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To reach the required droplet size, the manufacturer invested in a high-pressure homogeniser with a capital value exceeding $250,000. However, once commissioned, the system failed to consistently achieve the required submicron particle size.
Process engineers identified that insufficient pre-emulsification upstream of the homogeniser was limiting overall system performance.
Without proper conditioning of the formulation before high-pressure treatment, the homogeniser alone could not reliably meet the product specification.
Having previously implemented a Fristam Powder Mixer to pre-blend powders, oils, and liquid components into a semi-stable premix, the customer engaged Fristam again to resolve the nano-emulsification challenge.
Fristam proposed integrating the Fristam FCM Colloid Mixer between the Powder Mixer and the high-pressure homogeniser. This configuration was designed to generate high shear during pre-emulsification, reduce initial droplet size, and create optimal feed conditions for the downstream homogenisation stage.
Unlike conventional pre-conditioning equipment, the FCM also operates as a hygienic inline product pump, offers tool-free CIP capability, and supports continuous processing.
Trial set-up
1. System integration
The FCM was installed inline between the existing Powder Mixer and the high-pressure homogeniser. Premixed product flowed directly from the Powder Mixer through the FCM before entering the homogenisation stage.
2. Pre-emulsification through shear
As the formulation passed through the FCM, high shear forces reduced initial droplet size and created a stable preliminary emulsion while maintaining continuous product flow.
3. Final homogenisation stage
After exiting the FCM, the conditioned product entered the high-pressure homogeniser, where final droplet size reduction and nano-emulsification were completed.
4. Cleaning validation
Following production trials, the FCM was incorporated into the plant’s CIP programme to verify full internal cleaning coverage without dismantling.
With the FCM integrated into the process line, the system consistently achieved the target droplet size of 0.2 microns (200 nanometres). Droplet analysis confirmed stable nano-emulsion formation across repeated production runs.
The combination of high-shear pre-emulsification and downstream high-pressure homogenisation transformed overall process performance. While the homogeniser alone had previously failed to meet specification, the addition of the FCM enabled the complete system to operate within required parameters.
The improved pre-conditioning also reduced mechanical load on the homogeniser, stabilised operating conditions, and enhanced overall production reliability. As a result, the manufacturer standardised this configuration for additional nutraceutical formulations and expanded its use across multiple product lines.
