The development of cosmetic product formulation involves different operational parameters such as mixing, heating/cooling, dispersing, emulsifying, dissolving, and many more steps to ensure a homogeneous end product with aesthetic appeal. Traditional reactors are always difficult to set up and are not flexible enough to meet the changing demands of new projects. Often, better temperature control and active cooling are not up to the mark. To cope with these shortcomings, formulation chemists have to manage different devices and transfer the sample from one device to another device which leads to low reproducibility, longer duration and end up with scale up issues.
The Solution
IKA designed an innovative Lab Reactors (LR 1000 and LR 2.ST) to provide ‘one stop solution’ to formulation chemists. Lab reactor is a system which is suitable for optimizing operational parameters and to ensure successful reproduction of chemical synthesis, mixing, dispersion, emulsion, suspension and homogenization at the laboratory level. This system is especially suitable for the development of new product formulation. Lab reactors can perform most of the tasks involved in formulation and process development, including production of creams, lotions, ointments & pastes (emulsions & suspension) and incorporating & wetting of hydrocolloids, solids in liquids (gel, sticks) as well as the grinding and disintegrating /particle size reduction of solids or fibers in liquid (solutions & suspensions). Its versatile features make IKA LAB REACTORS suitable for Pharmaceutical, Personal Care & Cosmetics, Food and Chemical products. Working Principle
The lab reactors combine all vital functions in a single platform viz, i. Integrated anchor stirrer for mixing of high viscosity media, ii. Homogenizer for deagglomeration, suspension and emulsification process, iii. Easy to work under vacuum operation and built-in heating system for better temperature control. User can monitor the changes in 22
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pH and temperature by the sensors. Besides, the system has torque trend measurement that helps to identify the rheological changes in the product. Additionally, Lab reactor can be controlled and the parameters can be documented by using the Labworldsoft® software. Application Example-1: BB Cream Cushion
BB cushion compact is a small refillable foundation soaking into a cushion or sponge that one can use a special puff to gently dab the foundation onto the skin. BB cushion can improve skin complexion merely in few minutes time. This feature makes Cushion Compact one of the hottest makeup trends from South Korea. Initially, oil phase and aqueous phase are to be heated separately up to 85°C. Then the aqueous phase is poured into oil phase and mixed well in LR 1000 Control Lab Reactor. Silty material is then added into the mixture, and the mixture to be dispersed with Ultra Turrax T25 Disperser and mix temperature is maintained at 80°C. Stirring speed is increased for 5 minutes and the mixture is stirred until the temperature drops down to 40°C, thereafter fragrance is added into the mixture. Appplication Example-2: Facial Cleaser
A cleanser is a facial care product that is used to remove make-up, dead skin cells, oil, dirt, and other types of pollutants from
the skin of the face. This helps to unclog pores and prevent skin conditions such as acne. In the beginning, oil phase and aqueous phase are to be heated separately up to 75°C. Then the aqueous phase is poured into oil phase slowly and mix homogenously in LR 1000 control Lab Reactor. RC 2 Basic Chiller connected to LR 1000 control lab reactor helps to cool down the final emulsified product – facial cleanser to 30°C. Thereafter, heat sensitive ingredient is added into the mixture and stirred rapidly to mix well. High viscous, smooth apperance and homogenous product collected. MVP 10 Vacuum Pump is utilized throughout the whole process for degassing the product. IKA Application Support Team
Over a period of several years, IKA could able to try some of customers’ most difficult and complex formulations in the Lab Reactors. In all those cases, outcomes were extremely pleased. During product scale-up from laboratory to pilot/full scale production, a significant amount of time can be saved, if the correlation between laboratory reactors and production vessels is clearly understood. IKA has various types of agitator configurations to ensure its customers get the best results in terms of consistency and reproducibility.