1. Introduction
In modern industrial production, the quality of liquid products often depends on the efficiency and uniformity of emulsification. Liquid emulsifier equipment, as a core device to achieve stable mixing of oil-water and other immiscible substances, plays an irreplaceable role in fields such as cosmetics, pharmaceuticals, food processing, and chemical engineering. This case focuses on how a customer in the [specific industry, e.g., high-end skincare manufacturing] successfully solved long-standing production challenges by introducing advanced liquid emulsifier equipment, and ultimately achieved improvements in product quality, production efficiency, and cost control.
2. Background of the Project
2.1 Project Requirements
The customer mainly produces [product type, e.g., water-in-oil emulsion skincare products], which require strict control over the particle size of the emulsion, stability during storage, and consistency of product texture. Before introducing the new liquid emulsifier equipment, the customer’s production line had the following specific requirements:
- Emulsification Uniformity: The particle size of the emulsion needs to be controlled within 1-5 microns to ensure that the product has a smooth texture and no obvious granular feeling when used.
- Production Capacity: To meet the growing market demand, the daily production capacity of a single production line needs to reach at least 5,000 liters, and the equipment should support continuous production to avoid frequent batch switching.
- Product Stability: The emulsion after emulsification must maintain stable performance for 12 months under normal storage conditions, without stratification, precipitation, or color change.
- Safety and Compliance: The equipment must be made of food-grade or pharmaceutical-grade materials (such as 316L stainless steel) to avoid material contamination, and meet the industry’s safety standards for pressure, temperature, and electrical control.
2.2 Challenges Faced
Before using the new liquid emulsifier equipment, the customer relied on traditional stirring equipment for emulsification, which led to a series of problems that restricted the development of the enterprise:
- Poor Emulsification Uniformity: The traditional equipment used a single stirring paddle, which could not fully break the oil phase into small droplets. The particle size of the produced emulsion was often between 8-15 microns, and some batches even exceeded 20 microns. This not only made the product texture rough but also caused some customers to complain about "uneven application."
- Low Production Efficiency: The traditional equipment adopted a batch production mode. Each batch of emulsification required 4-5 hours (including heating, stirring, cooling, and sampling inspection), and the daily production capacity was only about 2,000 liters, which was far from meeting the market demand. In addition, after each batch, the equipment needed to be cleaned thoroughly, which took an additional 1-2 hours, further reducing the effective production time.
- Unstable Product Quality: Due to the inconsistent stirring speed and temperature control of the traditional equipment, the emulsion stability between different batches was significantly different. Approximately 5-8% of the products would appear stratification after 6-8 months of storage, resulting in product scrapping and increased cost losses.
- High Energy Consumption and Material Waste: The traditional equipment required high power to maintain the stirring speed, and the energy consumption per ton of product reached 120 kWh. At the same time, due to poor emulsification effect, some raw materials could not be fully mixed and reacted, leading to a material waste rate of about 3-5%.
3. Selection of the Liquid Emulsifier Equipment
3.1 Features and Advantages of the Chosen Equipment
After in-depth research on the market and multiple on-site inspections and tests, the customer finally selected a dual-shaft shear liquid emulsifier equipment. This equipment had the following key features and advantages:
- Dual-Shaft Shear Structure: The equipment was equipped with a high-speed shear rotor and a low-speed stirring paddle. The high-speed shear rotor could generate a shear force of up to 10,000 rpm, effectively breaking the oil phase into small droplets; the low-speed stirring paddle could ensure the uniform circulation of materials in the tank, avoiding local overheating or insufficient emulsification.
- Precise Temperature and Pressure Control: The equipment was equipped with a multi-point temperature sensor and an automatic pressure control system. The temperature control range was 0-150°C, with an error of ±0.5°C, and the pressure could be maintained at 0.1-0.3 MPa, ensuring that the emulsification reaction was carried out under stable process conditions.
- Food-Grade Material and Easy Cleaning: The inner tank and all contact parts with materials were made of 316L stainless steel, which had good corrosion resistance and could be sterilized at high temperatures. In addition, the equipment was designed with a CIP (Clean-in-Place) cleaning system, which could complete the cleaning process in 30 minutes without disassembly, reducing the labor intensity and cleaning time.
- Intelligent Control and Data Recording: The equipment was equipped with a touch screen control system, which could set and adjust parameters such as stirring speed, temperature, and time. At the same time, it could automatically record production data (such as temperature, pressure, time, and output) and generate reports, which was convenient for the customer to trace the production process and meet the industry’s quality management requirements.
3.2 How It Met the Requirements
The selected liquid emulsifier equipment fully met the customer’s production requirements and solved the previous challenges:
- Meeting Emulsification Uniformity Requirements: Through the high-speed shear rotor, the equipment could stably control the emulsion particle size within 1-3 microns, which was better than the customer’s required 1-5 microns. After testing, the product texture was significantly smoother, and the customer complaint rate related to "granular feeling" dropped to less than 0.5%.
- Meeting Production Capacity Requirements: The equipment supported continuous production. After optimizing the process, the emulsification time per ton of product was shortened to 1.5 hours, and the daily production capacity of a single production line reached 6,000 liters, exceeding the customer’s target of 5,000 liters. In addition, the CIP cleaning system reduced the cleaning time by 70%, further improving the effective production time.
- Meeting Product Stability Requirements: The precise temperature and pressure control system ensured that the emulsification process was consistent between different batches. After 12 months of storage testing, the stratification rate of the product was reduced to less than 0.3%, which fully met the customer’s stability requirements.
- Meeting Safety and Compliance Requirements: The 316L stainless steel material and strict quality inspection ensured that the equipment met the industry’s safety and hygiene standards. The data recording function also helped the customer pass the annual quality audit of relevant regulatory authorities smoothly.
4. Implementation Process
4.1 Installation and Setup
The installation and setup of the liquid emulsifier equipment were completed by a professional technical team sent by the equipment supplier, and the whole process took 10 working days:
- Pre-Installation Preparation: Before the equipment arrived, the technical team communicated with the customer in advance to confirm the site conditions (such as space size, power supply, water supply, and drainage) and made a detailed installation plan. At the same time, the customer arranged 2 full-time technicians to cooperate with the installation work.
- Equipment Installation: On the day the equipment arrived, the technical team first checked the integrity of the equipment and accessories, then carried out hoisting, positioning, and pipeline connection. During the installation process, the team paid special attention to the sealing performance of the tank body and the alignment of the rotating parts to avoid oil leakage or abnormal noise during operation.
- Commissioning and Testing: After the installation was completed, the technical team carried out a 3-day commissioning work. They first tested the electrical system, heating system, and cooling system to ensure that each component worked normally. Then, they used the customer’s actual raw materials for trial production. During the trial production, parameters such as stirring speed, temperature, and emulsification time were adjusted repeatedly until the emulsion particle size, texture, and stability all met the customer’s requirements.
4.2 Training and Familiarization
To ensure that the customer’s operators could use and maintain the equipment correctly, the supplier provided a 5-day training course, which included the following contents:
- Theoretical Training: The training teacher explained the working principle of the liquid emulsifier equipment, the function of each component, the common fault causes and solutions, and the safety operating procedures. The operators were required to master the basic knowledge of emulsification process and equipment control.
- Practical Operation Training: Under the guidance of the training teacher, each operator carried out practical operations such as parameter setting, raw material feeding, emulsification process monitoring, and equipment cleaning. The teacher corrected the incorrect operation methods in time and ensured that each operator could operate the equipment independently.
- Maintenance Training: The training also covered daily maintenance work, such as checking the lubrication of the rotating parts, cleaning the filter, and calibrating the temperature sensor. The operators were taught how to judge the abnormal state of the equipment through sound, temperature, and other signals, and how to take emergency measures when faults occurred.
After the training, the supplier conducted an assessment of the operators. All 8 operators passed the assessment and obtained the qualification certificate for operating the equipment.
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