Process / Product quality benefits
- Rapid, controlled wetting of Carbopol® 980 polymer
- Homogeneous 2% solution consistency
- Reduced risk of agglomerates and surface clumping
- Improved repeatability between batches
- Enhanced viscosity development control
Previously unsuccessful methods
The manufacturer relied on a traditional tank-mounted mixer with recirculation.
Challenges included:
- Long dispersion time (approximately 2 hours per batch)
- Thick suspension layers during addition
- Shear limitations within the bulk tank
- Recirculation required to approach homogeneity
- Reduced daily production capacity
While functional, the system could not deliver rapid powder wetting or efficient deagglomeration of the Carbopol polymer. Mixing performance depended heavily on batch size and operator technique.
Fristam’s solution
Fristam supplied a PM-D 2-52 Powder Induction System with a Typical induction rate: 10–15 lbs/min (4.5–6.8 kg/min)
The PMD Mixing System was equipped with:
- FDS 2 powder induction system (10 HP / 7.5 kW, 1200 rpm)
- FS 3522 high-shear rotor-stator blender (20 HP / 15 kW)
- Integrated VFD control panel
- Waist height table top and powder hopper.
A demonstration unit originally shown at Pack Expo 2024 was provided for on-site trial.
The system combines controlled powder induction with high-shear dispersion, enabling rapid wetting of Carbopol polymer while preventing clumping and surface floating – common challenges in cosmetic thickener applications.
Trial set-up
The on-site trial followed a structured evaluation process:
1. Liquid Recirculation
Water from the holding tank was recirculated through the PMD system. The liquid stream was established prior to powder addition to ensure immediate wetting conditions.
2. Controlled Powder Induction
Carbopol® 980 (approximately 400 lbs / 180kg) was introduced via the induction hopper.
The FDS induction pump created controlled suction beneath the hopper, drawing powder directly into the liquid stream at approximately 10–15 lbs/min (4.5–7 kg/min). At this rate, a 400 lb batch would typically induct in 30–40 minutes.
3. Inline High-Shear Dispersion
Immediately after wetting, the premix passed through the FS 3522 shear blender.
The rotor-stator configuration generated intense shear forces that:
- Broke down agglomerates
- Eliminated fish-eyes
- Distributed polymer uniformly
- Promoted rapid viscosity development
At moderate induction rates, a single pass achieved homogeneity. Higher induction rates may require recirculation, as effective shear dispersion can rapidly consume available free water during initial wetting.
4. Batch Completion and Evaluation
The complete slurry was produced in less than 30 minutes – compared with approximately two hours previously.
Following successful validation, the customer purchased the trial unit.
A successful outcome with the Fristam Powder Mixer
The PM-D 2-52 system reduced Carbopol slurry production time by approximately 75%.
Batch time was reduced from ~120 minutes to <30 minutes.
The trial unit was permanently installed and never returned.
With a production rate of five batches per day, the time savings significantly increased operational flexibility and plant throughput.
This video demonstrates controlled induction and hydration of Carbopol at 1% concentration into water using the Fristam hygienic ... powder mixer. Efficient wetting and high-shear dispersion produce a smooth, homogeneous solution in 2 minutes 44 seconds.
Rapid Carbopol Powder Induction and Hydration with the Fristam Powder Mixer
This video demonstrates controlled induction and hydration of Carbopol at 1% concentration into water using the Fristam hygienic ... powder mixer. Efficient wetting and high-shear dispersion produce a smooth, homogeneous solution in 2 minutes 44 seconds. See more
The Fristam powder mixer enables reliable induction and hydration of shear-sensitive thickening agents such as Carbopol without agglomeration or fish-eyes. Vacuum-assisted powder induction combined with inline high-shear mixing ensures uniform dispersion, predictable viscosity development and consistent product quality for personal care, pharmaceutical and chemical processing.
Sustainability benefits
- Lower overall power consumption per batch
- Reduced rework due to incomplete dispersion
- More efficient use of water during polymer hydration
Financial benefits
- Increased daily batch capacity
- Reduced mixing time by approximately 90 minutes per batch
- Lower energy consumption due to shorter operation
- Reduced labour supervision during dispersion
Other benefits
- Portable system design
- Inline processing reduces tank dependency
- VFD control allows induction optimisation
- Scalable to larger induction rates with larger pumps and piping