Hielscher Ultrasonics
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Ultrasonic Mixing for the Cosmetic Industry

Hielscher sonicators are used in the cosmetics industry for manifold processes, e.g. for the manufacturing of lotions, sunscreen, creams, gels or ointments. Probe-type sonicators play a crucial role in enhancing the quality, stability, and efficacy of cosmetic and beauty products. Their ability to finely control particle size, improve ingredient mixing, and facilitate the formation of advanced delivery systems makes them indispensable in modern cosmetic formulation processes.
 

Improve the Production of Cosmetic and Skin Care Producti with Sonication

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Ultrasonic emulsification is used to produce skin care products such as creams and lotions with a high load of active substances.

Ultrasonicator with glass flow cell for the inline mixing and emulsification of creams, lotions and other skin care products.

 

The video shows the highly efficient emulsification of oil. The ultrasonic processor used is a Hielscher UP400St ultrasonicator, which is ideal to prepare medium size batches of high-quality emulsions.

Video: UP400St - 400 Watts Ultrasonic Homogenizer

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Applications of Probe-Type Sonicators in Cosmetic and Beauty Product Production

Probe-type sonicators, also known as ultrasonic homogenizers, are widely used in the cosmetic and beauty product industry due to their ability to efficiently mix, emulsify, disperse, and dissolve ingredients. Here are some key applications:

  1. Emulsification:
    • Creams and Lotions: Sonicators are used to create stable emulsions, blending oil and water phases to form smooth creams and lotions. The high-frequency sound waves generated by sonicators help in breaking down droplets into fine particles, ensuring a uniform and stable emulsion.
    • Serums and Gels: For products like serums and gels, sonicators facilitate the dispersion of active ingredients, ensuring even distribution and enhanced stability.
  2. Dispersion of Nanoparticles:
    • Nanoemulsions: Sonicators are crucial in the formation of nanoemulsions, where they reduce the size of emulsion droplets to the nanometer scale. This improves the texture, appearance, and penetration of the product into the skin.
    • Suspensions: They help in the uniform dispersion of pigments, clays, and other solid particles in suspensions, enhancing the consistency and performance of the final product.
  3. Liposome and Niosome Formation:
    Delivery Systems: Sonicators aid in the preparation of liposomes and niosomes, which are vesicles used as delivery systems for active ingredients. These systems improve the bioavailability and efficacy of active compounds, making the products more effective.
  4. Extraction of Active Ingredients:
    Botanical Extracts: Ultrasonic extraction is an efficient method for obtaining active compounds from botanical sources. It enhances the yield and purity of extracts, which are then used in formulations for their beneficial properties.
  5. Deagglomeration:
    Pigments and Fillers: Sonicators break down agglomerates of pigments and fillers, ensuring a uniform distribution within the product. This results in a smoother texture and more consistent color in makeup products.
  6. Degassing:
    Bubble Removal, De-Aeration: Sonicators can remove dissolved gases and bubbles from liquids, which is essential in preventing the formation of air pockets in gels, creams, and other formulations. This results in a smoother product texture and improved stability.

The formulation of new cosmetic products involves many processing challenges, e.g. stable nano-emulsification of oil- and water-phases, dispersing and dissolving. Hielscher Ultrasonics offers powerful and reliable ultrasonic mixing equipment for use in both, laboratory research and industrial production.
 

The video is demonstrating ultrasonic dispersion of red color using the UP400St with a S24d 22mm probe.

Ultrasonic Red Color Dispersion using the UP400St

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Ultrasonic Mixers for the Cosmetic Industry

Ultrasonication can be scaled up easily. Laboratory tests will allow to select the required equipment size accurately. The table below shows general device recommendations depending on the batch volume or flow rate to be processed.

Batch Volume Flow Rate Recommended Devices
1 to 500mL 10 to 200mL/min UP100H
10 to 2000mL 20 to 400mL/min UP200Ht, UP400S
0.1 to 20L 0.2 to 4L/min UIP1000hd, UIP2000hd
10 to 100L 2 to 10L/min UIP4000hdT
n.a. 10 to 100L/min UIP16000
n.a. larger cluster of UIP16000

Inline Processing – Streamline your Production with Power Ultrasound

Discrete Recirculation for UltrasonicationHielscher ultrasonic reactors are commonly used in-line. The material is pumped into the reactor vessel. There it is exposed to ultrasonic cavitation at a controlled intensity. The exposure time is a result of the reactor volume and the material feed rate. Inline sonication eliminates by-passing because all particles pass the reactor chamber following a defined path. As all particles are exposed to identical sonication parameters for the same time during each cycle, ultrasonication typically shifts the distribution curve rather than widening it. Generally, “right tailing” can not be observed at sonicated samples.

Process Cooling during Sonication

For temperature-sensitive formulations, Hielscher offers jacketed flow cell reactors for all laboratory and industrial devices. By cooling the internal reactor walls, process heat can be dissipated effectively.
Read more about temperature control during sonication!

Robust and Easy to Clean

Ultrasonic Flow Cell Reactor made of stainless steel for the sonication of liquids.Hielscher ultrasonic mixing reactor consist of the reactor vessel and the ultrasonic sonotrode (also known as ultrasonic horn, probe or rod). This is the only part, that is subject to wear and it can be easily replaced within minutes. Oscillation-decoupling flanges allow to mount the sonotrode into open or closed pressurizable containers or flow cells in any orientation. No bearings are needed. Flow cell reactors are generally made of stainless steel and have simple geometries and can easily be disassembled and wiped out. There are no small orifices or hidden corners. Special flow cell reactors meeting the advanced CIP (clean-in-place) and SIP (sterilize-in-place) requirements are available, too.

Ultrasonic Cleaner in Place

The ultrasonic intensity used for dispersing applications is much higher than for typical ultrasonic cleaning. Therefore the ultrasonic power can be used to assist cleaning during flushing and rinsing, as the ultrasonic cavitation removes particles and liquid residues from the sonotrode and from the flow cell walls.

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Please use the form below to request additional information about our sonicators for sin care production, application notes, technical data and a non-binding quotation. We will be glad to discuss your mixing process with you and to offer you the ideal sonicator fulfilling your requirements!









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Sonication in Cosmetic Research and Analysis

Hielscher ultrasonic laboratory devices are ideal for research and development as well as for routine processes such as analysis and quality control. Sonicators like the handheld UP100H are suitable for manifold applications, e.g. mixing, dispersing, emulsifying, homogenizing, botanical extraction or dissolving. The laboratory devices are easy to use, and have an unmatched efficiency and flexibility. Ultrasonic lab sonicators are typically used for capacities from 1mL to 2 liters. Hielscher ultrasonicators offer accurate process control and excellent reproducibility for the scale up to production scale. Automatic amplitude control and frequency tuning is invaluable for process validation and repeatability. That is why, this feature is integrated in all Hielscher ultrasonic devices.

Adding oil to water under sonication to make a nano-size oil-in-water emulsion using a probe type sonicator UP400St

Making an Oil-in-Water Emulsion using the Sonicator UP400St



High performance ultrasonics! The Hielscher product range covers the full spectrum from the compact lab ultrasonicator over bench-top units to full-industrial ultrasonic systems.

Hielscher Ultrasonics manufactures high-performance ultrasonic homogenizers from lab to industrial size.

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