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Maker - Product Challenge

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Toothpaste mixing Equipment

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

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

Several issues often arise when your process requires batch-wise mixing of powders into liquids.  The mixing process can be slow, dust and liquid solvent may be released to the surrounding work area, agglomerate powder masses may form and the ratio of ingredients may be inconsistent.  The right equipment is needed to address all of these issues and improve the efficiency and quality of your process.
<h2>Reliable batch mixing improves process quality and efficiency</h2>
The CMX 2000 inline batch mixer from IKA incorporates powders into liquids and mixes these materials reliably and consistently in a batch process. Its multi-level design and unique pumping stage enables processing of high viscosity products without any additional aggregates. The system is usually supplied with a solid material dosing feeder and mixing containers.

Depending on the application and the requirements of the customer, the solid material can be fed via a bulk bag unloader, a funnel, sack-emptying boxes or directly from the bag via a suction lance.  Units are available with typical batch sizes from 2 to over 5.000 liters.

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Inline batch mixer for solids and liquids

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

For high viscosity products, better results and reduced process times can be achieved with kneading type rather than conventional extrusion type equipment.  Process engineers in a wide variety of industries need to reliably and efficiently mix highly viscous substrates.  Process engineers in these situations need efficient, thorough mixing with controllable parameters.
<h2>Better dispersion results with less processing time from a highly controllable process</h2>
IKA's high performance horizontal kneading machines known as HKD and HKS are twin-bowl kneaders with horizontally arranged kneading blades able to process mixtures with very high viscosities. These horizontal kneaders are unique in the selection of kneading elements that they can employ allowing them to process a wide variety of mixes with varying solid content.  This flexibility makes users' lives easy by facilitating product change over and allowing selection of  blades that are optimized o the particular products being mixed.

The kneading blades are inter meshing and driven at a 2:1 ratio crating an alternating motion of blade surfaces toward and away from one another.  This motion creates highly dynamic pressure gradients and shearing forces which achieve excellent dispersion results.  The blade speed is finitely controllable via a variable frequency drive.  The units are easy to clean and maintain with the entire side wall of the kneading bowl being removable.  This exposes the kneading blades and discharge screw for easy cleaning during product changeover.

Horizontal kneader

Production of highly viscous products with high solid content often benefits from kneading processes rather than conventional extrusion because more consistent dispersions can be achieved in a shorter time.  Competitive manufacturer's need controllable kneading processes with worry free seals and a degree of automated operation.
<h2>Better mixing in less time for highly viscous products</h2>
The Planetron HKV from IKA is a heavy-duty vertical kneading machine with two kneading blades.  The overhead mounting of the blades and drives allows all seals to never be in contact with the product.  These vertical kneaders achieve excellent kneading and dispersion results due to the action of inter-meshing kneading blades.  With one blade rotating in a planetary motion around the other and the two together having a mutual stripping action causing high pressure variations and shear forces in the substrate.  The geared motor that powers the machine is equipped with a variable frequency drive allowing the rotation speed of the blades to be infinitely adjustable giving the user precise control of the process and results.  All bowls in the HKV series are prepared for heating or cooling.  Units are available with working volumes from 0.5 to 1.600 liters.

Vertical kneader

Effective mixing of highly viscous products with extremely high solids content can be difficult and the results from traditional extrusion type equipment are often unsatisfactory.  Much more thorough and intense mixing can be achieved and higher solid contents attained with kneading technology.
<h2>Continuous highly controlled kneading from a flexible machine</h2>
IKA's Conterna machine is a multi-chambered continuous kneader which technology is patent protected all over the world. The standard continuous kneader consists of 6 chambers arranged together in a horizontal block.  Each chamber contains two kneading elements which are driven by a variable frequency AC motor.  There is one independently controlled motor for each chamber.  Liquid and solid ingredients are introduced into each chamber according to the process needs and the mix is advanced from chamber to chamber via the kneading action of the impellers.  By adjusting the motor speed and the discharge rate , users can control the resident time of the product in the machine to achieve the desired results.  The continuous kneading action ensures that evenly mixed products are produced and products with extremely high solids content can be processed. Units are available with approximate throughput rates of 80 to 4.000 kg/hour.

Continuous kneader

Equipment operating under the rotor/stator principal is often employed when more traditional methods of stirring cannot achieve desired results.  This technology can achieve desirable results for almost any mixing process in circumstances where other machines fail.
<h2>Rotor/stator mixing with flexible mounting and a robust simple package</h2>
The Ultra-Turrax UTC is IKA's batch dispersing machine for high quality mixing and dispersing of products when more conventional stirring equipment cannot be used. Working on the rotor/stator principal, the units consist of a motor, a mounting flange, a stator, a rotor, and a rotor drive shaft. A variety of dispersion tools known as generators can be fixed to the rotor making the units adaptable to most mixing tasks.  These units are designed for diagonal from above, diagonal from the side, or vertical off-center mounting orientations. They can be used with open, or pressurized vessels. For open vessel operations, the units are supported via wall mounts or floor stands. Units are available for batch sizes from 150 to 6.000 liters.

Batch dispersing machine

For mixing and dispersing tasks that cannot be completed by conventional stirring means, equipment using the rotor/stator principal are often well suited.  Batchwise production of emulsions and suspensions of abrasive products is highly demanding and the use of well suited equipment is crucial.
<h2>Top entry rotor/stator dispersing equipment for highly abrasive products</h2>
The Ultra-Turrax UTS is IKA's dispersing machine for abrasive products when more conventional stirring equipment cannot be used.  Working on the rotor/stator principal, the units consist of a motor, a mounting flange, a stator with extension rods, a rotor, and a rotor drive shaft.  A variety of dispersion tools known as generators can be fixed to the rotor making the units adaptable to most mixing tasks.  The shaft seal is located at the motor flange and therefore is never in contact with the product.

These units are designed for diagonal from above or vertical off-center mounting orientations.  They can be used with open, or pressurized vessels.  For open vessel operations, the units are supported via wall mounts or floor stands. All variants of the UTS dispersing machines stand out for their unique ability to process highly abrasive ingredients.  Units are available for batch sizes from 500 to 1.700 liters.

Batch dispersing machine for abrasive products

When your process requires high performance mixing or dispersion but conventional stirring methods cannot be employed due to access or other restrictions, you need a machine designed for bottom entry into a vessel.
<h2>Bottom entry mixing in a simple and compact package</h2>
IKA's Ultra-Turrax UTE is a high performance dispersing machine designd for bottom entry into vessels.  It mixes, emulsifies, and disperses free-flowing or liquid media with a viscosity of up to 5.000 mPas in batch operation.  The units use the rotor-stator principal and a wide variety of generators is available to tailor the process to your needs.  No strong vortices or product aeration occurs as a result of the mixing action even when the vessel is filled to a very low level or is emptied during the stirring operation.

The units are compact and simple, primarily consisting of a motor, a a rotor drive shaft, a dispersion tool (generator) and a mounting flange conbined by a lantern housing.  The shaft seal is of an easily maintained mechanical type with several variants depending on the particular application.  Options for speed control, special materials, and special surface finishes also exist.  The units are available with batch capacities from 70 to 4.000 liters.

Batch dispersing machine for bottom entry into vessels

Manufacturers of cosmetic products need mixing equipment that is capable, flexible, easy to maintain, and low-cost to stay competitive.  Accurate mixing from a reliable, user-friendly machine will give plant managers peace of mind and worry-free operation 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 the processing of small batches down to 30% of the rated working volume.

The system includes interchangeable dispersing tools and adjustable speed control, dispersing quality and options for a heated or cooled double-walled vessel, and vacuum degassing of the working chamber, among others.  The unit is 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 floor space of the units as low as possible. The SPP is available in working capacities from 25 to 4.000 liters.

Cost-effective homogenizing and emulsifying system

When manufacturing toothpaste, dispersing and mixing powders into liquids to create a consistent, homogeneous product is among the most difficult and challenging of mixing applications. The main problem associated with mixing powders into liquids is aeration and foaming. Unwanted air and oxidation can increase the risk of browning, off-flavors, and result in the loss of essential nutrients, like Vitamin C. Thus, it’s essential to use the right mixing equipment.
<h2>Precisely mix powders into liquids</h2>
The continuous plant type zoatec® CPU by AZO LIQUIDS is designed with a flow meter for liquid dosing and a loss-in-weight feeder for extremely precise powder dosing, thus allowing continuous production of high-quality products. It boasts intelligent control engineering and ensures optimum process control.

The machine is unique compared to conventional homogenizers as its flow direction is turned into the opposite direction of the drive. The mixer can also be used as a clean-in-place (CIP) pump due to its high pump capacity. It works by continuously dispersing and mixing variable amounts of dry solids into low viscosity to pasty liquids. Operators don’t need to premix raw materials, which makes the entire process easier.

Apart from fine powders, it is also able to process granules, and coated pellets, simultaneously. The shear rate can also be varied according to the nature of the materials, making the mixer incredibly flexible. It can thus also be used for the production of hair and skincare products, paint, food pastes etc.

Continuous mixer for toothpaste production

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

Producing high-quality lotions, creams, and gels requires specialized equipment due to the complexity of mixing and homogenizing high-viscosity products. This ensures uniform texture and optimal product quality, which traditional methods often fail to achieve efficiently.
<h2>Homogenize and mix with precision and speed</h2>
The EKATO UNIMIX vacuum processing units offer a versatile solution for producing various high-viscosity products such as lotions, creams, gels, and toothpastes. Combining the patented EKATO PARAVISC impeller and the EKATO S-JET homogenizer, these units ensure rapid, effective mixing and homogenization. The PARAVISC impeller provides excellent axial mixing, while its open design allows for the use of a central baffle and wall scrapers, optimizing heat transfer. The S-JET homogenizer is designed for internal and external homogenization, enabling swift and precise product dispersion. The system supports capacities ranging from 100 liters to 20,000 liters and includes features like heating and cooling functions, automated feeding, and Cleaning in Place (CIP) systems. It meets ASME, PED, and SELO standards, ensuring reliable performance across industries such as cosmetics and pharmaceuticals.

Vacuum processing units for high-viscosity products

In industries such as adhesives, sealants, and cosmetics, mixing medium to high-viscosity products presents challenges. Uniform dispersion and effective heat transfer are critical for product quality and efficiency.
<h2>Ensures uniformity and effective heat transfer</h2>
The HHL-II Dual Shaft Mixer/Disperser by Hockmeyer is a high-capacity solution designed for mixing medium to very high-viscosity products. It features a center-mounted low-speed helical or anchor blade, which sweeps the mixing vessel wall, and a high-speed dispersion shaft to ensure proper dispersion. The high-speed shaft provides the shear necessary to disperse or dissolve ingredients, while the low-speed sweep blends and folds the mass in the vessel, improving product uniformity. Patented scrapers on the low-speed blade assist with heat transfer and powder incorporation. Available in sizes from laboratory units to 3500 gallons, the mixer can operate under vacuum, pressure, or atmospheric conditions. The unit includes inverter-driven motors and can be constructed from stainless or carbon steel, depending on application needs. It is particularly applicable to the production of printing inks, sealants, caulks, hot melt adhesives, magnetic media slurry, creams, lotions, and toothpastes.

Dual shaft mixer for high viscosity products

ProXES specializes in liquid and semi-liquid foods, cosmetics, and pharmaceuticals process machines and lines. ProXES partners from co-creating first ideas,developping tailor-made concepts, go to market and scaling production.

Ever found yourself squeezing on a visibly empty toothpaste tube, hoping to extract every last bit on your toothbrush? So have we. While this daily ritual might go unnoticed, there is true magic behind the tube.



Now is your chance to find out more! ProXES is hosting a free webinar called “Discovering and solving the challenges of toothpaste production”. For all of us to learn more about an otherwise normal detail of our everyday routine.

Mark your calendar for the 28<sup>th</sup> of November and turn on your computer to attend the event online either at 9 AM or 4 PM (CET). <a href="https://go.proxes.com/en/webinar-toothpaste-production">Register</a> to secure a spot and be prepared to learn more about innovative technologies!

The event is hosted by Marc Cöslin, ProXES Non-Food Application Specialist, and Martin Koch ProXES Head of ProTec. With combined expertise of over 20 years, these two professionals are not only experts in processing technology but also excellent speakers, making even the most complex subjects easy to grasp.

Don’t miss out!

Webinar: unveil the secrets of toothpaste production

Cosmetic

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

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