Article by: Perry Romanowski

As a cosmetic formulator you will undoubtedly run into a situation where you screw up a batch.  Or maybe the batch just gets ruined through no fault of your own.  Most of the time you should simply throw the batch away and start over.  unstable-formula

Of course, I am speaking from the point of view of a cosmetic chemist who worked for a large corporation and usually had access to a nearly unlimited supply of most of the raw materials I was working with.  The only negative thing about pitching most batches was the extra time required to make a new one.  But for most cosmetic formulators pitching a product and starting over is a luxury and saving every batch is important.  So, here are some tricks I’ve used (for the times I couldn’t discard a batch) to save a batch.

When is a cosmetic batch bad?

Before we give tips on saving batches, it makes sense to consider how to decide whether the batch is really bad.  Since every cosmetic formula should have a set of specifications these can be used.  If a value such as the pH, viscosity, color, odor or consistency is “out of spec” then the batch is considered bad.  While this does not guarantee that every in-spec batch is good, it is a reasonable filter for most cosmetic chemists to follow.  The other way a batch can be considered bad is that it doesn’t perform the way it’s expected but that is a much more complicated situation which we will ignore for this post.

Figure out why it went bad

Once you’ve decided a batch is bad, you should figure out what went wrong.  This will depend on which characteristic is out of spec.  For example, if the pH is too low maybe you added too much acid or not enough base.  If the color is off perhaps the wrong amount of dye was added or one of your starting raw materials was a different color than usual.  Go through your batch notes and identify what the possible problem could have been.  Sometimes you just can’t know but it does make fixing things easier.

How to save a bad batch

Here are some tips and tricks on how to save a cosmetic batch.  The specific tactic you use depends highly on the type of formulation you are making.

Remix & Reheat

If your product is thin or has the wrong consistency one of the first things you can try is to reheat the product and mix it again.  Often an emulsion won’t form properly during the cooling phase and remixing at a high temperature can reset and fix things.  If you do try this however, be sure to add back more of your heat-sensitive ingredients like preservatives and fragrances as these can breakdown when heated for a significant period of time.

Add more of the missing ingredient

When you notice an obvious error in the amount of an ingredient, you can often add more of the ingredient at the end of the batch to make things come out properly.  This usually only works with liquid raw materials.

Add adjustment ingredients

If the pH is off you can add ingredients like acids or bases at the end to get the batch in spec.  This is where doing something like a formulation knockout experiment is extremely helpful.  By doing a knockout experiment you can determine the effect that every ingredient will have on the end characteristics of your formula.  Some of the ingredients will have a significant effect on thickness or pH even if you wouldn’t expect them to.

Dilute with a new batch

Sometimes you can’t adjust a batch for a variety of reasons such as adding 10 times too much dye.  In those cases, you can make a second batch where you leave out the color and then blend the two batches together to make one that is the correct color.  This can work for pH and viscosity too.  However, you should know that while this technique can lead to a fixed batch, it can also lead to two broken batches!  So, use it with caution.  There were times when we would have to dilute a production batch over months and many other batches just to save it.

Sometimes you have to throw things away.

While there are often ways to fix batches, there are times when things are a lost cause and you should pitch the product.  For example if your batch is microbial contaminated you should not use it.  Granted you can do things to kill off any contamination but certainly on a lab scale it is more safe to just discard these batches.  Remember the time and effort required to save a batch is sometimes not worth it.

Do you have any batch-saving tips or questions?  Leave a comment below.

April is Focus on Formulation month.  All month long the majority of blog posts will be about cosmetic formulating.   


  1. Avatar
    John Polson

    Use SMART Formulator to advise how to salvage a batch.
    We have the mathematical model which will suggest what to add, based on some questions the software will ask you and if you provide it, SF will suggest a rework and how to adjust a batch for salvaging a batch. The software has mathematical models to suggest how to do the rework.
    However, it is not possible all the time, as it depends on each situation.
    If interested, please contact Rachel Schneider @ (732) 235-1288 or visit and enter your contact information on the website and submit it and we will contact you.

  2. Avatar
    David Roman

    I work for a small family owned company. We can’t afford to waste any money so I have not choice but to try and fix a bad batch. Every dollar counts.

  3. Avatar

    Blending off batches is pretty common. Figuring out (or guessing) what went wrong is a great first step. Other fixes that I can think of are: adding more liquids; usually water, ‘burning off’ liquids; usually water, cold homogenizing, hot homogenizing, rapid chilling, reheat/remix but stop mixing at a certain point while cooling (say 40C) to leave some heat energy in the bulk, versating, filtering, adding additional emulsifier, adding masking agent, etc.

  4. Avatar

    I believe if it can be salvaged then it should be. Why throw away stuff when it can still be useful?

  5. Avatar
    Lise M Andersen

    The fact that anyone would even consider diluting with a new batch is a little disconcerting to me – it would of course depend on the product. My mind immediately lept to emulsions, but perhaps a cold-mix product might be salvagable this way… still. My first instinct would be to discard anything that was even slightly off. (Probably because I work only in small batches).

    1. Avatar
      Perry Romanowski

      I understand your position and when I was at a big corporation doing small lab batches, we discarded anything that was off. But on a production scale (3000 gallon batches), they didn’t want to throw anything away. The disposal & lost raw material costs would kill the production numbers. So they looked for any way they could to salvage an out of spec batch.

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