Process / Product quality benefits
- Homogeneous, lump-free product consistency
- Preservation of shear-sensitive product structure
- Improved visual appearance and glossy finish
- Repeatable and controlled mixing performance
Previously unsuccessful methods
The customer was operating a conventional agitator combined with a recirculation-based mixing system. While suitable for standard formulations, this approach proved inadequate for a shear-sensitive cosmetic product where both texture and visual appearance were critical.
In practice, the system struggled to achieve uniform mixing, resulting in inconsistent texture across batches. The uncontrolled shear generated during processing also altered the product structure, negatively impacting its appearance and performance.
Batch production times were extended, with each cycle taking approximately 6 hours, limiting throughput and operational efficiency. Despite this, the system failed to achieve the required shiny glaze finish, which was essential for the final product.
The result was a process that delivered neither consistent quality nor efficient production, highlighting the limitations of traditional mixing technology in this application.
Fristam’s solution
To address these challenges, Fristam implemented an FS Shear Blender equipped with a Low Shear Stator-Rotor Combination 2020, specifically developed for shear-sensitive and high-viscosity formulations.
Rather than applying excessive mechanical force, the system was engineered to provide a controlled and optimised shear profile. The specialised rotor-stator geometry enabled effective dispersion while maintaining gentle handling of the product, preserving its structure and visual characteristics.
Flow conditions were carefully optimised to improve mixing efficiency without over-processing the formulation. This ensured that both product quality and process performance were achieved simultaneously.
The solution was tailored to meet the customer’s key objective: delivering a smooth, homogeneous and visually consistent product with a high-quality glossy finish, while maintaining product integrity throughout processing.
Trial Set-Up
A structured evaluation and implementation process was carried out to ensure optimal performance.
1. Process Evaluation
Fristam conducted a detailed analysis of the existing mixing process, including flow behaviour, shear impact and areas of inefficiency.
2. Product Assessment
The formulation was assessed for viscosity and sensitivity to shear forces, enabling the correct configuration of the rotor-stator system.
3. Equipment Integration
The FS Shear Blender system was installed alongside the existing infrastructure, allowing a smooth transition without major process disruption.
4. Testing and Optimisation
Operating parameters, including flow rates and rotor-stator configuration, were fine-tuned to achieve the optimal balance between mixing efficiency and low shear.
5. Operator Training
Fristam provided on-site training to ensure correct operation and maximise long-term system performance.
A Successful Outcome with the Fristam FS Shear Blender
Following installation and optimisation, the customer achieved a significant improvement in both product quality and production efficiency.
Batch time was reduced from approximately 6 hours to 3.5 hours, representing an increase in throughput of around 40%. At the same time, the mixing process consistently delivered a homogeneous, lump-free formulation, eliminating the variability previously experienced.
Crucially, the required shiny glaze finish was achieved, confirming that the product’s structure and visual characteristics had been preserved. The controlled shear environment prevented product damage, ensuring consistent results across batches.
Operational reliability was also improved, with reduced maintenance requirements compared to the previous system.
This project demonstrated that:
- Controlled shear is essential for maintaining product integrity in cosmetic formulations
- Tailored rotor-stator configurations enable precise and application-specific mixing performance
- Process validation through testing is critical when replacing conventional systems
- Optimised mixing technology supports scalable, repeatable and efficient production
Financial benefits
- Reduction in batch time by approximately 40%
- Increased production throughput
- Lower maintenance and operational costs
- Reduced product waste and rework
Operational Benefits
- Seamless integration into existing production systems
- Improved process control and reliability
- Straightforward operation for production teams
- Scalable solution for future production requirements