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Scalable Technology for Cosmetic Manufacturing

Dr. Yang Su, of the Microfluidics team, recently offered an insightful webinar focused on cosmetic manufacturing and methods of gaining competitive advantages through stable nanoemulsions, liposome formations, and other applications.

The topic of the webinar discussed:

A Scalable Technology for Cosmetic Manufacturing

Covering a broad scope of cosmetic manufacturing issues, this webinar not only explored achieving contamination-free, small formulations but it also examined duplicating these high-caliber results to large-scale commercialization.

This webinar explored pressure profile impact, uniform treatments and the differences between constant pressure versus constant volume. All these factors contribute significantly to creating an efficient process for a constant and repeatable solution.

Microfluidizer® technology is an effective solution for achieving small particle sizes and uniform particle size distributions. Uniform size and distribution considerations including target properties (such as physiochemical properties), repeatability from batch-to-batch and scalability across lab and production volumes were explained. Other factors such as easy downstream processes (i.e. sterile filtration) and the ability to meet regulation requirements (such as cGMP) were examined.

Microfluidizer® processors achieve and sustain peak pressure significantly longer than traditional homogenizers and therefore results in significantly greater particle size reductions while using less energy and fewer passes thereby saving time.

Questions From Our Webinar

During the webinar, Dr. Su answered questions from the audience. Below is an abbreviated version of each answer with the timestamp where the full explanation can be found on the webinar.

  1. How can Microfluidics be used in large scale industrial production? (47:00)
    Microfluidics has designed a range of products with a pumping system for a higher throughput with the same Interaction Chamber™ system. By maintaining the same Interaction Chamber™ and increasing the number of channels, results should be the same. 
  2. Is there a viscosity limitation to using our tools? (49:00)
    There is a wide range of viscosity level considerations and transfer issues that should be addressed. The pump is powerful enough to process a higher viscosity. For benchtop, we would generally process liquids but some other substances such as ink are also processed.
  3. Is temperature control possible? (51:10)
    Benchtop and large-scale processors have temperature control capabilities. All of our equipment has cooling capabilities with the cooling coil or heat exchanger. Some have options for better control. Larger systems all have cooling capabilities, and some have closed loop temperature control by regulating of coolant flow rate.
  4. Which parameters need to be controlled for particle size and how can Microfluidics assess uniformity? (53:00)
    There are parameters which determine particle size and parameter which can also be used to achieve the desired particle size. Our constant pressure and the design and dimension of the Interaction Chamber are key. Pressure, shear rate, chamber size of micro-channels will impact along with temperature control and passes.  The measure of the particle size and the width of the curve (polydispersity index – or PdI) in particle size analysis will best show uniformity.
  5. Can the channel withstand the high pressure considering the viscous flow? (55:45)
    Yes, the channel is designed to withstand pressures up to a maximum of 30,000 psi. Microfluidics also offers a diamond Interaction Chamber for great wear resistance and a long processing life.
  6. Is this same emulsion and dispersion technology applicable for solid lipid nanoparticles? (57:00)
    Yes, it is although the system will need to be used by heating the lipid so it becomes a liquid form which can be dispersed in an aqueous phase which can be processed through our system like an emulsion. A more thorough explanation of the processing procedure is provided.
  7. To achieve a water-based emulsion, can you address the challenges of surfactants? (57:58)
    In general, the technology can be used in oil-in-water and water-in-oil emulsions. Of particular importance is stability, water-oil ratio and surfactant issues which will need to be fine-tuned along with the processing conditions.
  8. How does Microfluidics encapsulate active ingredients into liposomes? (59:25)
    There are various ways based on how the liposome is formulated.  This is based on whether it is hydrophilic or hydrophobic. Microfluidics is highly efficient on both. For a detailed explanation on both, go to our webinar.
  9. For scale up, when you use the microchannels, how do you ensure the flow behavior (particularly the flow rate and pressure) is the same in the different channels? (1:00:01)
    Extensive work has been applied to the design of the microchannels with consideration of maintaining the pressure. For a multi-slotted production machine, carefully choosing the appropriate number of channels is critical to ensuring that the machine can maintain the pressure. Therefore, by maintaining the constant pressure, we know that the pressure and conditions will be the same. This technology has been proven time and again based on the data from our customers.


Case Studies of this Discussion Included: 

  • Solvent-free perfume
  • Specialty shampoo
  • Liposomal serum
  • Cell lysis for cosmetic application

To learn more about this subject, contact us directly.

Related reading:

Speak to our team to learn more Please contact us to discuss this subject further or ask a question
Posted by Cathy Silva


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