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Maker - Product Challenge

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Changemakers

Cream loading

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

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

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

The easiest and most commonly used method of making gels is mixing gelling agents with water to form a weakly cohesive internal structure. The gel production process is pretty linear and straightforward, from mixing hydrocolloids and water to labeling and sealing containers.

Gels

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

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

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

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

Neige de lait in French or neve di latte in Italian, as referred to in very old texts and both meaning milk snow, has been used in recipes since the 15th century. Withstanding the test of time, whipped cream is still one of the most beloved dessert toppings. What starts with milk ends as a silky delicacy with the help of whipped cream equipment and specified manufacturing processes.

Whipped cream

iwk-tz-series-2017-en-1-pdf

IWK-TZ-series-2017-EN-1.pdf

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

Simple to operate, tool-free size changes

Gentle tube handling, minimises dents or damage

Handles various tube setting patterns in their shipping boxes

Feeds up to 120 tubes per minute

The reservoir allows for constant feeding even during the refill

Loading Arms

Sensors

A tube is a collapsible package, made of plastic or metal, used for packaging highly viscous liquids or pastes. Considerations for choosing a suitable tube filling system include the nature and viscosity of the product to be filled, the tube material, capping requirements, and the desired filling speed and volume. Tube fillers are used in the food industry for the packaging of food pastes; in the chemical industry for packaging caulk, glues, and sealants. In the cosmetics industry, tube fillers are used for the packaging of gels and creams and in the pharmaceutical industry for the packaging of toothpaste and ointments.

Tube filling equipment

Chemical

Cosmetic

Pharmaceutical

Loading systems

A loading system feeds your continuous or batch processing machine with the specified material or item in line with the flow of production. Loaders transfer the articles from one stage of preparation to the next with uniformity and accuracy.

Loading

Connect directly with world leading manufacturers of Loading equipment and find technology to build or improve your production line.

Loading &#8211; Making.com

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

Although not all women use makeup every day, almost all of them own at least one makeup product, be it lipstick or face powder. Most makeup products share the same basic ingredients of waxes, oils, and fillers with pigments like iron oxide used for colors and shades. Makeup manufacturing equipment includes pulverizers, mixers, and mechanical press machines to produce cosmetic products in different forms such as powder, liquid, or mousse.

Makeup

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

Process

Continuous

Conveyor systems are used for moving materials from one location to another. Considerations for choosing a suitable industrial conveying system include the nature of the product, its physical state, the desired conveying rate, and sensitivity of the product to heat and mechanical shock. Conveying equipment is used in the food, pharmaceutical, chemical, biomass, and mineral industries to move materials around a warehouse as well as to transport bulk powders, granules, and grains for processing and filling. These types of systems are usually automated and there is a wide variety of solutions to choose when it comes to the type of conveyor. Types include screw, gravity, chain, roller and belt conveyors.

Conveying

Filling lines are used extensively in all industries, such as food, pharmaceutical, chemical, and cosmetics, to accurately package different products into a container suitable for that product. Although the filling process is at the very end of the production line, it is no less important than the earlier steps. Last but not least, the idiom that dates back to 1382 when John Wyclif wrote the firste the laste, and the laste the firste, indicates just that the last things on a list are just as valuable as the previous ones. In this case, this idiom fits perfectly.

Filling

solid

High performance tube-filling machines are used in the pharmaceutical and cosmetic industries. Their performance is greatly enhanced by the use of

Loading cassette for a tube filler &#8211; Making.com

We open production technology to everyone

Making.com

iwt_cleaning-equipment-pdf

IWT_Cleaning-equipment.pdf

Bespoke design ensures perfect, repeatable cleaning results of even the most complex parts

Computer-modelled water flow to ensure optimised flushing and rinsing

Maximise throughput, optimising number of parts per wash cycle

Works with IWT Pharma 200 and 300 series COP contact part washers

GMP Washers

Biopharmaceuticals are drugs in which the active substance is manufactured or extracted from biological origin materials. They are usually produced in bioreactors by plant cells, microbial cells, yeast cultures, or mammalian cells. Also known as biomanufacturing, they are used to either treat or diagnose and prevent a patient’s medical condition or disease. Biopharmaceuticals are typically complex macromolecules administered by injection or infusions, and examples include vaccines, serums, and insulin.

Biopharmaceuticals

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

The most important part of a capsule is its contents. But if the shell is not carefully made, the dosage ingredients inside lose effectiveness. From molding to sizing, capsule manufacturing equipment forms perfectly-matching husks ready for filling. The simplicity of encapsulation revolutionized pharmaceuticals since it was introduced in the 19<sup>th</sup> century. However, capsules are changing to increase delivery efficiency and reduce the dependency on gelatin.

Capsules

Essential oils are known as the liquid gems of nature. The sweet-smelling essences impact not just our senses but also our biochemical and cellular make-up. Besides aromatherapy, the products of an essential oil extraction system found applications in pharmaceuticals and foods.

Essential oil

Parenteral preparations refer to drugs using non-oral means of administration. Injectables, such as needles and syringes, are used to deliver a drug into the systemic circulation directly in the veins, muscles, under the skin, or in the tissue.

These parenteral formulations are pharmaceutical dosage forms that have strict regulations on being sterile, pyrogen-free, and free from visible particulate matter including reconstituted sterile powders. Solutions, suspensions, emulsions, and gels with APIs intended for administration by injection are usually supplied in vials, ampoules, pre-filled syringes, or pens to facilitate ease of use.

Injectables

<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 powders provide longer shelf life and better stability than liquid dosage forms. But the processing of pharmaceutical powders is crucial for growing segments besides pharmacy. Functional foods and cosmetics formulated with active ingredients and excipients depend on powdered forms to fulfill their promises.

Pharmaceutical powder

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

Among all dosage forms in use today, tablets constitute the most common one. They are pharmaceutical solid dosage forms containing active ingredients and excipients such as diluents, binders, glidants, and lubricants. Using tablet making equipment, these solid dosage forms are made by compression of granules or powder blends and then shaped by molding.

Tablets

Logistics

Batch

To ensure perfect cleaning of contact parts they must be placed in the GMP washer in such a way as to guarantee flushing of even the most hidden parts.

Loading basket for GMP washer &#8211; Making.com

Low cost solution for slow speed tube fillers

Quick and simple size change for maximum uptime

Effective tube separator mechanism minimises tube jams in the hopper

Simple and quick refill

Capable of working with all tube materials and a wide range of diameters

Industrial feeders and hoppers are used to provide a consistent, regulated flow of material to the production line for further processing. Feeders and hoppers are generally used in the industry in conjunction with other processing machines like crushers, dryers, conveyors, and mixers. Considerations for choosing a suitable feeding system include the physical state and particle size of the infeed, the output volumetric flow rate required and the type of connection to be made with the processing machinery.

Industrial hoppers

R&amp;D

Industrial feeding systems allows you to control the flow of solid bulk materials throughout the manufacturing line. After loading your material onto the vibrating hopper, a screw at the base drives it out in uniform doses to the next stage of processing. New feeding technologies are designed to deal with challenges of powders clumping together in the hopper (bridging and ratholing) that interrupt the outflow. Common feeder systems include centrifugal feeders, vibratory feeders as well as elevator, linear and pneumatic feeders.

Feeding

Low speed tube-filling machines are used for small scale production lines in the pharmaceutical and cosmetic industries. Traditionally low speed machines

Tube feeder for a small scale production tube filler &#8211; Making.com

High capacity of up to 300 tubes per minute for high efficiency

Built-in drive system allows standalone operation

Rapid and simple product changeover via HMI input

Four different variants in two sizes to suit your exact requirements

A belt conveyor system uses pulleys or drums to keep an endless loop of conveying belts in continuous motion for material handling. Considerations for choosing a suitable conveyor belt system include the physical form of the product, processing requirements, and the desired speed and volume of transportation. Belt conveying systems find numerous applications in the food, pharmaceutical, and chemical industries such as filling and packaging operations. In the biomass industry, these systems are used for moving biomass feedstock to the boiler. In the mineral industry, conveying belts process and transport granular and crushed minerals. Conveyor belts are heavy-duty machinery that is used to move materials from one place to another. They are commonly used in factories, warehouses, and other industrial settings to move items such as boxes, containers, and other materials along a production line.

Conveyor belts

The pharmaceutical and cosmetic industries utilise high speed tube fillers on large-scale production lines. Automated tube unloading and feeding systems

Tube unloader and feeder &#8211; Making.com

iwk_tfs_en_2014-pdf

IWK_TFS_EN_2014.pdf

Short changeover times minimise downtime, increase productivity

High-quality tube fold and tube seal functions reduce rejections

No mechanical drive in the filling area prevents product contamination

Minimum maintenance due to optimal mechanical machine components

Able to fill and close a wide range of tubes

Food

Due to their potential hazardous nature, chemicals are classified for proper identification and safety during production. Chemical classification depends on their properties, structures and functions. In the chemical industry, you can regard them as basic chemicals such as acids, chemical products to produce plastic materials and finished chemicals for use in cosmetology. As a manufacturer or engineer, you want to know their reactivity when using chemical processing equipment.

Chemicals

Packaging

When looking for capping equipment, it is crucial to know first which type of capper your product requires. Do you want screw caps, twist-off caps, hand pumps, or push-pull caps on your bottle or container? If you require different cap types for format changeover times can be time-consuming. The bottle cap seals the top opening of a bottle to guard the product against leakage and spoilage and sterility and filling requirements depend on the nature of your product.

Capping

Dosing systems are a line of hoppers, feeders, filling machines, and checkweighers that operate in sync to dispense materials accurately. Dosing is an essential feature of the packaging process, whether you’re filling shampoo bottles or tea bags. But dosing equipment is critical for formulations, too, particularly in the pharmaceutical and chemical industries. Imprecise dosing may cause quality degradation in the best-case scenario. In the worst scenario, it creates serious health risks.

Dosing

<span style="font-weight: 400">At last, you reached the final stage of processing your product - welcome to the packing world! Packing preserves and protects a product from damage, spoilage, and contamination while it makes its way from the production line to the consumer or further production. Depending on which industry your products belong to, the type of primary packaging equipment can change drastically. You need to pay careful attention to products with </span><span style="font-weight: 400">chemicals or hazardous substances since they can be potentially dangerous to human health. </span>

Packing

liquid

A wide variety of pharmaceutical, cosmetic and food products require tube-style packaging. An automated tube-filler adds flexibility to production lines

A two-component filling application tube filler &#8211; Making.com

iwk_fp10-filling-platform_en_2014-pdf

IWK_FP10-filling-platform_EN_2014.pdf

Modern servo drive and HMI for reliability and ease of use

Fills, seals and caps a wide range of tube containers with 15 minute changeover

Minimal maintenance requirements reduces downtime

High-accuracy dosing with no dripping or stringing - no contamination

Bad tube detection and rejection

Increasing numbers of products in the pharmaceutical, cosmetic and food industries are delivered in flexible tubes, bottles or dispensers. Automated tube

Low speed tube filler &#8211; Making.com

Modern servo drives for enhanced reliability and maintenance-free operation

Small footprint with “large machine” performance

Highly accurate filling and exceptional sealing reliability

Simple to operate with large touchscreen controls and graphical status monitoring

Rapid changeover times allows for multiple product use, increasing efficiency

When scaling up production of pharmaceutical, food or cosmetic products that use tube containers, increasing speed and throughput without compromising on

Medium and high speed range automatic tube filler &#8211; Making.com

iwk_fpseries_en_2014-pdf

IWK_FPseries_EN_2014.pdf

Proven pedigree from IWK for reliability and robustness

Servo technology maximises reliability and uptime

Enhanced HMI for ease of use, monitoring, and regulatory compliance

Modular design for a completely tailored filling solution

Quick product changeover, minimal downtime

For scale-up filling of tube packaging for pharmaceuticals, cosmetics and food products, a medium-speed automatic tube filler is required that meets

Medium speed tube filler and sealer &#8211; Making.com

High capacity tube magazine reduces number of refills

Effective yet gentle separator and alignment system

Feeds up to 220 tubes per minute to keep pace with the fastest tube fillers

Self-contained drive unit means standalone operation if required

Backup sensor alerts when minimum/maximum fill levels are met

High performance tube-filling machines are used for large scale production of pharmaceutical and cosmetic products. Automated feed systems must be able to

Tube feeding unit for high volume and high speed tube filler &#8211; Making.com

<h3>Raise the API content to 99%</h3>
Pharmaceutical creams are mostly used to treat skin issues such as rashes, stings, or fungal infections. Unlike <a href="https://making.com/cosmetic-creams" target="_blank" rel="noopener">cosmetic creams</a>, medicated creams penetrate the epidermis and target cells in the lower layers of the skin.

Pharmaceutical creams must contain 99% pure active ingredients. However, APIs are applied in lower concentrations than in other formulations like tablets.

The preparation of oil and water phases involves different cream manufacturing equipment. Oils are extracted and purified from biological materials using <a href="https://making.com/technologies/extraction" target="_blank" rel="noopener">extraction technology</a>. Water is filtered from contaminants and distilled.

The two come together in specialized mixing systems that suspend the liquids into an emulsion. A finer droplet renders a more stable emulsion and a smoother cream consistency.

Mix the water and oil phases to produce a stable emulsion

Find dispersing technology

The oil phase can be either a mineral oil or a silicone, enriched with emollients and lubricants. If the additives are in wax form, heating equipment is used to melt them into the oil base.

Excipients such as binders, thickeners, and stabilizers help the two phases to emulsify. But these agents are dispersed into the water phase. Active ingredients are dispersed into both phases depending on their reactive properties.

Disperse the drugs and additives in the liquids before emulsification

Use high-shear mixing equipment to prevent lumps

Not all mixing technologies are suitable for manufacturing pharmaceutical creams. The mechanism needs to incorporate the drugs (typically in powder form) into the emulsion droplets. Failing to combine the materials homogeneously causes agglomerate in the formulation down the line.

<a href="https://making.com/technologies/high-shear-mixers" target="_blank" rel="noopener">High-shear mixers</a> disperse the API and excipients uniformly in the oil and water phases. Similarly, the high rate of agitation lowers the interfacial tension between the phases, producing a more stable emulsion.

Excipients are used to facilitate drug delivery. But, at the same time, molecules can coalesce into a microstructure forming large crystals.

Lubricants keep the fluidity of the formulation. But changing temperatures alter their behavior, and creams may feel greasy in warmer environments. Viscosity modifiers reduce the change of stickiness in lubricants to keep a consistent structure.

Add viscosity modifiers to retain a consistent texture in creams

<h2>How to pack your creams and ointments</h2>
When filling topical formulations it is essential to get the amount of product in various consistencies per container just right and to be able to accommodate various container shapes and sizes. There are many factors that influence the decision for choosing a container to fill in topical dosage forms. Some of these factors are materials and visual appearance while others are specific to the usage of the product filled. The most common containers for filling creams are tubes and glass or plastic jars.

Tubes have narrow openings that protect the creams against contamination and preserve the product's shelf life. Tubes are mostly made from low or high-density polyethylene and aluminum. They have various top shapes that can be applied. For example, triangular toppers allow to push out as much product as needed with precision. Push tops are also common for creams that need controlled amounts produced with each pump. Tubes can be of different diameters ranging from 16mm to 50mm and the capacity ranging from 5ml to 240ml. A filling machine, therefore, becomes a critical piece of equipment for any cream manufacturing plant.

Cream Manufacturing Equipment

Connect with leading producers of cream manufacturing equipment and find production technology to mix, fill and pack your pharmaceutical creams.

Cream &#8211; Making.com

Cream Manufacturing Equipment - Making.com

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Delicacies such as meringue, ganache, and marzipan undergo various processes like mixing, whipping, emulsifying, heating, and cooling. Traditionally, each process requires different equipment and a lot of manual interventions that can lead to inconsistent product quality.


<h2>Preparing bakery creams and egg whites in a single system with easy tools changeover</h2>
The Stephan UM from ProXES is a versatile all-in-one processing system for the bakery market and includes different functions for cutting, mixing, whipping, emulsifying, heating, and cooling your bakery creams and pastries. The system can be coupled to application-specific processing tools and has vacuum support to produce even the finest professional-quality ganache. The integrated cooling function ensures cream stability and enhances shelf life.

The whipping process for creams and egg whites has shorter production times – up to 50% - with maximum throughput for different batch sizes. In addition, for mid and larger-scale bakeries, production costs of marzipan have proven to be 50% less than purchasing ready marzipan.

The mixing system is equipped with a tilting bowl for easy product and ingredient handling. The set of processing tools is specially designed for all bakery applications and allows easy, quick changeover. The UM family has a wide capacity range of 0.5 to 170 liters per batch. Its design allows easy water cleaning, which results in low energy costs. The different programming options for temperature regulations and recipe controls help reduce process time and ensure product quality.

Cream loading

Which cream loading equipment do you need?

Loading cassette for a tube filler

Loading basket for GMP washer

Tube feeder for a small scale production tube filler

Tube unloader and feeder

A two-component filling application tube filler

Low speed tube filler

Medium and high speed range automatic tube filler

Medium speed tube filler and sealer

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