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The manufacturer had previously trialled a competing colloid mill for similar emulsification tasks. However, the system proved unsuitable for production use due to:
These limitations increased downtime and reduced line efficiency, prompting the search for a more adaptable, hygienic, and production-friendly mixing solution.
Fristam recommended an on-site production trial using the Fristam FCM Colloid Mixer, an advanced inline mixing system designed to handle difficult emulsions and formulations containing suspended solids.
The objective of the trial was to evaluate emulsification performance, process stability, operational flexibility, and the potential to simplify the overall production line layout.
Trial set-up
1. Initial feed pump configuration
The formulation was initially supplied to the FCM using a conventional rubber lobe feed pump. A secondary pump was used downstream to maintain process flow. Multiple operating speeds and rotor-stator settings were tested to establish baseline shear performance.
2. Self-suction capability evaluation
During operation, inlet pressure readings indicated vacuum at the mixer inlet, suggesting that the FCM was capable of drawing product directly from the supply tote. The feed pump was removed to validate this capability.
3. Direct suction processing
With the feed pump removed, the FCM maintained continuous, stable flow above 40 gallons per minute (150 litres per minute). Product samples were collected and compared against the original pump-fed configuration.
4. Laboratory verification
Processed samples were sent for laboratory analysis to confirm emulsification quality, suspended solid distribution, and long-term stability under storage conditions.
The Fristam FCM delivered consistent, stable emulsification while completely eliminating ingredient separation during production and storage. Laboratory testing confirmed uniform dispersion of suspended solids, ensuring consistent product appearance and active ingredient performance.
By operating reliably in direct suction mode, the FCM removed the need for a separate feed pump while maintaining production flow rates above 150 litres per minute. This simplified the production layout, reduced equipment complexity, and lowered overall energy demand.
Operational flexibility was significantly improved. Operators were able to adjust shear rates and process parameters quickly without disassembly, allowing fast optimisation for different formulations.
Following the successful trial, the contract packager committed to full-scale deployment of the Fristam FCM and is now evaluating the addition of a second unit to support redundancy and future production expansion.
