Ultrasonic Mixing for the Cosmetic Industry

Hielscher ultrasonic devices are used in the cosmetics industry for manifold processes, e.g. for the manufacturing of lotions, sunscreen, creams or ointments.

The formulation of new cosmetic products involves many processing challenges, such as the disintegration of cells and solids, or the dispersion and dissolving of powders into liquids. For such processes, as well as for the production of stable emulsions, degassing and homogenizing Hielscher offers ultrasonic mixing equipment for use in both, laboratory research and industrial production.

Laboratory Research and Analysis

Hielscher ultrasonic laboratory devices are ideal for research and development as well as for routine processes. Devices like the handheld UP100H are suitable for manifold applications, e.g. mixing, dispersing, emulsifying, homogenizing, disintegrating or dissolving. The laboratory devices are easy to use, and have an unmatched efficiency and flexibility. Ultrasonic laboratory devices are typically used for capacities from 1mL to 2 liters. Hielscher ultrasonic devices offer accurate process control and excellent reproducibility for the scale up to production scale. Automatic amplitude control and frequency tuning is invaluable for process validation and repeatability. That is why, this feature is integrated in all Hielscher ultrasonic devices.

Ultrasonic Mixing in Production

Ultrasonication can be scaled up easily. Laboratory tests will allow to select the required equipment size accurately. The table below shows general device recommendations depending on the batch volume or flow rate to be processed.

Batch Volume	Flow Rate	Recommended Devices
0.5 to 1.5mL	n.a.	VialTweeter
1 to 500mL	10 to 200mL/min	UP100H
10 to 2000mL	20 to 400mL/min	UP200S, UP400S
0.1 to 20L	0.2 to 4L/min	UIP1000, UIP2000
10 to 100L	2 to 10L/min	UIP4000
n.a.	10 to 100L/min	UIP16000
n.a.	larger	cluster of UIP16000

Inline Processing

Hielscher ultrasonic reactors are commonly used in-line. The material is pumped into the reactor vessel. There it is exposed to ultrasonic cavitation at a controlled intensity. The exposure time is a result of the reactor volume and the material feed rate. Inline sonication eliminates by-passing because all particles pass the reactor chamber following a defined path. As all particles are exposed to identical sonication parameters for the same time during each cycle, ultrasonication typically shifts the distribution curve rather than widening it. Generally, "right tailing" can not be observed at sonicated samples.

Process Cooling

For temperature-sensitive formulations, Hielscher offers jacketed flow cell reactors for all laboratory and industrial devices. By cooling the internal reactor walls, process heat can be dissipated effectively.

Robust and Easy to Clean

An ultrasonic reactor consist of the reactor vessel and the ultrasonic sonotrode. This is the only part, that is subject to wear and it can be easily replaced within minutes. Oscillation-decoupling flanges allow to mount the sonotrode into open or closed pressurizable containers or flow cells in any orientation. No bearings are needed. Flow cell reactors are generally made of stainless steel and have simple geometries and can easily be disassembled and wiped out. There are no small orifices or hidden corners. Special flow cell reactors meeting the advanced CIP (clean-in-place) and SIP (sterilize-in-place) requirements are available, too.

Ultrasonic Cleaner in Place

The ultrasonic intensity used for dispersing applications is much higher than for typical ultrasonic cleaning. Therefore the ultrasonic power can be used to assist cleaning during flushing and rinsing, as the ultrasonic cavitation removes particles and liquid residues from the sonotrode and from the flow cell walls.