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Viscosity problem in emulsion
Hi all , i want explanation from experts of happened phenomen (For viscosity variation in production scale and why i got laboratory’s cream more viscous then production’s one?<div>
For formulation :
Water : Qsp
Emulsifier (combinaison of GMS ,cetearteh 20 ,cetearteh 12) : from 4.5%to 5.5%
Cetearyl alcohol :4%
EDTA 0.1%
Citric acid to ph=5
Paraffin oil : 8%
Shea butter : 1%
Sensicare c1060 : 0.6%
Parfum : 0.5%
*For production scale the cooling process need from 6 hours (or more)to reach 40 °C and the process is heating two phases separately to 75°C then add oil phase to water phase mixing by turbine in frequence of 45 hz (2700 rpm) For 15 minutes and something near to Anchor agitator with 40 rpm speed working For all process.
*Laboratory scale the cooling process need just one hour or less to reach 40°C and the process is heating two phases separately to 75°C then add oil phase to water phase mixing by with turbine balade from 600 to 1200 rpm .
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This discussion was modified 2 months ago by
Fekher.
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This discussion was modified 2 months ago by
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16 Replies
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How many “production scale” have you done? have you prepared an intermediate pilot batch when upscaling?
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Two productions for shared formulation , but the curve is repeated for others creams always in evry production ( at T=50 °C the viscosity drop dramatically where there is no add to any ingredient preservative , parfum..) .
And there is only production and laboratory scale .
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Please don;t use “Parfum” preservative. You’ve no idea what’s in it, it’s safety or consistency.
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your comment isn’t clear for me can you explain more?
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Sure
“Parfum : 0.5%”, if this is Natacide, please do not use it.
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Thanks i guess i got your idea however the inci of fragrance is parfum so i meant fragrance, odorant ingredient…
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Thanks - got it
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you are welcome , waiting from experts comments.
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have you solved it? i was suspecting the speed in case everything else remains the same. I know that you can break your emulsion if you upscale from lab to factory when you increase speed and don’t adjust the emulsifier’s concentration (higher speed= smaller intern phase droplets= bigger Surface T.= more emulsifier) maybe you need a thickener for you ext. phase… Keep us updated
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Actually it is not really problem because we got nice texture (better texture then laboratary sample) and viscosity is acceptable just i want to understand the phenomen . About the speed of turbine i guess it is not the reason because we turn off it at high temperature where the viscosity reached the maximum of viscosity so the decreasing of viscosity is in function with temperature decreasing only in that case .
just we took two samples from production one without turn on turbine after 50 °C and one with then there is not really important difference between them.
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So the emulsion didn’t break, you just ended up with different texture? as the previous comment stated, maybe it’s the cooling down. (When working with emulsions, i prefer not to skip intermediate upscaling because you always end up with different results in factory comparing to lab due to the complexe emulsion’s structure, lot of parameters to consider)
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I guess it didn’t break, as I said too near texture and viscosity.
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I’ve seen that happening many times. When scaling up, you need to keep more or less the same cooling rate, heat and mixing energy as in the lab. For what I see, the cooling rate is clearly not proportional, so crystalization profile (and final viscosity) will be diferent. Also, what’s the ratio of blade diameter/tank diameter in your reactor compared to the lab?
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As always , awsome comment from expert @ketchito. Thanks a lot for sharing your interesting knowledege , my big guess was about cooling ratio (because it is the most important difference between labo and production scale) . about ratio (turbine diamater /reactor diamater) laboratory > ratio (turbine diamater /reactor diamater) production
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If the blade diameter is very small compared to the tanks diameter, you’ll get lower mixing energy transfer and batch turnover (BTO), and that can also account for the lower viscosity. If that’s the case, you can use both an external pump to recirculate during the emulsion, and also a planetary mixer (if your tank has one) along with your turbine. This is specially useful when the emulsion gets thicker.
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