IKA competence for the cosmetics industry

IKA competence for the cosmetics industry


Every new product is born in the lab - every new process is born in small batches, but often evolves into large scale production. IKA uses this knowledge to your advantage and expands the product range for the cosmetics industry with innovative machines and equipment that will help you tap into new markets. With machines ranging in size from lab to pilot, IKA offers you the accurately functioning pattern to realize your production idea.

IKA versatile mixing technologies improve the dispersing quality. This decreases production times and therefore increases your company's productivity. Experiences in the lab can be reliably transferred over to the actual production scale. After all, regardless of their size, IKA machines of any series achieve consistent results.

Several different mixing systems are available for the production of O/W, W/O, W/O/W emulsions, suspensions, particulate matter, and colloidal substance solutions. The most challenging task innovative mixing technologists are faced with is the production of stabile and effective emulsions. Here, IKA has extensive experience and world-wide references. A classic cosmetic emulsion is meant to preserve or build up the acid mantle and permeation barriers of healthy skin. Modern cosmetic emulsions additionally contain specific ingredients that influence the skin cells' processes. This is why maintaining the current hygiene standards during the production of cosmetic products is of utmost priority to IKA.

IKA Standard Production Plant is ideal for optimally producing liquid-liquid or solid-liquid mixtures. This high-quality and reasonably-priced machine is universally useable and works in an extremely economic fashion. With this batch machine's top design you will profit from high flexibility and excellent ease of use:
  • automatic feeding of liquid components
  • dust and lump-free feeding of free-flowing solids thanks to optimal moistening
  • efficient stirring, dispersing, emulsifying or suspending
  • temperature and vacuum control
  • electronic steering of all components

With IKA mixing technology are produced:
  • Creams
  • Shower gels
  • Hair care products
  • Lotions
  • Shaving cream
  • Bubble baths
  • Soap
  • Shampoos
  • Sunscreen
  • Lipsticks
  • Mascara
  • Flavourings
  • Deodorants
  • Perfume


The most popular equipment

ProductgroupMachines and plants
 
Inline dispersers / Mills DISPAX-REACTOR® DR 2000/05 Flow rate (max.) : 2500 l/h
DISPAX-REACTOR® DR 2000/10 Flow rate (max.) : 10000 l/h
DISPAX-REACTOR® DR 2000/20 Flow rate (max.) : 20000 l/h
DISPAX-REACTOR® DR 2000/30 Flow rate (max.) : 40000 l/h
DISPAX-REACTOR® DR 2000/40 Flow rate (max.) : 80000 l/h
DISPAX-REACTOR® DRS 2000/05 Flow rate (max.) : 700 l/h
DISPAX-REACTOR® DRS 2000/50 Flow rate (max.) : 40000 l/h
 
Batch dispersers UTC 115/KT Batch size max. (H2O): 500 l
UTC 150/KT Batch size max. (H2O): 1700 l
UTE 115 Batch size max. (H2O): 400 l
 
Process plants DPV 3000 Total capacity to: 3000 l/h
MP 10 Useful volume max.: 10 l
MP 500 Useful volume max.: 500 l
MP 1000 Useful volume max.: 1000 l
SPP 25 Useful volume max.: 25 l
SPP 500 Useful volume max.: 500 l
SPP 1000 Useful volume max.: 1000 l
 
Pilot plants Labor-Pilot 2000/4 Flow rate (max.) : 300 l/h
magic LAB® with module UTL Motor power: 0.9 kW
PROCESS-PILOT 2000/4 Flow rate (max.) : 350 l/h
 



Applications

Carbopol® emulsions
Deodorants
Dilution of WAS (ether sulphate)
Emulsions for sun protection spray
Lipsticks
Processing of vegetable oils
Shampoos
Shaving products
Silicone emulsions
Sun protection gel


Carbopol® emulsions
Production in a batch process
There are two methods of producing Carbopol® emulsions in a batch process: the "direct" and the "indirect" method.

Working with the "indirect method" means producing a premix with the oily phase (non-solvent). With this method concentrations of up to 30% can be achieved, nevertheless maintaining a good flowability. When this premix is fed into an aqueous phase (with a neutralizing agent) and moderately stirred or dispersed, a smooth emulsion is forming after approx. 20 minutes.

A suitable dispersing machine is e.g. an IKA® ULTRA-TURRAX® type UTC with variable speed.

Working with the "direct method" means that the Carbopol® is directly fed into the stirring vortex of the water. Care has to be taken that there are no lumps in the Carbopol® itself. The oily phase is then added under continuous stirring. Thus a shining mixture is produced which has to be subsequently neutralized by means of a suitable lye.


Carbopol® emulsions
Production in a batch enrichment process
Carbopol® emulsions can also be produced in a batch enrichment process using the powder incorporation and dispersing machine of the type IKA® CMS 2000/... The powder is sucked-in via the funnel that is connected to the aspiration socket of the machine, and directly dispersed into the circulating flow of liquid. Thus agglomerations are avoided from the beginning and homogeneous emulsions can be produced in a very short time.

Special funnel geometries help avoiding a "chimney effect" in the funnel. The incorporation of air is thus restricted to the quantity included in the powder. After incorporation of the solids, the final product can be circulated with the IKA® CMS 2000/.. for further homogenization.


Deodorants
Production in a batch process
Production in a batch process with IKA® Master Plant

The continuous phase (alcohols, propylene glycol, glycerine or silicone oil) is prepared in the mixing vessel of the IKA® Master Plant MP, while the spiral agitator and the dispersing machine of the type DBI 2000 are running slowly, and heated up to approx. 50°.

In a separate vessel the disperse phase is premixed with an IKA® ULTRA-TURRAX® and heated. The disperse phase may e.g. consist of cetyl alcohol or hexadecanol compounds (flakes or powders) and maybe thickeners, gelling agents, bentonite as well as water or oil.

The speed of the dispersing machine DBI 2000 is then increased to normal speed and the premix (disperse phase) is step by step fed into the main mixing vessel. After some time additional active substances, odorous substances (fragrances) and maybe colorants and gelling agents (polymer) are added. During that process the temperature has to be surveyed.


Dilution of WAS (ether sulphate)
Dilution in an inline process
When water and ether sulphate are brought together, e.g. in a beaker, you will see that gel lumps are formed even under stirring, which are very difficult to be solved. It is therefore very important in a dilution process that water and ether sulphate are kept apart as long as possible. i.e. until they directly reach the mixing tool, so that there does not remain any time for gel formation.
A high shear rate and shear frequency, as e.g. in the IKA® DISPAX-REACTOR®; drastically shorten the molecular chain of the ether sulphate. This creates enough surface for the water to settle down, resulting in a dilution of low viscosity.
The dilution plant type DPV designed by IKA® is working as an inline system, i.e. both phases are continuously fed to the DISPAX-REACTOR® by means of dosing pumps. During just one passage a concentration of approx. 70% is diluted to a clear product free of air bubbles and pinholes with a concentration of approx. 28%.
This way of production also offers the advantage, that big storage and mixing vessels are no more necessary. Any requested quantity can be diluted within short time and made available for further process steps. On demand a preservative may be added to the water inlet by a dosing pump.
The electric control can be designed acc. to the customer's requirements. Special attention has to be drawn to the sequence of switching on and off.
In a clever arrangement the dilution plant can even be used for further mixing, dilution and homogenizing of the final products like e.g. shampoos and similar.
The plant is available for capacities up to approx. 30 t/h


Emulsions for sun protection spray
Production in a batch process
Production in the IKA® Master Plant MP

The spray is produced in following steps:
  • The mixing vessel is pre-heated to approx. 80°C.
  • Stearates, fats and waxes are fed from upside and melted (approx. 27% of the formulation). During that process the spiral agitator is slowly running. The DBI 2000 is also running slowly, in order to keep the material in the lower part of the vessel in movement.
  • The polymer is added to the melt.
  • Hot water of approx. 80°C (approx. 40% of the formulation) is added via the lateral funnel, while the homogenizing machine DBI 2000 is running with a tip speed of 23 m/s. This quickly creates a W/O-emulsion. After adding the water the material is several times circulated.
  • A premix of cold water (approx. 25°C) and the oily phase (approx. 35% of the formulation) is prepared and added very slowly via the lateral funnel, so that the emulsion is converted into an O/W-emulsion.
  • The emulsion is then stirred to become cold - approx. 25°C - and alcohols and odorous substances are added via the funnel.
  • Finally the emulsion is carefully homogenized and maybe also cooled, so that a temperature of approx. 25°C is not exceeded.





Lipsticks
Production in a circulating batch process
The production process for lipsticks may be as follows:
  • Filling of the double-jacketed mixing and melting vessel with castor oil at room temperature
  • Heating is switched-on and heating temperature is limited to 75°C
  • Let the stirrer type IKA® TURBOTRON®, which is installed in the mixing vessel, run slowly
  • Wax pellets or powder are added via the funnel and melted in the heated castor oil
  • Increase the speed of the stirrer
  • Pull vacuum and de-aerate the melt for about 5 minutes
  • Switch-on the IKA® DISPAX-REACTOR® DR 2000 or IKA® Colloid Mill MK 2000 and mix the product in a circulation process while controlling the temperature and limiting it to approx. 75°C.
  • Add pigments via the funnel, stir for a short time and de-aerate again by pulling vacuum.
  • Adjust the DISPAX REACTOR® to full speed and circulate for approx. 10 minutes.
  • Add the remaining additives like acetates and glycols while de-aerating again and again.
When using the DISPAX-REACTOR® or maybe the Colloid Mill MK a rather big amount of heat is introduced. Therefore care has to be taken for suitable cooling capacity. It might also be recommendable to install a pump in front of the dispersing machine in order to shorten the residence time. The drive power of the dispersing machines has to be doubled.


Processing of vegetable oils
Processing in an inline process
Vegetable oils are processed in following steps:

A) Degumming
Part of the phosphatides in the raw oil are hydrogenizable with water and can thus easily be separated. The remaining non-hydrogenizable phosphatides can be separated by adding acid.
The untreated oil is heated up to 60°C - 70°C and thoroughly mixed with up to 1% of phosphoric acid. The acid is reacting with the phosphatides, thus enabling a settlement of the water. The phosphatides can then be separated by filtration or centrifuging. This results in a "degummed" oil and gum resin, from which, under certain conditions, lecithin can be produced. For a thorough mixing of acid and oil the IKA®-dispersing machine type DISPAX-REACTOR® DR 2000 proved to be very suitable.

B) Neutralization
Free fatty acids (FFA) are influencing the taste of the oil and accelerate its spoiling. For neutralization of the FFA the oil is intensively mixed with sodium hydroxide at a temperature of approx. 90° to 100°C. The FFA are settling as soaps and can be sperated by centrifuging. The DISPAX-REACTOR® DR 2000 as well as the single stage dispersing machine of type ULTRA-TURRAX®UTL 2000 proved to be the right machines for neutralization of the FFA.

C) Bleaching
In order to remove remaining impurities like colour and oxidation products the oil can finally be bleached. For this purpose it is intensively mixed with bleaching clay.For this process we recommend the IKA® inline mixing and dispersing machine type MHD 2000.




Shampoos
Production in a batch process
Diluted lauryl ether sulphate and water are given into a vessel and emulsified by moderate stirring.
Step by step the other components are added. In case of wax like materials the vessel is heated. Depending on recipe and requested homogeneity a rotor/stator machine like IKA®-ULTRA-TURRAX® UTE is incorporated in the bottom of the vessel additionally to the normal stirrer. In most cases this rotor/stator machine is working at reduced speed.





Shaving products
Production in a circulating batch process
Production with IKA® Master Plant MP

The IKA® Master plant is very well suited for the production of shaving cream.

The used recipes differ of course from manufacturer to manufacturer, but the production process usually looks like follows:
  • Melting and mixing of the fatty phase in the mixing vessel of the MP at a temperature of approx. 90°C and running spiral agitator.
  • In a separate vessel the lye (soda lye or caustic potash solution), water and glycerine are mixed and heated to a temperature of  approx. 75° - 80°C.
  • This mixture is given into the vessel and emulsified with the fatty phase in circulating operation and at the same time deaerated.
  • The remaining stearic acid is added via the funnel as quickly as possible, and the whole mixture is further dispersed under vacuum.
  • The remaining additives like fragrances, lactic acid, etc. are also added via the funnel and further homogenized under vacuum.
  • The mixture has to be quickly cooled down to 30° - 35°C, while only the stirrer is running. The heatable spiral of the MP-agitator is effectively supporting the cooling procedure.



Silicone emulsions
Production in an inline process

Production of a silicone/water-emulsion

It is recommended first to make a preparation with little water (approx. 15%) and to produce a gel-like emulsion. The suitable machine for this purpose is a colloid mill of the type IKA® MK 2000 with a stronger motor (approx. 30 kW, 1.000 l/h). Moreover it has to be worked with high shear gradient.

As soon as a homogeneous, transparent and very viscous mixture is reached, any requested viscosity can be adjusted by further mixing in of water and emulsifier.





Sun protection gel
Production in a batch process
A sun protection gel with aloe vera can be produced acc. to the following procedure:
  1. De-mineralized water and aloe vera gel in relation 1 : 1 are mixed in a vessel; total approx. 75% vol. in the mixing vessel.
  2. A thickener, e.g. Carbopol, is added
  3. Propylene glycol and further additives in small quantities are added
  4. Triethanolamine is added
  5. Colorants are added
All components are directly dosed to the mixing head of the stirring and dispersing machine of the type DBI 2000/.. via the funnel and its piping system. Thus an optimum dispersion is reached within short time. Care has to be taken for an intensive mixing after adding of the Carbopol.