Custom FRM-20 high-speed mixer — cosmetics multi-component powder spray mixing trial. Mixing at 4000 rpm/ 60 m/s blade tip speed after spraying.
A multi-component cosmetics powder blend was processed on a custom FRM-20 fitted with a spray nozzle. The customer required zero visible color variation on spatula scrape inspection — the standard acceptance criterion for pressed-powder formulations. The unit ran at 4000 rpm (140 Hz overclocked), reaching a blade tip speed of 60 m/s. Vortex circulation mixing distributed the spray liquid uniformly through the full powder mass. Acceptance was passed; the entire batch discharged cleanly with minimal residual material on vessel walls.
Challenge
Cosmetics powder formulations combine multiple components — mineral bases, pigments, pearlescents, and fillers — each with distinct particle size and bulk density. Achieving micro-scale liquid distribution across this heterogeneous system is critical; color banding at the spatula level is a direct rejection criterion.
Conventional paddle or ribbon mixers generate macro-scale flow only. Liquid binders added via external top-spray settle unevenly; dead zones near vessel corners retain dry powder. These defects produce color streaks detectable by spatula inspection — the failure mode this trial was designed to address.
Solution
A custom FRM-20 high-speed mixer from Taixian, equipped with an integrated spray nozzle, was configured for this trial. The spray nozzle injects liquid into the powder bed during the low-speed mixing phase. The rotor then accelerates to 4000 rpm for the post-spray phase — vortex circulation mixing drives the liquid to microscale distribution throughout the powder mass.
Material
| Parameter | Value |
|---|---|
| Material type | Multi-component cosmetics powder blend |
| Pigment / filler composition | Confidential |
| Liquid binder identity | Confidential |
| Batch size | Confidential |
| Acceptance criterion | No color variation on spatula scrape test |
Equipment
| Parameter | Value |
|---|---|
| Manufacturer | Taixian |
| Model | Custom FRM-20 |
| Configuration | Integrated in-vessel spray nozzle |
| Drive | Variable-frequency, overclocked to 140 Hz |
| Vessel design | Arc-bottom, no dead zones; 360° wall contact |
| Discharge | Bottom bucket-type outlet |
Process Parameters
| Parameter | Value |
|---|---|
| Drive frequency | 140 Hz (overclocked; standard 50 Hz) |
| Rotor speed | 4000 rpm |
| Blade tip speed | 60 m/s |
| Spray dosing rate | Confidential |
| Mixing duration | Confidential |
| Vessel temperature control | Water-jacket cooling |
Procedure
The process followed a 2-phase sequence: low-speed powder blending and liquid spray, then high-speed post-spray homogenization.
- Pre-mixed the dry powder charge at low speed to establish macro-scale uniformity before liquid contact — ensuring a consistent base state across all components.
- Activated the integrated spray nozzle at low speed; liquid was injected at a controlled rate into the rotating bed — preventing local agglomeration at the nozzle point.
- Completed spray dosing and shut off the nozzle; the powder mass was fully wetted at this stage.
- Increased rotor speed to 4000 rpm, reaching 60 m/s blade tip speed — sustained high-speed vortex circulation drives micro-scale homogenization beyond what low-speed spray distribution alone achieves.
- Discharged via the bottom bucket-type outlet; the full batch poured out cleanly — the arc-bottom vessel geometry eliminated dry dead zones.
Achievement
The batch passed customer acceptance at 60 m/s and 4000 rpm. Spatula scrape inspection showed no visible color variation across the discharged powder mass — confirming that vortex circulation mixing achieved micro-scale liquid distribution.
Operation at 140 Hz — well above the standard 50 Hz supply — demonstrated stable performance without discharge anomalies. The bottom bucket-type outlet allowed the full batch to pour cleanly, with negligible residual powder on the vessel surface.
Note: Color uniformity was assessed by visual spatula inspection per the customer’s acceptance protocol. Quantitative colorimetric data (e.g., ΔE) were not collected in this trial.
| Parameter | Conventional Mixer | Custom FRM-20 Trial |
|---|---|---|
| Liquid addition | External top-spray, uneven distribution | Integrated nozzle and post-spary mixing at 4000 rpm |
| Blade tip speed | Not documented | 60 m/s |
| Mixing mechanism | Macro-scale tumbling | Vortex circulation mixing |
| Spatula scrape result | Color variation present (customer concern) | No color variation — acceptance passed |
| Discharge residual | Dry pockets in vessel corners | Full-barrel pour, minimal residue |
Tags
#CosmeticsPowderMixing #MultiComponentBlending #LiquidSprayMixing #PigmentDispersion #PowderHomogeneity
#TaixianFRM20 #FRMHighSpeedMixer #CustomHighSpeedMixer
#VortexCirculationMixing #HighSpeedMixing #SprayAssistedBlending #InVesselSpray
#HosokawaAlternative #HenschelMixerAlternative #RibbonMixerAlternative
#PressedPowderProduction #LoosePowderManufacturing #SunscreenFormulation #CosmeticsRD
Enquiry
Tell us your material, target particle size, and throughput. We will advise on
model selection and run a trial on your own powder before you commit to equipment.
Yibin Andy Wei — Application Engineer
Email: [email protected]
LinkedIn: Yibin Andy Wei
WhatsApp: +1 380 900 2442