Manufacturing Sunblocks and Creams
The manufacturing of sunblock creams and lotions has been on a steady increase in recent years as a result of increased awareness on the effects of ultra-violet rays (UV) and the exposure to skin. Increased awareness has created the requirement for specialty products such as water resistant formulas, infant formulas, and increased sun protection factors (SPF) formulas. Manufacturing techniques play an important role in adapting to the changing market to meet the requirements of the consumer while maximizing the performance of the ingredients. Manufacturing sunblock creams and lotions involves either oil-in-water or water-in-oil emulsions. Typical ingredients include emollients (smoothing agents), lubricants, emulsifying and thickening agents, perfume, color, preservatives and UV filters and absorbers such as titanium dioxide or zinc oxide. In the case of the latter ingredients, UV protection is directly related to the dispersion quality and particle size on the UV filters and absorbers.
Most sunblock products are produced in the following manner:
Using conventional mixers and agitators several challenges arise:
Quadro Liquids Solution
Quadro recommends the combined use of a Ytron ZC Powder Disperser and a Ytron Jet Mixer. The ZC is designed to disperse extremely difficult to wet powders in a single pass without lumps or "fisheyes".
The powder incorporation can be completed during the addition of water or oil phase to the processing vessel or in a recirculation loop from the vessel. Powder incorporation is achieved by the presence of significant vacuum in the reactor generated by a liquid ring seal created between the rotor and stator. The powders are then subjected to enough shear to provide a complete dispersion in a single pass before returning to the processing vessel. The second phase is added to the vessel and the Jet Mixer provides a good top to bottom turnover of the tank ingredients to ensure a homogeneous blend and a finished emulsion.
ZC Powder Disperser Advantages