaneously inside the pump housing to move the liquid. Lobe pumps are able to pump materials without damaging them, which is why they are widely used in the food, pharmaceutical, chemical and petroleum industries. These pumps are suitable for transporting liquids such as oils, sauces, sweets and polymeric materials due to their simple design and high efficiency.

Homogenizer pump

A homogenizer pump is one of the important tools in various industries that is used to create a uniform mixture and reduce the particle size of materials. This device is usually used in the food, pharmaceutical, chemical and cosmetic industries to produce high-quality products. The function of a homogenizer pump is based on creating high pressure and passing the materials through a series of special nozzles or valves. This process causes the materials to be divided into fine and uniform particles and a uniform composition is achieved in the final product. This feature is especially important in the production of emulsion products such as sauces, creams, lotions and liquid medicines.

Homogenizer pumps are commonly used in the food industry to produce products such as milk, yogurt, sauces, jams and packaged drinks. In the pharmaceutical industry, this device is used to prepare creams, ointments and pharmaceutical solutions to ensure that the composition of the materials is complete and uniform. This device improves quality, increases the shelf life of products and reduces the separation of materials over time. In addition, the use of a homogenizer pump helps to increase productivity and reduce waste in the production process.

Types of industrial pumps

Industrial pumps are tools designed to move liquids and gases in various industries. These pumps are divided into different types according to the type of application and the characteristics of the liquids they move. Below we have mentioned some of the most important types of industrial pumps:

Positive Displacement Pumps: These pumps move liquids in fixed volumes through mechanical movement. Different types of these pumps include:

Gear Pumps: Suitable for viscous liquids such as oils.

Piston Pumps: For high pressures and heavy liquids.

Lobe Pumps: For thick materials and liquids with large particles.

Centrifugal Pumps: These pumps use centrifugal force to direct the liquid into and out of the pump at high speed. These types of pumps are suitable for transporting thin and low-viscosity liquids.

Diaphragm Pumps: Use a rubber or plastic diaphragm to move fluids. These pumps are used in the chemical and pharmaceutical industries to prevent the leakage of hazardous materials.

Centrifugal Pumps: Mostly used in the oil, water, and chemical industries to transfer large volumes of fluids.

Hydraulic Pumps: These pumps are mainly used in hydraulic systems to create pressure and movement in industrial machinery.

These pumps are used in various industries such as oil and gas, chemical, food, pharmaceutical, and water and wastewater, and the selection of the appropriate pump is done depending on the type of fluid and the needs of the system. Arkan Felez Company, utilizing advanced technical knowledge and world-class technologies, has gained a special place in the design and production of two-stage, multi-stage, top-down, bottom-up, and lobe-type homogenizer pumps in various industries. These pumps are designed to meet the complex needs of the industry, specifically designed for precise mixing of ingredients. In the cosmetic industry, these equipment play a key role in the production of sensitive creams and skin care products, where accuracy and uniformity are of vital importance. Also in the food industry, these pumps are used to produce products such as sauces, beverages and dairy products, as their advanced performance prevents the formation of unwanted lumps and ensures the quality of the final product. In the pharmaceutical industry, these pumps are also used to mix sensitive materials and liquid medicines. With a robust design, the use of high-quality raw materials and the ability to withstand high pressures, these equipment have a long life and provide reliable performance while reducing maintenance costs. Arkan Felez brings innovation and quality to customers’ production lines and defines new standards in the industry by providing these advanced products.

 

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 (homogenizer) 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 homogenizer mixer of the ArkanFelez Company.

• A vacuum 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 ArkanFelez vacuum homogenizer mixer 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.

Cosmetic cream production 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.

 

Challenges in producing cosmetic creams

Using regular mixers you will have a number of problems:

• Some ingredients can form pellets that conventional mixers are unable to break down.
• Dispersing thickeners and suspensions is one of the most difficult tasks in the homogenizer 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

You can eliminate extra production steps, improve product quality, and significantly reduce process time by using Arkan Felez‘s vacuum homogenizer mixer.

• 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.