Case Study of a Customized External Circulation Homogenizing Vacuum Emulsifier for a Philippine Client |High Automation Solution with PLC Touch Screen
A cosmetics and daily chemical product manufacturer from the Philippines customized a high-configuration vacuum emulsifying machine from us to improve the production efficiency and stability of its emulsions and creams. The client had high requirements for the homogenization effect, automation level, and production stability, so several customized upgrades were made to the standard vacuum emulsifier. The most crucial improvement was upgrading the traditional bottom homogenizing structure to an external circulation homogenizing system. High-shear homogenization is achieved through external material circulation pipelines, resulting in more uniform and delicate emulsification, reducing dead zones, and improving overall processing efficiency.
Furthermore, the equipment is equipped with a PLC touch screen control system, enabling parameter setting, temperature control, stirring speed adjustment, and production process monitoring, significantly enhancing the automation level. The entire system operates stably and is easy to operate, achieving a high degree of repeatability in formula production, helping the client improve product quality consistency.
Our technical team followed up on the entire project, from needs assessment and solution design to production commissioning. After delivery, the client reported excellent emulsification results and significantly improved production efficiency, successfully meeting their large-scale production needs and providing a reliable guarantee for upgrading their product quality.
I. Project Background
A Philippine company specializing in skincare product manufacturing, primarily producing creams, lotions, serums, and ointments, found its existing equipment increasingly inadequate in terms of emulsification fineness, production efficiency, and automation control, due to growing market demand. Particularly in the production of high-quality skincare products, higher requirements were placed on emulsification uniformity and stability. Therefore, the client decided to purchase a high-performance vacuum emulsification machine.
After comparing multiple suppliers, the client ultimately chose to cooperate with us, and requested customized solutions for their production processes.
II. Customized Equipment Solution
Based on the client's production processes and product characteristics, we designed a customized vacuum emulsifier solution. The equipment underwent the following key upgrades based on the standard configuration:
1. External Circulation Homogenization System
Traditional vacuum emulsifiers typically employ a bottom homogenization structure, while this project replaced the bottom homogenization with an external circulation homogenization design. Materials enter the high-shear homogenizer through circulation pipes and then flow back to the main pot for further mixing.
This design offers several advantages:
Improved emulsification uniformity and fineness
Reduced dead zones within the equipment
Increased material circulation efficiency
Suitable for the production of high-viscosity cream products
Through external circulation homogenization, materials can continuously undergo high-shear emulsification, resulting in finer and more stable product particles.
2. PLC Touchscreen Intelligent Control System
The equipment is equipped with an advanced PLC control system and a touchscreen operating interface, allowing operators to easily complete various operations, including:
Temperature control
Stirring speed adjustment
Homogenization speed control
Vacuum monitoring
Production process parameter recording
This system significantly improves the automation level of the equipment while reducing human error, making the production process more stable and reliable.
3. Highly Automated Production Design
The entire equipment achieves integrated automatic control from heating, stirring, emulsification to vacuum degassing. By preset production parameters, the equipment can automatically complete the production process, improving production efficiency and ensuring consistent product quality.
III. Equipment Application Results
After installation and commissioning, the customer immediately put the equipment into production. According to customer feedback:
Product emulsification fineness is significantly improved.
Cream texture is more delicate and stable.
Production efficiency increased by approximately 30%.
Operation is simpler, reducing labor costs.
At the same time, the PLC system makes production management more intelligent, and production data is easier to record and trace.
IV. Customer Feedback
The Philippine customer expressed high satisfaction with the overall performance and stability of the equipment. In particular, the design of the external circulation homogenization system effectively solved the emulsification problem for their high-viscosity skincare products, further improving product quality.
In the future, the customer plans to expand production and is considering purchasing more vacuum emulsification equipment to meet growing market demand.
You May Also Like
Automatic Acid Chemical Plastic Bottle Capping Anti Corrosion Bleach Filling Machine
This machine is specifically designed for filling highly corrosive liquids such as acids, alkalis, disinfectants, and pesticides. Wetted parts are constructed from corrosion-resistant materials like PTFE and PP, while fluoroelastomer seals prevent leakage and corrosion. Equipped with an intelligent PLC control system and a gear pump for precise metering, it accommodates various plastic bottles and containers. The machine features an overall anti-corrosion design and supports submerged filling to minimize foaming; it is easy to disassemble and clean, making it ideal for production lines in the personal care, fine chemical, and disinfectant industries. It offers stable, durable performance and safe operation.
Fixed Type Vacuum Mixing Emulsifying Equipment for Cosmetic Cream Ointment Lotion Vacuum Homogenizer Mixer
The fixed vacuum emulsifier is an industrial device designed specifically for homogenizing and emulsifying high-viscosity materials. It utilizes a fixed installation structure and features a high-efficiency vacuum system, which rapidly removes air bubbles from materials within a closed environment, preventing oxidation and ensuring product smoothness and stability.
Equipped with a high-speed homogenizing head, it uses strong shear forces to micronize materials to a fine level, achieving uniform mixing of different ingredients and easily preparing products such as creams, lotions, and gels. Furthermore, the device integrates intelligent temperature control and wall scraping and stirring functions to precisely control process temperatures, eliminating material adhesion and dead corners. It meets the production needs of various industries, including cosmetics, pharmaceuticals, and food, and offers both efficiency and reliability.
Automatic Labeling Machine Best Selling Automatic Tabletop Flat Surface Labeling Machine Round and Flat Bottle Automatic Labeler Machine
This universal labeling machine for round and flat bottles is suitable for labeling round, flat, single-sided, or double-sided bottles. Its rational overall design and ease of operation allow for flexible adjustment of different bottle shapes. Its highly elastic scraper and unpowered sponge wheel ensure zero anaerobic bubble generation. The machine's mechanical structure features a reinforced rigidity design, resulting in a simple, elegant, and stable design. The entire machine is constructed entirely of 304 stainless steel and aluminum alloy, with standardized components for interchangeability. The label feed mechanism utilizes an aluminum alloy structure with a sanded surface for a polished, clean finish and easy maintenance. The feed chain is imported, offering excellent strength, durability, easy cleaning, and excellent GMP compliance. This machine can operate as a stand-alone unit or as part of a production line.
Utilizing cutting-edge technologies and high-performance actuators, it utilizes servo motors for enhanced labeling accuracy. The system utilizes a Siemens programmable controller for closed-loop control of the servo motors, coupled with a large human-machine interface. The PLC incorporates over 100 memory banks for quick replacement. The sensor sensors are high-quality, manufactured in Japan or West Germany.
Storage Tank Mobile Fixed Chemical Liquid Storage Tank for Cosmetic, Perfume Food Grade Storage Tank Sealed Open Container
Designed and manufactured in accordance with GMP standards, the tank body is available in SUS316L or SUS304. The interior and exterior are mirror-polished, and the tank body features corner welds for easy cleaning. The sealed type head is equipped with a manhole, spray balls, etc., and can be connected to CIP cleaning, feeding holes, and discharge holes.
The open style features a half open lid that is convenient for cleaning. Liquid level measurement, heating, and cooling systems are also available upon request. These tanks are suitable for storing liquid products such as creams and lotions.
Get in touch with FULUKE
If you have any comments or good suggestions, please leave us a message, later our professional staff will contact you as soon as possible.
A leading manufacturer specializing in advanced machinery and complete production lines for the cosmetics, food, pharmaceutical, and chemical industries worldwide.
Contact FULUKE
Facebook
Instagram
YouTube