What are the common problems encountered during the use of cosmetic emulsifier equipment, and how to troubleshoot them?

(1) Poor Emulsification (Product Stratification or Granular Texture)

• Possible Causes:
  1. The homogenization speed is too low, or the time is insufficient.
  2. The oil and water phases are not preheated to the correct temperature.
  3. The stator-rotor gap is too large (due to wear), reducing shear force.
• Troubleshooting:
  1. Increase the homogenization speed (within the equipment’s rated range) or extend the homogenization time by 5-10 minutes.
  2. Adjust the preheating temperature of the oil and water phases to the formula’s recommended range (e.g., 70-75°C for most creams).
  3. Inspect the stator-rotor gap; if it exceeds 0.5 mm, replace the worn parts.

(2) Air Bubbles in the Product (Visible Bubbles on the Surface or Inside)

• Possible Causes:
  1. The vacuum system of the vacuum emulsifier is faulty (e.g., vacuum pump leakage).
  2. The material is fed too quickly, introducing air.
  3. The stirring speed is too high, causing air to be sucked into the material.
• Troubleshooting:
  1. Check the vacuum pump’s pressure; if it cannot reach -0.095 MPa, replace the pump seal or filter.
  2. Reduce the feeding speed and ensure the material flows along the tank wall to avoid splashing.
  3. Lower the stirring speed during the initial feeding stage and increase it gradually after the material is mixed.

(3) Equipment Vibration or Abnormal Noise

• Possible Causes:
  1. The equipment is not placed horizontally, leading to unbalanced rotation.
  2. The stator-rotor is loose or worn.
  3. There is foreign matter (e.g., solid particles) stuck between the stator and rotor.
• Troubleshooting:
  1. Use a level to adjust the equipment’s feet until it is horizontal.
  2. Tighten the stator-rotor fixing bolts; if wear is severe, replace the parts.
  3. Stop the equipment, disassemble the homogenizer head, and remove the foreign matter.

(4) Material Contamination (Detected by Microbial or Heavy Metal Tests)

• Possible Causes:
  1. The equipment is not cleaned thoroughly (e.g., residue in pipelines or dead corners).
  2. The inner tank or parts are corroded (e.g., using carbon steel instead of 316L stainless steel).
• Troubleshooting:
  1. Use a CIP system with hot water (80-85°C) and neutral disinfectant to clean the equipment, focusing on pipelines and valves.
  2. Replace non-compliant parts with 316L stainless steel and conduct regular corrosion inspections.