Air-free vacuum mixing, phase heating and cooling for cream, lotion, shampoo, gel and fragrance production, sized from your process data.
In cosmetics production, the mixer turns oil and water phases into a stable emulsion, disperses polymer and pigment powders without lumps, evens out temperature during heating and cooling, and keeps air out of the product. If the duty is set up incorrectly, cream separates, fish eyes stay in the gel, shampoo foams and fill weight drifts. Mechanimix designs the mixer, vacuum, thermal system and scrapers together, based on the viscosity and shear sensitivity of the formula.
No two formulas behave the same way in the same tank. Here is the duty, the main risk and our approach for each process.
Clarifying these points before you request a quote leads to the right design and the right price.
| Criterion | Why it matters | How we handle it |
|---|---|---|
| Viscosity and flow behaviour | Cream thickens as it cools. A mixer chosen for the starting viscosity falls short at the end of the batch. | The thickest moment of the batch is the design point. HVM from 500 to 100,000 cP, and a scraped RC-L where there is wall film. |
| Emulsion type and droplet target | O/W, W/O and the phase ratio set texture and separation risk. An anchor alone does not reduce droplet size. | Homogenizer integration is assessed against target texture and shelf life, and the phase addition order is defined with the recipe. |
| Air sensitivity | In foaming and oxidizing products, air bubbles affect appearance, fill weight and shelf life. | Vacuum need follows from the product, with the RC-L vacuum option and a temperature-dependent vacuum level. |
| Heating and cooling rate | Much of the batch time is often spent on heating and cooling. | Double jacket and scraper are assessed together, with the target temperature profile as a design input. |
| Powders and polymers | Thickening polymers carry both lump risk and the risk of viscosity loss from excess shear. | Powder feed point and rate, post-wetting speed and the neutralization step are set from the recipe. |
| Volatile and flammable ingredients | Alcohol and fragrance lead to both product loss and explosive atmosphere risk. | A closed tank and suitable sealing are selected. We can design for ATEX and Ex-proof requirements. |
| Batch range and product changeover | Frequent recipe changes turn residual product and cleaning time into cost. | RC-L works from 500 to 5,000 L and RP from 5 to 100 L. Draining and the cleaning path are planned from the start. |
On the RC-L series, PTFE scrapers remove the wall film, reduce residue and keep heat moving through the double jacket. The speed range is 5 to 60 rpm.
The RC-L vessel is designed for -1 to +4 bar and the jacket for up to 6 bar. Vacuum and homogenizer integration are optional, and the working range is 20 to 160 °C.
RC-L, RP and BED-N have a CIP/SIP-compatible design. On BED-N, a Ra ≤ 0.4 µm electropolished finish reduces product adhesion.
We can design for ATEX and Ex-proof requirements for alcohol-based fragrance and similar products.
The right equipment follows from the process duty. These are the starting points.
500 to 5,000 L reactor with a PTFE-scraped anchor for creams, lotions and gels. Vacuum and homogenizer are optional.
View details →Magnetically coupled, CIP/SIP-compatible design for low-shear mixing in tanks from 10 L to 30 m³.
View details →PLC/HMI-controlled reactor for formulation trials and scale-up from 5 to 100 L, with optional vacuum.
View details →Start with product viscosity, phase temperatures and batch size. We will define the duty and size the right mixer with you.
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