Process / Product quality benefits
- Full Carbopol deglomeration and fisheye elimination
- Stable, repeatable lotion viscosity and texture
- Improved emulsion homogeneity and appearance
- Faster hydration and rheology development
Previously unsuccessful methods
The manufacturer relied on a propeller agitator combined with a scrape agitator inside a batch vessel. This approach resulted in:
- Incomplete Carbopol dispersion and visible clumping
- Formation of fisheyes within the lotion matrix
- Extended blending times to reach target viscosity
- Additional Carbopol addition to compensate for losses
- Increased ingredient cost and reduced batch efficiency
Fristam’s solution
Fristam recommended integration of an FS high‑shear blender featuring an intermeshed rotor‑stator design capable of rapid particle dispersion on the first pass. The FS model 3522 was installed downstream of the positive displacement pump within the system’s recirculation loop while the vessel agitator continued operating.
This configuration enabled intensive localized shear without requiring replacement of the existing batch mixing infrastructure, providing an efficient upgrade path for viscosity‑control applications.
Trial set-up
1. Lotion batches were prepared using the existing vessel agitation system.
2. Product recirculated through a positive displacement pump and inline FS shear blender.
3. High‑shear rotor‑stator action rapidly blended Carbopol particles and eliminated fisheyes.
4. The fully dispersed Carbopol hydrated uniformly within the emulsion, increasing the effective viscosity. Final lotion returned to the vessel with consistent texture and rheology.
A successful outcome with the Fristam Powder Mixer
Complete Carbopol dispersion enabled the processor to reduce Carbopol usage by 50 lb per batch while still achieving the required viscosity. This delivered ingredient savings of approximately $800 per batch and about $400,000 annually across roughly 500 yearly batches.
Blending time was also shortened by around one hour per batch, improving production throughput and operational efficiency. The manufacturer continues to benefit from sustained cost reduction, faster processing and improved product consistency.
Sustainability benefits
- Reduced raw‑material usage and formulation waste
- Lower energy consumption from shorter mixing duration
- Improved process efficiency within existing equipment footprint
Financial benefits
- Reduction of Carbopol consumption by 50 lb per batch
- Approximate $800 saving per batch
- Around $400,000 annual raw‑material cost reduction
- Shorter blending cycles increasing production capacity
Other benefits
- Retrofit installation without full system replacement
- Improved process control for viscosity‑critical formulations
- Continued long‑term operational savings