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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

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

Equipment operating under the rotor/stator principal is often employed when more traditional methods of stirring cannot achieve desired results. High performance continuous dispersing equipment is needed to achieve desirable results for almost any mixing process in circumstances where other machines fail.
<h2>Rotor/stator mixing in a robust and simple package that is easy to clean</h2>
The IKA ULTRA-TURRAX UTL 2000 is inline high-performance single-stage dispersing machine used for the production of emulsions and suspensions. The UTL 2000 uses the rotor/stator principle and is best suited for continuous applications that cannot be accomplished using conventional stirring methods.

During the full continuous process the components to be mixed are fed into the machine at an appropriate rate through various inlet connections. These components are then thoroughly mixed, dispersed or homogenized within the machine and discharged from the machine through the outlet. Thus, all particles or droplets are treated producing a narrow particle or droplet size distribution with minimal concentration/quality variations. Additionally, the UTL 2000 creates a pumping action which can be used for transfer purposes at low to moderate viscosities with a maximum of about 20 m (ca. 2 bar).

The machines are designed for easy and reliable scale-up and sizes are available with throughput from 50 to 125.000 liters per hour.

Dispersing machine for emulsions and suspensions

For products of medium viscosity and relatively consistent particle size such as honey, cremes, and some plastics, a simple, low cost mixing machine is useful to ensure even dispersion.  The most efficient production plants take advantage of such equipment in continuous production processes to minimize required floor space and serve double-duty as mixing and pumping/transfer equipment.
<h2>A basic effective mixing machine with transport pump capabilities and low cost</h2>
The lower-priced ULTRA-TURRAX UTL 1000 machines from IKA are particularly multifunctional and are used for the mixing, dispersing (emulsifying/suspending) and homogenizing of solid and liquid substances up to viscosities of several thousand mPa·s, such as honey, plastic masses and crèmes. The mixing components are fed into the machine at the inlet connection. The materials are mixed, homogenized and then discharged from the machine via the outlet connection. The economic dispersing machine does not have automatic suction, but does have a conveyor height of up to 20 meters.  Units are available with flow rates from 4.800 to 125.000 liters per hour.

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Economic dispersing machine for emulsions and suspensions

Certain mixing tasks present unique challenges and manufacturers need equipment that is specifically designed to handle them.  When a single pass process is needed, high solid concentrations are involved, the ingredients quickly react with one-another, the product is sensitive to air inclusions, or the solid is granular and needs to be mechanically crushed as well as mixed, the right equipment is needed to get the job done.
<h2>A single pass mixer, disperser, and homogenizer for difficult mixing tasks</h2>
IKA's MHD-2000 system is a continuous homogenizing system designed for the high quality dispersions of solids in liquids.  The system includes two horizontal liquid connections and one vertical connection for solids.  the liquids and solid components of the mixture are brought together in a controlled fashion in a pre-mixing chamber in which the liquid is evenly distributed by entering through several different apertures.  Immediately after mixing, the liquid and solid components are dispersed through a rotor/stator system with high shearing action creating a high quality, output product that is free of agglomerations.

Use of this system greatly reduces production times due to its continuous operation.  Its design allows it to process highly viscous liquid ingredients, mixtures with solid contents up to 80%, and even solids that are granular and must be mechanically crushed during the mixing process.  Units are available with throughput volumes from 60 and 40.000 liters per hour.
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Continuous homogenizing system

When extremely high accuracy is required in your recipe or formulation traditional mixing machines often give unsatisfactory results.  For precisely controlled, quantitative mixes of liquid and solid ingredients you need a machine with better control designed to create a ready-to-use product that meets your exact requirements every time.
<h2>Create precise, quantitative mixes and fine suspensions in a single pass</h2>
The Dispax-Reactor from IKA is a purpose-built high accuracy homogenizing system for the food, chemical, pharmaceutical, and other industries.  It achieves extremely accurate mixes and suspensions by dosing both the liquid and the solid phase into the mixing chamber unlike traditional mixers which typically only dose the solid.  In this way the exact quantities of the raw materials in the final product are known regardless of variations in the physical characteristics of inputs.  The units include three distinct dispersing stages which allow for the creation of extremely fine suspensions from a wide range of solid raw materials.  Different rotor/stator dispersing heads are available allowing the machine to be optimized to your particular process.  Capacities are available from 500 to 35.000 liters per hour.

High accuracy homogenizing system

Manufacturers need production mixing equipment that is capable, flexible, and easy to maintain. Accurate mixing form a reliable, user friendly machine will give plant managers the peace of mind and worry free operation they need to focus on improving other areas of their process. A high quality piece of equipment allows for low maintenance, easy cleaning, enables the direct feed of solids and liquids, mixing and dispersing of the vessel contents, heating or cooling of the product, and processing under vacuum or under pressure.
<h2> A universal mixing system with precise, reproducible results and safe operation</h2>
The Master Plant homogenizing and emulsifying system from IKA was designed specifically to meet the production mixing needs of the pharmaceuticals industry but has also proven useful in the production of food, beverages, cosmetics, and chemicals.  Several mixing heads are interchangeable depending on the process and desired results.  Each mixing head can be heated or cooled to control product temperature simultaneous to the mixing process. Flexible PTFE scrapers move with the mixing head and keep product from adhering to the vessel walls.  Products of up to 100.000 mPas viscosity can be processed.  The GMP homogenizing systems  can be fully discharged without the need for additional pumping and are available in capacities from 10 to 4.000 liters.

GMP homogenizing system

Manufacturers need production mixing equipment that is capable, flexible, easy to maintain, and low cost to stay competitive.  Accurate mixing form a reliable, user friendly machine will give plant managers the peace of mind and worry free operation they need  to focus on improving other areas of their process.
<h2>Consistent mix quality from an easy to use, low cost system</h2>
IKA's SPP Standard Production Plant is a simple yet very capable system for all standard mixing processes such as homogenizing, emulsifying, stirring, and dispersing ingredients.  The emulsifying system includes a robust anchor agitator with a fixed flow breaker which moves the entire batch volume even  for mixes of high viscosities.  A highly advanced scraper design keeps the vessel walls free from scaling and unique vessel geometry allows processing of small batches down to 30% or the rated working volume.

IKA's SPP systems include interchangeable dispersing tools and adjustable speed control and dispersing quality and options exist for a heated or cooled double walled vessel, and vacuum degassing of the working chamber among others.  The systems are easy to clean using a CIP system and maintenance and inspection is simplified by concentrating major components in easily accessible areas.  This design also helps keep the required floorspace of the units as low as possible. Units are available with working capacities from 25 to 4.000 liters.

Cost-effective homogenizing and emulsifying system

Producers in a wide variety of industries benefit from equipment that can continuously create highly accurate homogeneous mixtures of liquid and solid ingredients.  The use of a continuous process requires less floor space for storage and greatly reduces production times.  Closed systems eliminate the creation of dust thereby enhancing safety and efficiency.  Equipment that offers all these characteristics will give its users an edge over the competition.
<h2>Continuous dispersion of solids into liquids without the generation of dust</h2>
IKA's mixing Plant MHD includes a mixing machine, metering units, an electrical control system, and peripheral equipment which is customized to meet the customer's facility and process needs.  The Plant MHD is a homogenizing system that allows the dust-free mixing of liquids and solid granules or powders in a continuous process.  The ingredients are continuously fed into the plant's working chamber in the precisely controlled ratios required by the final product, where they are mixed and then dispersed.  In this way, a ready-to-use final product is produced in just one pass.

The units can handle mixtures of up to 80% solid content and viscosities of up to 50.000 mPas.  Since the only agitation of the solid occurs within the machines working chamber after the liquid components have been introduced, no dust is generated.  A wide variety of solid feeding systems is available and IKA can help select the process that is best suited to your needs.  The Plant MHD unit is available with capacities from 200 to 40.000 liters per hour.

Dust-free continuous homogenizing system

Innovators in process development need laboratory equipment that helps their ideas be reliably scaled up to production.  For dispersion equipment, this requires important process parameters like circumferential speed, tool, and mixing chamber geometry to be structurally identical to production level equipment.
<h2>A highly adaptable dispersion machine for the lab, designed for reliable scale-up</h2>
IKA's Labor-Pilot is a versatile, compact, and highly reliable inline laboratory dispersing machine.  It is designed for solid-liquid mixing, homogenizing, emulsifying, suspending, and wet milling.  It is designed specifically to match process characteristics of larger dispersion machines so developed processes can be reliably scaled up.  The units can work at elevated temperatures, pressure/vacuum conditions, and with abrasive substrates.  Changeout between the several different working modules is quick and easy with each module giving the machine the particular characteristics needed to perform particular tasks and work with a particular type of product.  Compared to stirrers, mixing time for a wide variety of dispersions from coarse to fine can be reduced by up to 50%.

Pilot dispersing machine for testing and scale-up

Innovators in a wide variety of industries need laboratory equipment on which processes and products can be developed and reliably scaled up to production.  For dispersion equipment, this requires important process parameters like circumferential speed, tool, and mixing chamber geometry to be structurally identical to production level equipment.
<h2>A highly adaptable dispersion machine for the lab, designed for reliable scale-up</h2>
IKA's Processs-Pilot is a versatile and highly reliable inline laboratory dispersing machine.  It is designed for solid-liquid mixing, homogenizing, emulsifying, suspending, and wet milling.  It is designed specifically to match process characteristics of larger dispersion machines so developed processes can be reliably scaled up.  The units can work at elevated temperatures, pressure/vacuum conditions, and with abrasive substrates.  Changeout between the several different working modules is quick and easy with each module giving the machine the particular characteristics needed to perform particular tasks and work with a particular type of product.  Compared to stirrers, mixing time for a wide variety of dispersions from coarse to fine can be reduced by up to 50%.

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In-line laboratory dispersing machine

Processes including homogenization, dispersing, suspension, emulsification and dissolving benefit with the addition of a dispersing rotor/stator system to the functionality of traditional overhead stirring equipment.  With traditional equipment, achieving desired results in high viscosity media is often difficult and slow and issues such as sediment formation and air inclusions are common.  Adding a high speed rotor and jet pipe in close proximity to the mixing vane greatly enhances the process and helps avoid many of these issues.
<h2>Fast and efficient agitation of highly viscous fluids</h2>
IKA's Rototron RTS is a line of agitators that uses jet-flow technology to speed mixing processes while avoiding many of the issues seen when more traditional equipment is used.  The jet flow agitators use a high speed rotor and jet pipe in close proximity to the mixing vanes to disperse and circulate products within a vessel while avoiding inefficiency caused by back flow, air inclusions caused by a static whirlpool effect, and the need for flow breakers caused by continuously rotating mixtures.  The circulation mechanism also avoids the common issue of sediment formation when being used to produce emulsions.  The units can be used with open and pressurized vessels and mounting options exist to accommodate a wide variety of vessels and configurations.  With this equipment, no seal material makes contact with the product and food or pharmaceutical grade versions are readily available.  Motor sizes are available from 2,2 to 15 kW with max batch sizes from 1.000 to 20.000 liters.

Jet flow agitator for high-viscosity media

When processes call for homogenized emulsions with extremely fine particle sizes the traditional toothed ring dispensers are not always sufficient.  For extremely high levels of disintegration required to produce true micro-emulsions, extreme pressure cycling is more successfully used.
<h2>Homogenization with pressure shock to achieve extremely small particle sizes</h2>
The HPH High Pressure Homogenizer from IKA uses one or more piston pumps to apply pressure up to 2000 bar to the liquid medium to be homogenized.  The fluid is then fed through a homogenizing valve which very quickly reduces the pressure to the atmosphere.  This abrupt change in pressure in the moving fluid causes cavitation, a high degree of turbulent flow, and internal shearing forces in the fluid all of which serve to break up and distribute larger particles forming a very fine emulsion.  The pressure applied on the uphill side of the homogenizing valve is infinitely adjustable as is the flow rate through the valve, so the process can be easily adapted to achieve a wide range of outcomes and to accommodate fluids with different flow characteristics.  All parts that contact the product flow are stainless steel and autoclavable and the entire unit is designed for robustness and long service life.

High-pressure homogenizer

<span style="font-weight: 400;">The production of high quality pharmaceuticals often requires mixing of suspensions and similar solutions. A key challenge to overcome is the unwanted incorporation of air to the mix. Air incorporation causes major problems in processing and end-product quality. Air in the product may </span><span style="font-weight: 400;">cause excessive foaming, increased fouling in heat exchangers, and cavitation in homogenizers. A modern vacuum mixing solution can overcome these problems, as well as ensuring efficient operations with longer production hours, lower maintenance costs, and a safe, high-quality end product.</span>
<h2>Mobile and fixed vacuum mixing units for pharmaceutical production</h2>
<span style="font-weight: 400;">The vacuum mixer range from Ipros has been designed specifically for the pharmaceutical industry, and units are tailor made to suit your exact solution production requirements.</span>

<span style="font-weight: 400;">Based on an all-stainless GMP frame design, the vacuum mixer range is available with vessel sizes from as small as 30 litres up to 500 litres in a portable format, and from 500 litres up to 1000 litres in fixed format with forklift supports. This makes the range suitable for all scales of production.</span>

<span style="font-weight: 400;">The Ipros vacuum mixer units can run with a vacuum down to -1 bar, and can be specified with heating or cooling elements, and as insulated or non-insulated vessels as your requirements dictate. All vessels can be designed to connect to a wide variety of automated, semi-automated and manual process systems for simple integration.</span>

<span style="font-weight: 400;">Perfect for use in the most stringent pharmaceutical production environments, the vacuum mixers have integrated cleanable and sterilisable energy connections, GMP motor and utility housings, and are supplied with an operator panel and software allowing for full process control. These mixers can be used for any ATEX compliant executions.</span>

Vacuum mixer for suspensions

<span style="font-weight: 400;">Homogenization (or pharmaceutical micronization) is the process of reducing particle sizes, and is a vital step in making pharmaceutical creams and ointments more stable and clinically effective, and in producing high quality cosmetics. Homogenizing under vacuum produces the highest quality results, and a bespoke plant built to your exact requirements will increase your productivity and quality.</span>
<h2>Homogenization plants for the pharmaceutical and cosmetic sectors</h2>
<span style="font-weight: 400;">The homogenization plants from Ipros are a custom-built solution for the manufacture of high quality creams, ointments and other suspensions, whether under pharmaceutical or non-pharmaceutical production conditions.</span>

<span style="font-weight: 400;">Ipros modular design allows full configuration over mixing and homogenising equipment. Options range from vacuum processing to processing under the most stringent sterile and/or toxic conditions. The integrated engineering of the counter-rotating gearbox brings mixing, homogenising, cleaning, sterilisation, and drying systems together into one validated piece of equipment.</span>

<span style="font-weight: 400;">A range of solutions for Clean in Place and Sterilise in Place (CIP and SIP) can be selected to fit your exact production needs, and Ipros is pleased to offer the highest performing CIP/SIP performance currently available on the market, perfect for stringent pharmaceutical production.</span>

Homogenizer for creams

From food to pharma, homogenization is an essential step in the production process that provides uniformity to the product by improving its physical properties. If not homogenized, the fluid product might degenerate over time, leading to the formation of sediments and phase separation. This will lead to the loss of desirable product properties like uniformity, viscosity, consistency and reduced shelf life. 
<h2>Reducing product particle size using cavitation provides fluid stability</h2>
High Pressure Industrial Homogenizer from HOMMAK facilitates permanent homogenization of heterogeneous fluid products like milk, fruit juices, creams, ointments and more. The homogenization effect is achieved by reducing the product particle size through cavitation, shear force, impact velocity and turbulence effect under pressure, thereby preventing phase separation in the product.

The homogenizer consists of two main elements – the compression block and the homogenization unit. As the name suggests, the compression block compresses the ingredients under high pressure. The homogenization unit micronizes the decomposed particles to the specified size per the product.

The equipment's design and manufacturing considerations like capacity, pressure, material selection and valve design are tailored to its specific industrial application.

Pilot plant homogeniser

AZO LIQUIDS is the partner you can rely on when it comes to innovative solutions for liquid and semi-solid processes in the pharmaceuticals, cosmetics, food and chemicals industries.

If you are <a href="https://making.com/products/creams">producing a therapeutic cream</a> that prevents, cures or alleviates a disease or injury, a license from a government is needed to sell the product.  The requirements for keeping such a license are quite stringent, looking at – for example- traceability, documentation and hygiene. The products must be safe, and you must be able to have proof of this. What does this mean for the manufacturing process, especially for smaller scale companies? What do you as a producer need to have in place?


<h2>Meeting the targets of the Pharmaceutical Quality System</h2>
In order to get and to be able to keep the pharmaceutical license, most authorized government bodies demand the producer to have a Pharmaceutical Quality System that follows Good Manufacturing Practice. Looking at for example the production, operations must follow clearly defined procedures. All materials and products must be stored under the appropriate conditions established by the manufacturer and in an orderly fashion to permit batch segregation and stock rotation. Operations on different products should not be carried out simultaneously or consecutively in the same room unless there is no risk of mix-up or cross contamination. At all times during processing, all materials, must be labelled or otherwise identified with an indication of the product or material being processed, its strength (where applicable) and batch number. This means almost everything needs to be documented or monitored to reach these standards.
<h2>Automated production when upscaling</h2>
Switching to an automated production line can reduce the risk of cross-contamination and make it easier to meet all these standards. If you want to adhere to these standards, it is rather difficult to do with manual production. Many companies decide to scale up and  a first step could be to install a second processing vessel that will only be used to manufacture the final product, where the other vessel is used for the intermediate product. A cleaning system (CIP) would also make it easier to follow stringent hygiene rules. As you grow, a next step could be the incorporation of machines that automate a part of the process or installation of fully automated plant design to eliminate all manual operations and automate a lot of documentation of the production. Apart from tracking all this information, the product would also be fully traced from the start of the manufacturing process all the way to the packaging, a topic that is at the heart of this pharmaceutical license. A good example of automated plants for creams production, is shown in the video below, of the modular vacuum processing plant of AZO LIQUIDS.

[embed]https://www.youtube.com/watch?v=YJQZ8u-r5Gc[/embed]

How to keep your government license for therapeutic cream production?

Pharmaceutical

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

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

Find production technology for Ointments homogenization, and connect directly with leading machine manufacturers worldwide

Ointments homogenization

Which ointments homogenization equipment do you need?