Why a Consistent Mixing Technology Range is Key to Scaling Up Cosmetic Productions

Developing a new cosmetic product must often be achieved within increasingly shorter timeframes, driven by more frequent market demands and consumer expectations for diverse, personalized, and effective products.

Scale-up refers to the transition from laboratory trials and formulations to large-scale production - a critical step in replicating the quality and properties (texture, color, appearance, odor, stability) of the product by adjusting machine parameters. For every new cosmetic product or formulation, this shift from the lab to industrial production is crucial. The choice of these parameters, which partly depend on the mixer chosen, must be made very early on, based on the formulation.

Understanding the process and considering key factors

• Tank design, types and number of mixing tools
• Tool rotation parameters (speed, flow rate)
• Mixing duration
• Physical conditions such as pressure, vacuum, and temperature

Choosing the right similarity
Homothety, which involves maintaining ratios between two or three manufacturing capacities (e.g. bench/pilot/industrial)

• Geometric similarity: maintaining constant dimension ratios between lab and large-scale equipment to retain similar flow patterns and heat transfer rates or other important parameters
• Kinematic similarity: constant speed ratios to preserve fluid dynamics, shear forces, and mixing patterns despite changes in vessel size
• Dynamic similarity: constant force ratios between any point on two scales: such as pressure in the tank, friction, and inertia

Selecting the appropriate mixing equipment:

Selecting the appropriate mixing equipment is a crucial aspect of a successful scale-up process for cosmetic productions. It involves conducting trials at various scales, starting from the laboratory to develop the formula, then progressing to pilot-scale for larger volumes or when smaller batches are needed, and finally transitioning to large-scale production. Throughout these stages, maintaining consistent design and process parameters across different scales is essential for ensuring product quality and reproducibility.

VMI offers a comprehensive range of mixing solutions for cosmetics and pharmaceutical manufacturers. From bench to pilot and turnkey mixing solutions, our mixer designs facilitate a seamless transition from laboratory trials to large-scale production.