ika-master-plant-brochure-pdf

IKA-Master-Plant-brochure.pdf

Hyaluronic acid is a natural lubricant found in all mammals. An effective humectant, its molecules can hold a thousand times their weight in water. However, hyaluronic acid extraction is a complex biotechnological process that requires a specialized manufacturing technique.

Hyaluronic acid

The most significant decision when making ointments is likely to be the choice between automatic or semi-automatic processes for it. This impacts on individual phases of the ointment cream manufacturing process - the water phase and oil phase.

Ointment

Every minute, your skin loses between 30,000 and 40,000 dead skin cells. This means losing millions of cells every day, which makes your skin look less glowing. Being a moisturizing agent, body lotion has the power to hydrate your skin and  give the glow back to it. Production involves water and oil phases, which you then mix with an emulsifier and blend until homogeneous. Preservatives are essential for any solution containing water for the prevention of microbial growth.

Body lotion

Did you know that in the 30s, cosmetic creams that contained radioactive material were booming on the market because they promised to reduce wrinkles? Thank God that's no longer the case. To make a cosmetic cream today, you need to create a stable mixture of oil and water and add an emulsifier to join these otherwise immiscible substances.

Cosmetic creams

Shampoo is a unique form of cleaning agent composed primarily of water and some form of surfactant. This surfactant provides the ability to bind oily substances for removal without leaving a residue, as traditional soaps might. The production process involves the batch mixing of its laboratory-defined formula, quality control, and filling stages.

Shampoo

Cosmetic serums are a very light formulation with a high density of active ingredients dispersed in oil, water, or gel. This makes serums well suited to the delivery of vitamins, antioxidants, and anti-aging ingredients, but provide less moisturization and protection. Serum production is mainly divided into stages related to optimal mixing and preventing degradation of the active ingredients.

Serums

API making equipment must observe rigorous quality control standards across the entire manufacturing process. The pharmacodynamic properties of active pharmaceutical ingredients API make them highly sensitive to their environment, making API manufacturing and production a tightly regulated field.

Active pharmaceutical ingredients (API)

You can make emulsions by combining two immiscible liquids (oil and water, for example) in a suspension through the use of force. The use of emulsifiers is necessary to keep this mixture stable and permanent.

Emulsions

In 2009, billionaire Stanley Ho made the winning bid for a giant white truffle weighing 3.3 pounds during an auction. Price: $330,000. Looking at the price, there's no need to explain why truffles are called the diamonds of the kitchen. After harvesting, they are selected to be sold fresh or processed to make truffle products such as truffle cream. Truffle processing involves cleaning, cutting, grinding, cooking, packaging, and sterilizing.

Truffle cream

After shaving, anti-aging, with organic ingredients, for the feet... Lotions are many. They compose the skincare world, which has been growing in recent years. More consumers look for the benefits of products that promise to enhance well-being and self-care. Whether you want to help prevent wrinkles, provide vitamins or just hydrate your consumers’ skin, get your formula and select lotion making equipment to get started.

Lotion

Sunscreen is an emulsion which can be either oil-in-water or water-in-oil. To create it, you must prepare an oil phase and a water phase separately, then mix and heat them. Homogenization is a key process to guarantee that the product will have the right consistency. When manufacturing sunscreen, give special attention to protection against UV filters.

Sunscreen

It's been estimated that we spend an average of 3,000 hours brushing our teeth. In fact, in our daily routine, toothpaste is something we use at least twice a day. Making toothpaste is a very straightforward process; just mix together water, abrasives, humectants, thickening and foaming agents, sweeteners, and flavors in the right amounts until you get a paste. Once you have added the colors, you can fill a tube with your colorful toothpaste and seal it before being shipped to stores.

Toothpaste

Tomato sauce is a popular ingredient for adding a sweet, slightly acidic touch of flavor to food and recipes. Sauce production involves cooking the tomatoes, removing the seeds and stems with a strainer, using a grinder or milling machine, and then further cooking to the desired consistency. Tomato sauce making equipment is used in industrial production to speed up the various preparation steps while maintaining the quality of the sauce.

Tomato sauce

Chili sauce is produced worldwide, but each is augmented by the cultural elements of where it is made. Most chili sauces consist primarily of chilis, though some preparations include tomato as the primary ingredient. Vinegar, sugar, and salt are added to the chili sauce making machinery, and the mixture is thickened mainly by cooking.

Chili sauce

Cocoa butter is the fat product of cocoa liquor. It is an integral part of the chocolate-making process. To make cocoa butter, roast and process cocoa beans with the help of a cocoa butter production machine. After that, it undergoes continuous crushing – forming a rich liquid, known as cocoa liquor. You can finally press the liquid to extract cocoa butter.

Cocoa butter

To put into perspective, the average number of peanuts that you use to make a 12-ounce jar of peanut butter is 540 pieces. Peanut butter is widely used as a spread for most bread and biscuits. To make it, use raw peanuts and process them using peanut butter making machines.

Peanut butter

People have always loved butter. Suffice it to say that Ancient Norsemen were buried with it to take to the afterlife. It seems impossible but making butter is all about separation. First, you separate the raw milk to get the buttercream using a cream separator. After cooling, mixing and pasteurizing your buttercream, the churning process separates it into buttermilk and butter grains. Then, mix butter grains with salt and use a butter churner to mix the ingredients again, before shaping begins using butter molds. Which butter-making equipment can improve your process?

Butter

A cosmetic foundation comes in a powder, cream, or liquid form. And did you know that the liquid form came about because women in the 30s and 40s didn't want to wear stockings? So to cover up their legs, they turned to leg makeup, which played an essential role in our liquid foundation formula. The foundation making process involves balancing the oil and water phase interactions during the formulation stage, mixing ingredients, and packaging using a liquid foundation filling machine.

Cosmetic foundation

Star-shaped, lavender-scented, yellow, green, in a dispenser, today’s hand soap comes in a variety of shapes, fragrances, and colors. But whatever type of soap you choose for your good hand-washing habits, the basis of all soap making is mixing animal fats or vegetable oils with an alkali - in this case, a strong base - in a kettle to produce a chemical reaction called saponification.

Hand soap

Broth

Hummus processing begins by blending chickpeas, tahini, lemon juice and olive oil to create the simple yet versatile dip loved by so many around the world. To prove their love for hummus, the Lebanese, in 2010, made the largest plate of hummus that weighed over 10 tonnes! To produce hummus industrially, you need a hummus production line that includes processing equipment such as cookers, industrial grinders, pasteurizers and packaging equipment.

Hummus

To produce condensed milk, you need to remove a large portion of the water content from the milk. Usually, you add sugar to it to create a sweet flavor. First, milk is standardized and pasteurized. Then, it goes through an evaporation process to remove the excess water content while sugar is added. After that, the mixture undergoes homogenization. The condensed milk is cooled and crystallized before being ready for packaging.

Condensed milk

Formation of lumps is avoided by feeding additives directly into the dispersion chamber

CIP cleaning and complete plant sterilization using steam are possible

Low maintenance requirements

Exchangeable dispersing tools

Agitator can be heated or cooled--reducing required process times for temperature control

Food

Pharmaceutical

An emulsifier is used to mix two immiscible liquids. Heating or cooling requirements during emulsification, overpressure or vacuum requirements, the need for wall scrapers, design of the mixing head, the viscosity of the liquids, and the desired droplet size are all important considerations when selecting an emulsifying system. Emulsifiers are typically used in the food industry for the production of batters, creams, and sauces, in the pharmaceutical and cosmetics industry for the production of creams and lotions, and in the chemical industry for the production of paint and other emulsions.

Emulsifying

Homogenization is the process of reducing particle size in mixtures to improve the consistency, uniformity, and stability of the product. The choice of a homogenizer depends on the nature of the product, desired particle size, the physical state of the ingredients, and pressure requirements during the process. Homogenization is widely used in the biotech industry for cell lysis and in the pharmaceutical industry for the emulsification of creams and ointments; it also finds applications in the cosmetics and food industries for improving the consistency and uniformity of various products.

Homogenization

Industrial mixing equipment is used to combine two or more solid, liquid or gaseous segregated ingredients into a homogenous single product. The choice of mixing technology depends largely on the physical state of the ingredients and the desired final product. But the sensitivity of the ingredients, the process temperature, and pressure requirements are also critical factors. All these parameters result in a wide range of industrial mixers.

Mixing

Cannabinoids are natural compounds obtained from the Cannabis sativa plant. Delta-9-tetrahydrocannabinol or THC is a psychotropic substance. Cannabidiol, or CBD, is non-psychotropic and often used for nutraceutical purposes. Cannabinoid equipment extracts THC and CBD from the plant and prepares the substance for formulations that treat pain, nausea, anxiety, and inflammations. Cannabinoids are processed in various forms, including creams, capsules, and oils.

Cannabinoids

According to a legend, Cleopatra soaked her sails in her perfume so that Mark Antony could smell her ships before they arrived. This is to say that, from soaps and shampoos to perfumes, conditioners and pomades, cosmetics have always been highly valued and used for their properties of aesthetic enhancement. Cosmetics are a broad class of topical agents applied for various purposes such as cleansing, protecting, beautifying, or otherwise altering your appearance. As a result, a wide array of processing equipment is used in the cosmetics industry.

Cosmetics

The topical route is a convenient route for the self-administration of drugs. But turning a pharmaceutical formulation into an easy-to-use cream involves specialized cream manufacturing equipment. Topical dosage forms are essentially an emulsion of oil and water.  But the ratios can be changed to process it into lotions, ointments, and gels.

Cream

Liquid

<p class="filterable-grid__description">Liquid dosage forms are designed for easy absorption. The body quickly carries the active ingredients through the system and triggers the required response. But the greatest advantage of this medicinal type is its flexibility in formulation and dispensation. From lotions and syrups to drops and sprays, liquid solutions can be adapted to different administration routes including parenteral, topical, and oral. The fundamental liquid dosage manufacturing process involves dissolving or suspending solutes in a fluid. But that is not enough. A precise blend of excipients is needed to make the medicine go down.</p>

Liquid dosage forms

Eating is more than just nutrition, but we have found ways to increase the nourishing power of our foods. Nutraceuticals manufacturing, from vitamin C powder and probiotics to omega 3 oil, is a concentration of natural ingredients and health supplements that complement our diets. While dietary supplements are not quite haute cuisine, the process of extraction and purification is no less a blend of science and art.

Nutraceuticals

Pharmaceutical developments walk side by side with health advances to provide new medicines, treatments, and therapies that have increased life quality and extended life expectancy by years. Pharmaceutical manufacturing equipment helps deliver products to a great deal of the population, but there’s a significant share that doesn’t benefit from them yet. Over 2 billion people cannot get the medicines they need, according to the United Nations Industrial Development Organization, and local production might be a way to provide for these people.

Pharmaceuticals

Ancient civilizations discovered that plant extracts were useful for the treatment of pathologies. The origin of plant extraction cannot be specifically verified, but we can infer that the earliest attempts at plant extraction were more intuitive than scientific. Today, the extraction of compounds is a precise process with plant extraction systems complimenting traditional knowledge.

Plant extracts

The building blocks of matter have driven the imagination of philosophers, scientists, and artists for millennia. But, for manufacturers, these elements have a more concrete existence as powders. Powder processing technology conditions these primary materials to create a vast range of products, from chemicals and foods to pharmaceuticals and ceramics.

Powder

Process

Batch

liquid

The Master Plant GMP homogenizing system from IKA was designed specifically to meet the production mixing needs of the pharma industry.

Manufacturers need production mixing equipment that is capable, flexible, and easy to maintain. Accurate mixing form a reliable, user friendly machine

GMP homogenizing system - Making.com

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