Home Cosmetic Science Talk Formulating General How do I scale up production?

  • How do I scale up production?

    Posted by Reno21 on January 20, 2024 at 9:20 am

    I was wondering if someone could tell me what equipment I need to scale my production up.

    I’m currently mixing emulsions in 12 buckets with an immersion blender. I’d like to scale up to 25gals or 55gals.

    What do i need to purchase?

    Do I get a tank and high sheer mixer attachment? Do I even need high sheer??

    Can someone recommend a setup?


    KMRCSMiami replied 1 month, 1 week ago 3 Members · 5 Replies
  • 5 Replies
  • KMRCSMiami

    January 22, 2024 at 11:33 am

    This is a loaded question that is difficult to answer well with the information provided. Your existing method is not sustainable so I am happy you’re considering improving existing methods.

    I guess my next question would be what are you making? share the formula and viscosity, budget …. all of these things affect recommendations. My next question would be where is this formula being scaled/prepared?

    • Reno21

      January 22, 2024 at 6:33 pm

      Hi @KMRCSMiami , thanks for replying!

      I’m making lotions with various viscosities. Some light lotions and some thicker creams. I’m in Nevada. My budget is probably up to around $5k - $10k.

      I’m looking at maybe getting 2 big melting/heat tanks and finding a mixer for one of them, but then I’m trying to wrap my head around how I transfer the thicker lotions out of the tank, as I’m not sure gravity will be sufficent. Also, I’m not sure what kind of mixer I should get.

  • mikethair

    January 22, 2024 at 7:31 pm

    I have been there and done that. We scaled up to establish two factories. One in Ha Noi, Viet Nam, and another on Penang Island, Malaysia.

    But I see alarm bells when you say “I’m making lotions with various viscosities.” With these products, we stuck to large stainless steel buckets. Although we had very large thermostatically controlled tanks with mixers, the viscosities were always an issue. Thus, the reason we stuck with large stainless steel buckets.

    • This reply was modified 1 month, 1 week ago by  mikethair.
  • Reno21

    January 24, 2024 at 8:44 pm

    What I seem to be seeing people do is mix in 55 gallon drums. And then my question is that a secondary mix after emulsion? Or is that the emulsion mix, and they are pouring both phases into the drum and mixing?

    I can purchase a heated tank with a mixer, but how do I ensure the mixer will homogenize?

    • KMRCSMiami

      January 25, 2024 at 11:14 am

      often what we see being done isn’t the most effective or efficient- but I wouldn’t know if its the best for you without a clear picture of what it is you truly need.

      There are still a lot of unknowns here. You may message me directly and I can see if I can provide you with some pointers. Scaling in manufacturing is nuanced, and can be expensive if you dont know what to purchase, items to consider, etc. etc. So lets see if we can get a clearer picture and we can see if there are economical solutions here.

      • This reply was modified 1 month, 1 week ago by  KMRCSMiami.

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