Core Functions & Technical Advantages
Combined with the characteristics of cosmetic raw materials (high viscosity, sensitivity to temperature and oxygen, complex formulas) and actual production operation needs, the equipment has the following core functions and technical advantages, which comprehensively improve production efficiency and product quality:
1. Hydraulic Lifting System - Convenient Operation & Safe Maintenance
The equipment is equipped with an intelligent hydraulic lifting system, which can realize the stable lifting and lowering of the mixing tank or homogenizing head (adjustable lifting stroke 300-800 mm) through PLC control. The lifting speed can be steplessly adjusted (50-200 mm/min), and the positioning accuracy is ±2 mm, ensuring smooth and stable operation without jitter. This system greatly facilitates the feeding, discharging, and cleaning operations: during feeding, the tank body can be lowered to the optimal height to avoid material splashing; during discharging, the tank body can be tilted (optional tilting function, tilting angle 0-30°) to ensure complete discharge without residue; during maintenance and cleaning, the homogenizing head can be lifted to a suitable height, allowing operators to easily disassemble, clean, and maintain core components such as the stator-rotor and scraper. The hydraulic system is equipped with overload protection and pressure relief devices, which can automatically cut off the power supply when the load exceeds the rated value, avoiding equipment damage and ensuring operator safety.
2. High-Shear Homogenizing Emulsification - Fine Texture & Stable Quality
The core component of the equipment is a high-speed high-shear homogenizing head, which adopts a 4-stage stator-rotor structure with a shear gap of 0.03-0.1 mm. The rotor speed can be steplessly adjusted within the range of 3000-15000 rpm, generating a maximum shear rate of 100000 s⁻¹. Under high vacuum conditions (vacuum degree ≤ -0.095 MPa), the homogenizing head can quickly break down oil droplets and water droplets into micro-droplets (average particle size 0.1-3 μm), and disperse them evenly in each other to form a stable emulsion system. The fine particle size distribution (polydispersity index PDI ≤ 0.16) ensures that the cosmetic cream and lotion have a smooth, delicate texture and good skin penetration. At the same time, the high-shear force can promote the uniform dispersion of powder additives (such as titanium dioxide, zinc oxide) and functional ingredients (such as hyaluronic acid, plant extracts) in the emulsion, avoiding agglomeration and improving the utilization rate of raw materials.
3. Vacuum Mixing & Deaeration - Anti-Oxidation & Bubble-Free
The equipment is equipped with a high-performance rotary vane vacuum pump (or roots vacuum pump, optional) and a fully closed mixing tank, which can quickly extract the air in the tank, maintaining a high vacuum environment (vacuum degree ≤ -0.095 MPa) during the entire production process. This not only avoids the introduction of air bubbles during mixing and emulsification, preventing the product from turning white, rough, or deteriorating due to bubble residues, but also effectively isolates oxygen, preventing the oxidation of easily oxidized raw materials such as vegetable oils, essential oils, vitamins, and plant extracts. For cosmetic products containing active ingredients, the vacuum environment can extend the shelf life by 30-50% compared to normal pressure production. In addition, the vacuum system is equipped with a precision filter and a check valve, which can prevent material backflow and pump damage, ensuring the stable operation of the equipment.
4. Multi-Mode Mixing System - Uniform Integration of Complex Materials
The equipment adopts a three-dimensional multi-mode mixing system, consisting of a frame-type mixing paddle, a scraper paddle, and a bottom high-shear homogenizing head, realizing all-round and dead-angle-free mixing of materials. The frame-type mixing paddle (speed 10-100 rpm) is suitable for mixing high-viscosity materials (50-100000 mPa·s), ensuring the overall uniformity of the material system; the scraper paddle is closely attached to the inner wall of the mixing tank (adjustable tightness), continuously scraping off the materials adhered to the wall, avoiding local overheating or under-processing caused by material adhesion, and ensuring that all materials are involved in the mixing and emulsification process; the bottom homogenizing head cooperates with the upper mixing paddle to form a circulating mixing effect, further enhancing the uniformity of the emulsion. This multi-mode mixing system can adapt to the production requirements of complex cosmetic formulas, including water phase, oil phase, powder additives, and functional ingredients, realizing the uniform integration of various raw materials.
5. Precise Temperature Control - Protection of Active Ingredients
Cosmetic raw materials such as vitamins, plant extracts, and peptides are highly sensitive to temperature, and excessive temperature will cause the degradation and failure of active ingredients. The equipment is equipped with a jacketed mixing tank and an intelligent temperature control system, which can realize precise control of the material temperature within the range of 5-95℃, with a temperature fluctuation accuracy of ±0.5℃. The temperature control system supports two modes of heating and cooling: heating is realized through electric heating (power 2-45 kW) or steam heating (optional), with over-temperature protection function; cooling is realized through circulating cooling water, which can quickly cool the materials to the required temperature. During production, the temperature can be adjusted according to the formula requirements: for heat-sensitive ingredients, the temperature can be controlled at 30-40℃ to ensure their activity; for melting solid oils and waxes, the temperature can be raised to 60-80℃ to ensure complete melting. The precise temperature control effectively guarantees the efficacy and stability of cosmetic products.
6. Hygienic Design - Compliance with GMP & FDA Standards
The equipment adopts a fully closed structure and uses cosmetic-grade and food-grade materials that meet GMP and FDA standards. The mixing tank, stator-rotor, scraper, feeding port, discharge port, and all parts in contact with materials are made of 316L stainless steel, with a mirror-polished inner surface (surface roughness Ra ≤ 0.4 μm), which is corrosion-resistant, easy to clean, and avoids material adhesion and bacterial growth. The equipment is equipped with a CIP (Clean-In-Place) automatic cleaning system, which is equipped with 360-degree rotating cleaning nozzles inside the mixing tank, and can complete the cleaning of the tank body, pipelines, homogenizing head, and other components within 20-30 minutes without dead corners. The sealing parts are made of food-grade silicone rubber or PTFE materials, which are non-toxic, odorless, and compatible with various cosmetic raw materials, ensuring no cross-contamination between different batches and different types of products.
7. Intelligent Control System - Easy Operation & Stable Production
The equipment is equipped with a PLC touch screen control system, with a 10-inch color touch screen (optional 7-inch) and Chinese/English bilingual interface, which is easy to operate. The control system can realize real-time monitoring and precise control of hydraulic lifting, mixing speed, homogenizing speed, temperature, vacuum degree, working time, and other parameters. It supports parameter storage (up to 50 sets of formulas), and operators can directly call the stored parameters when producing the same product, avoiding manual adjustment errors and ensuring the consistency of batch production. The system is equipped with multiple protection functions, including overload protection, over-temperature protection, vacuum abnormal protection, emergency stop function, and hydraulic system pressure protection, which can automatically alarm and shut down when abnormal conditions occur, ensuring the safety of equipment and operators.
