High standards on cosmetics manufacturing

The production of cosmetics, particularly skin powders, requires advanced process engineering. When producing face powder, eyeshadow, makeup or bleaching powder in modern cosmetics production, a wide variety of raw materials have to be processed quickly, homogeneously and in a gentle manner.

A typical feature of cosmetics production is the combination of components that vary greatly in quantity. While the carrier material makes up most of the product, colour pigments are often used only in very small quantities. However, precise mixing of colour pigments is crucial for achieving the desired colour intensity, homogeneity and reproducibility of the product.

Challenges in the manufacture of colour pigments and powders

Cosmetic powder products consist of several ingredients with very different physical properties. As well as carrier materials and colour pigments, they also contain effect pigments, binding liquids and sensitive additives such as mica (CI 77019).

The manufacturing and processing of colour pigments is a complex process involving several challenges:

• Fast and homogeneous mixing of micro and macro components
• Clean dispersion of pigment agglomerates
• Uniform, speckle-free distribution of binding liquids
• Careful processing of delicate or valuable raw materials
• Controlled temperature to prevent colour changes

These requirements apply to both the production of cosmetics and bleaching powder production where the uniform distribution of active ingredients is essential.

Use a Ploughshare® Mixer

The horizontal Ploughshare® Mixers of make LÖDIGE are practice proven for these demanding applications. Operating in batch operation, they enable all cosmetic production processes to be carried out in a single machine, providing clear advantages in terms of efficiency, product quality and flexibility.

Learn more about the Ploughshare® Mixer of type FKM

The fluid bed process developed by LÖDIGE ensures high energy input and intensive mixing. This achieves both the production of colour pigments and their homogeneous mixing into the carrier material in a reliable manner. Liquids and additives are gently introduced via airless nozzles, making the use of a complex air-assisted nozzle unnecessary.

With a total volume of 130 or 300 litres, these small machines are ideal for production lines with frequently changing recipes, such as those used for face powder, eyeshadow and make-up. 

The cooling jacket has a large heat transfer surface enabling precise temperature control – a crucial requirement when working with heat-sensitive and colour-mixing pigments.

A patented mixing principle that ensures optimum product quality

The Ploughshare® Shovels which are arranged on a horizontal shaft are at the heart of the Ploughshare® Mixer. These shovels are designed to set the product mix in a three- dimensional motion, thus preventing dead spaces or zones with little movement.

This process is particularly suitable for sensitive materials as the product is constantly lifted from the wall of the drum. The Ploughshare® Mixer is ideal for producing cosmetics where consistent quality and gentle processing are top priorities.

For specific applications such as intensive pigment dispersion or the uniform distribution of binding liquids, additional high-speed choppers can be used.

 

Hygienic design of machinery:

Hygienic design is central to the manufacture of cosmetic machinery. The Ploughshare® Mixers are designed with hygiene in mind to prevent cross-contamination between product batches. 

 

Machine characteristics, for example:

• Minimal clearance between the mixing shovels and the drum wall
• Ground and polished stainless steel surfaces (Ra <0.8 µm).
• Electropolished surfaces for product contact parts on request
• Fully welded mixing shovels and choppers
• Air purge or mechanical face seals for the mixing shaft.

This design allows the product to be discharged from the machine with minimal residue and enables simple, reproducible cleaning. This is a decisive advantage when producing cosmetics with frequent recipe changes.

Conclusion: A flexible solution for producing cosmetic powders

Manufacturing cosmetics such as face powder, eye shadow and bleaching powder requires precise mixing technology, short process times and the highest hygiene standards. Homogeneous mixing of colour pigments, gentle dispersion of pigments and controlled temperature are particularly crucial for achieving a high-quality product.

The LÖDIGE horizontal Ploughshare® Mixers combine all the necessary process steps in one machine, providing an efficient, flexible and economical solution for cosmetics production. This type of mixers is practice-proven in the production of colour pigments as well as in the industrial production of bleaching powder and cosmetics.

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