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Silverson x Beauty Science Labs: Mixing Innovation in Cosmetic Formulation

Every luxurious face cream, every crystal-clear gel, every velvety lotion begins with the same challenge: combining ingredients that don’t naturally want to come together. How do professional formulators overcome this hurdle to create consistent, commercially viable products?

That’s exactly what Silverson Machines set out to demonstrate in partnership with Beauty Science Labs. In a series of hands-on demonstration videos filmed at Silverson’s Customer Resource Centre—what Technical Sales Engineer James Cardus calls “our indoor mixing playground”—Beauty Science Labs’ Principal Chemist Tumi Siwoku reveals the techniques and technology behind professional-grade cosmetic formulation.

A Partnership Built on Experience

For Tumi, a veteran formulator, Silverson equipment has been integral from the start.

“[Silverson] became a firm favorite when it came to emulsifying and creating new products because of the ease of use and how we were able to scale from lab to production with great ease.”
— Tumi Siwoku, Principal Chemist, Beauty Science Labs

Together, Tumi and James explore two fundamental cosmetic bases, a Hot Process Emulsion and a Cold Process Gel, demonstrating how Silverson Laboratory Mixers deliver the precision and control that turn good formulations into consistently great products.

Hot Process Method: Creating Stable Creams and Lotions

For many cosmetic formulations, the hot process method is essential, particularly when creating creams and lotions. By using controlled heat and precise mixing, this method successfully transforms two opposing elements, oil and water, into a cohesive, stable emulsion.

Demonstration: Emulsifying Oil and Water Phases at Temperature

Monitoring Temperature for Optimal Formulation

Before emulsification can occur, any waxes must be heated until fully melted and combined with any other ingredients in the oil phase. This typically happens around 70 °C (158 °F). The water phase is warmed to a similar temperature so both phases meet evenly, allowing them to combine without separating or shocking the mixture.

At this stage, the Silverson High Shear Laboratory Mixer plays a critical role. Its rotor/stator workhead generates intense shear, instantly dispersing the oil phase into the water phase to form a fine, uniform emulsion. After a stable base has formed, the batch is allowed to cool gradually. As the temperature falls, viscosity builds and the emulsion structure stabilizes.

“We all know that oil and water don’t mix,” Tumi explains. “Once there is an emulsifier within the oil phase, the Silverson allows us to homogenize and bring the two phases together.”
— Tumi Siwoku, Principal Chemist

Silverson Laboratory Mixers can also be fitted with a temperature probe that sits alongside the workhead directly in the product, with a digital readout on the head unit. This allows formulators to monitor temperature in real time throughout heating and cooling, critical for ensuring sensitive ingredients are added at precisely the right moment.

“The [Silverson] temperature probe is amazing because it allows us to understand the internal temperature of the system. And once it’s at the relevant temperature, we can then have that confidence to add all our preservatives, our fragrances.”

— Tumi Siwoku, Principal Chemist

Once the temperature drops below 40 °C (104 °F), formulators can safely incorporate the final components that define the product’s character: its fragrance, color, preservatives, and botanical extracts. Adding these ingredients too soon can compromise both performance and appearance:

Careful temperature control at this stage is key to preserving the integrity of these ingredients and achieving consistent results. With accurate temperature monitoring and the high shear efficiency of Silverson mixers, formulators can carry out a successful hot process method that delivers smooth, stable emulsions and repeatable results, giving confidence that each product will look, feel, and perform exactly as intended.

Cold Process for Crystal-Clear Gels

Unlike emulsions that require heating and cooling, gel formulations are built at ambient temperature. Some gels use polymers that thicken through simple hydration while others, like the pH-sensitive system demonstrated here, respond to chemical activation to develop viscosity. This cold process approach is the standard method for creating gels and surfactant systems like body washes and shampoos.

See It in Action: Achieving Clarity Without Aeration

Mixing Techniques for Gel Formation

In this demonstration, Tumi uses a pH-sensitive copolymer, which responds to the alkaline addition of a 10% sodium hydroxide solution to thicken the gel. Achieving the right viscosity and clarity is a delicate balancing act; too little shear and the polymer won’t fully activate, too much and unwanted air can become trapped in the system.

This critical factor highlights the importance of controlled mixing to avoid aeration, which can cloud an otherwise clear product. As Tumi notes:

“If we have the speed of our homogenizer up too high, we find that the air bubbles get trapped into the system, and then we have an aerated gel which affects the clarity.”

— Tumi Siwoku, Principal Chemist

With its infinitely variable speed control, the Silverson Laboratory Homogenizer Mixer gives formulators the fine-tuned control needed to strike that balance. The result is a smooth, crystal-clear gel ready for final customization with actives, fragrances, or colorants. With the right technique and Silverson’s precision control, formulators can achieve this level of clarity and consistency every time.

Shared Expertise in Formulation and Mixing

This collaboration highlights not only the capabilities of Silverson mixers but also the value of bringing formulation chemists and process engineers together. As Tumi reflects:

“There are so many different variables and factors that we can consider, and I really enjoy that Silverson have considered those things, which makes my scale up process so much easier.”

— Tumi Siwoku, Principal Chemist

Whether you’re developing skincare, haircare, personal care formulations, or other cosmetic applications, these demonstrations show how the Silverson Laboratory Mixer provides the precision and power needed to achieve consistent results with ease.



A big thank you to Tumi Siwoku for sharing her time, expertise, and insights, and for helping us showcase what’s possible when formulation and mixing innovation come together.

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Silverson Mixers Pave the Way for Scalable Graphene Production

New Research Highlights the Role of High Shear Mixing in Commercializing Graphene

Scientists at the forefront of graphene production research have identified mixing as a critical stage in scaling up this revolutionary nanomaterial from lab trials to commercial production. To tackle this challenge, they turned to Silverson Machines, a leader in high-shear mixing technology.

Scaling Graphene Production

Silverson’s L5M-A High Shear Laboratory Mixer played a significant role in groundbreaking research published in Nature Materials, titled “Scalable production of large quantities of defect-free few-layer graphene by shear exfoliation in liquids.”

Conducted at Trinity College Dublin’s Centre for Research on Adaptive Nanostructures and Nanodevices, the study demonstrated that high-shear mixing enables large-scale exfoliation of graphene from graphite while maintaining its structural integrity. Researchers selected Silverson mixers for their proven performance in dispersing carbon nanotubes and seamless scalability from lab to full production.

High Shear Graphene Production & Scale-Up at GEIC
“Previously we had used Silverson mixers to disperse carbon nanotubes, which had proved to be very effective.”
— Dr. Keith Paton, Researcher-in-Residence, Trinity College Dublin

The Graphene Revolution: Stronger, Lighter, and Thinner

Graphene, first isolated in 2004, has fascinated scientists and industries alike with its unparalleled strength, electrical conductivity, and extreme thinness—just one atom thick, one million times thinner than a sheet of paper. Its potential applications span a wide range of industries, including:

However, scaling graphene production for commercial applications has been a major challenge. Early research showed that graphite could be exfoliated into graphene by mixing, even in a kitchen blender. But achieving industrial-scale, defect-free production required specialized mixing technology.

“Scale-up can be a tricky problem for manufacturers. You need to be able to replicate your lab results on a large scale in production, and many specialized laboratory mixers have no production-scale counterparts.”

“At Silverson, we’ve designed, engineered, and constructed our laboratory mixers to the same tolerances as our production units. In fact, our entire range of mixers produces comparable rotor tip speeds and shear rates. And because of this, our machines produce scalable results.”

— Ian Snowball, Silverson Sales Engineer

Silverson Test Labs: A Key to Success

To ensure successful scalability, the research team worked with Silverson’s Applications and Testing Center in Chesham, England, where they conducted trials on various production-scale Silverson mixers to:

“The availability of the test labs at Silverson’s site, where we were able to test the scalability of the process, was a key advantage for the development of the process.”
— Dr. Keith Paton, Researcher-in-Residence, Trinity College Dublin

A Breakthrough in Scalable Graphene Production

The successful trials at Silverson’s facility demonstrated that high-shear mixing is a viable, industrially scalable solution for graphene production. The research team was able to develop industrially scalable methods for producing defect-free graphene using Silverson technology.

Snowball added:

“By coming to our Applications and Testing Center, the team was able to not only test the full range of our machinery but also tap into our scale-up knowledge. This is an area in which Silverson has a great deal of experience and has conducted thousands of applications research trials. We’re proud to be part of this successful project.”
— Ian Snowball, Silverson Sales Engineer

Advancing Graphene Commercialization

The research conducted at Trinity College Dublin, in collaboration with Silverson Machines, marks a significant step in bringing graphene from the lab to large-scale commercial applications. As industry demand for high-performance nanomaterials continues to grow, Silverson’s expertise in scalable high-shear mixing will remain at the forefront of innovation.

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Silverson High Shear Mixers More than a Match for High Active Surfactants

High Shear In-line Mixers Pose the Answer to High Viscosity Ingredients

Silverson Machines has released its latest “how-to” video demonstrating the benefits of high shear mixing to dilute high active surfactants, or Sodium Laureth Sulfate (SLES). This is a common ingredient used in personal care products, such as shampoo and bubble bath or cleaning products, such as liquid detergent. The video “How to Dilute SLES” joins a library of similar videos housed on Silverson.com, designed to aid formulators facing challenging industrial mixing situations.

High active surfactants are often sold at concentration levels of 65 to 70 percent, for greater economy when shipping or storing the ingredient. However, when employing a conventional system to dilute the surfactants with water, the disparity in viscosity between the two liquids causes stratification. Achieving a uniform mixture typically took a long time and yielded uncertain results, until now.

Uniform Blending and Aeration Free

The Silverson High Shear In-line Mixer ensures a uniform mix of SLES within water, in a fraction of the time taken by conventional methods, and often in a single pass. One key is to dilute the high active surfactant before adding other ingredients. The in-line mixer rapidly blends the water and surfactant either on a batch or continuous basis with an engineered design that incorporates an aeration-free process.

Silverson offers a complete line of high shear in-line mixers that can offer solutions for diluting high active surfactants for personal care products or manufacturers of cleansers, such as liquid detergents.

When complete, Silverson’s “How-To” video collection will feature dozens of high-quality, easy-to-understand videos. These videos including How to Dilute SLES can be viewed in the How-To Video Library. 

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Starch Dispersion a Snap with Silverson Mixing Equipment

Engineered to Eliminate Agglomerates for a Thorough Blend in Short Order

While native and modified starches might behave differently in the manufacturing environment, your mixing equipment should provide consistent results regardless of viscosity or ingredient form. Silverson Machines has released its latest “how-to” video, “How to Disperse Starch” on Silverson.com as part of a series of videos designed to aid formulators facing challenging industrial mixing situations.

Starch is used as a thickening, stabilizing and binding agent in many applications in the food and pharmaceutical industries. Various forms of starch can range from fine powders to granules or other varieties that may be difficult to hydrate. As starch is added to the liquid, viscosity increases. This can cause poor dispersion, lengthen mix times and result in agglomerates.

Full Hydration without Agglomerates

Silverson high-shear mixing equipment drastically reduces operator error and rapidly and thoroughly blends powders, such as starches even as viscosity increases. Achieve an agglomerate-free mixture in rapid order, maximizing yield of a fully-hydrated starch blend for greater uniformity between batches.

Silverson offers a complete line of high shear in-line mixers that can hydrate starch powders and granules thoroughly into liquid for uniform production runs time after time. Choose from the Silverson High Shear Batch Mixers, Ultramix, High Shear In-Line Mixers or the Silverson Flashmix. The Flashmix loads starch at floor level and is ideal for larger volume operations, for fast, effective hydration with minimal aeration.

When complete, Silverson’s “How-To” video collection will feature dozens of high-quality, easy-to-understand videos. These videos including How to Disperse Starch can be viewed in the How-To Video Library. 

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New Silverson “How-to” Video Dispels the Mystery of Xanthan Gum Dispersion

Thorough, Rapid Dispersion Yields Uniform Results

Xanthan gum, although used in small concentrations in formulation, can cause big problems when attempting to disperse it in formulation. Silverson mixers more than meet this challenge simply and easily dispersing it thoroughly in formulation. Silverson Machines shows how easily it can be achieved in its latest “how-to” video, “How to Disperse Xanthan Gum” on Silverson.com, one of a series of videos designed to aid formulators facing challenging industrial mixing situations.

Xanthan gum is widely used as a thickening agent in foods, pharmaceuticals, cosmetics and the chemical industry. While xanthan gum is incorporated as a fractional percent of the total formulation, it has a strong tendency to form lumps when attempting hydration and blending.

Rapid Dispersion/Uniform Results

Silverson equipment effectively and easily disperses xanthan gum in a fraction of the time compared to conventional agitators. Achieve a uniform, agglomerate-free mix in hot or cold liquid with the high shear mixing technology of a Silverson rotor/stator mixer.

Silverson high shear mixing equipment rapidly and thoroughly hydrates essential ingredients, such as xanthan gum to help save time and production costs. Operators frequently add unnecessarily high levels of gum to compensate for poor yield. This not only adds to raw material costs, but in addition, extra and unhydrated gums can wreak havoc with formulations during subsequent processing or storage. Rapid, effective hydration saves production costs and time and yields a consistent batch for each production run.

While the Silverson Ultramix is best suited for effective dispersion of xanthan gum, Silverson offers a complete line of high shear mixers that can blend xanthan gum or other powders into liquid for agglomerate-free, consistent blending in a fraction of the time required by conventional methods. Choose from the Silverson High Shear Batch Mixers, Ultramix or High Shear in-Line Mixers.

When complete, Silverson’s “How-To” video collection will feature dozens of high-quality, easy-to-understand videos. These videos including How to Disperse Xanthan Gum can be viewed in the How-To Video Library. 

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The Right Rx for Pharmaceutical Emulsions—Silverson Mixers

Creams and Ointments Thoroughly Blended Every Production Run

The right prescription for pharmaceutical production begins with the proper mixing equipment, designed to meet the strict specifications and rigid guidelines common to the industry. Silverson pioneered the types of mixers that offer ultra-sanitary production, stable emulsions and thorough mixing for functional efficacy of pharmaceutical creams and ointments. Silverson Machines explains the process in its latest “how-to” video, “How to Make Pharmaceutical Creams” on Silverson.com.

Pharmaceutical creams and ointments of all varieties, whether water in oil (w/o) or oil in water (o/w) emulsions, depend on thorough blending to ensure efficacy in the final product. Each type offers different production challenges. In addition, maintaining production volumes is equally as important as meeting or exceeding the strict hygienic guidelines dictated by regulatory bodies like the Food and Drug Administration.

Ultra-Sanitary High Shear

Silverson mixers help achieve a thorough blend of active pharmaceutical agents with other ingredients for consistency and functionality in the end product, repeatable every production run. Whether the product begins with a w/o or o/w phase, intense shear reduces the droplet size to ensure a fine, stable emulsion, eliminating the agglomerates and lumps common with conventional agitators. Droplet sizes of two to five microns are common, but finer droplet sizes can be obtained depending on the type of emulsion. In a short time, all ingredients are fully hydrated to obtain required viscosity and develop yield, while active ingredients are thoroughly dispersed throughout the batch to maximize their effectiveness in the final product.

Silverson manufactures a variety of different mixers suitable for pharmaceutical grade products depending on the application. Higher viscosity products would benefit most from the High Shear Bottom Entry Mixer with a stirrer/scraper to help maintain uniformity in the vessel. For large batches, Silverson In-Line Mixers offer greater efficiency at high volumes.

When complete, Silverson’s “How-To” video collection will feature dozens of high-quality, easy-to-understand videos. These videos including How to Make Pharmaceutical Creams can be viewed in the How-To Video Library. 

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Silverson Mixers Provide Smooth Operations for Cosmetic Creams and Lotions

Achieve Stable, Homogenous Emulsions in Seconds

Cosmetic creams and lotions’ major appeal to consumers is their skin feel and texture. The key to creating the smooth texture in a cosmetic cream or lotion is a stable emulsion with a fine, uniform droplet size. Silverson High Shear Mixers can create stable emulsions in seconds, as the company demonstrates in its latest “how-to” video, “How to Make Cosmetic Creams” located on Silverson.com. This “how-to” video joins a series designed to aid formulators facing challenging industrial mixing situations.

Stable Emulsions in Seconds

A Silverson mixer with high shear action can create a stable emulsion in cosmetic products after just a few seconds of mixing. Standard results yield droplet sizes of two to five microns, however smaller sizes down to .5 microns can be attained depending on production requirements.

Silverson Laboratory Mixers are perfect for R&D and small production runs, but formulators can achieve identical results with production-scale batch mixers, capable of blending anywhere from five to 250 gallons per batch. A production-scale in-line mixer also creates a homogeneous, fine emulsion, and is self-pumping and aeration free.

When complete, Silverson’s “How-To” video collection will feature dozens of high-quality, easy-to-understand videos. These videos including How to Make Cosmetic Creams can be viewed in the How-To Video Library. 

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See how Silverson mixers disperse titanium dioxide in new How-to video

Industry-leading technology creates fast, easy solution for multiple industries

Silverson Machines has released a “how-to” video demonstrating methods of easily and efficiently dispersing titanium dioxide, solving an ongoing need for the chemical, personal care and pharmaceutical industries.

Titanium dioxide comes in pre-micronized powder form, but the particles tend to reagglomerate when added to water. Conventional mixers cannot break these agglomerates down and therefore cannot obtain the fine particle size needed to give products such as pill coatings, paint, ink and even suntan lotion, maximum opacity and gloss.

Silverson’s precision-engineered mixers offer positive high shear mixing that will rapidly disperse the pigment to give a uniform, agglomerate-free dispersion.

Customized solution

First, the mixer’s rotor/stator workhead draws the powder and liquid into the center of the workhead at high speed. Centrifugal force then drives the materials to the periphery of the workhead where they are subjected to a milling action in the precision clearance between the tip of the rotator blade and the inner wall of the stator.

“That intense mechanical shear breaks down any agglomerates, and then projects them back into the body of the mix in a circulatory pattern,” says Matt Smith, International Sales Director. “With each successive pass through the workhead, their size is progressively reduced, and the result is a fine, uniform and agglomerate-free dispersion.”

Silverson offers a number of solutions for titanium dioxide dispersion: high-speed Batch mixers for small volumes such as tablet coatings and other specialist products, and In-Line mixers that can be used in a self-pumping recirculation system for intensive and targeted high shear on larger batches.

To showcase these mixers and other precision-engineered solutions the company offers, Silverson has created a series of “How-To” Videos. These videos including the high-speed Dispersion of Titanium Dioxide can be viewed in the How-To Video Library. 

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Take the heat out of your sugar dissolving process with a Silverson mixer

Industry-leading technology creates efficient, affordable process

Silverson Machines has released “High Speed Sugar Dissolving,” the latest in its new series of “how-to” videos in a growing, informative and easily accessible online library outlining the company’s solutions to challenging and complex mixing applications.

“Our new videos show the clear advantages of Silverson high shear mixers,” says Matt Smith, International Sales Director. “In the case of dissolving sugar, we demonstrate how our equipment can create a 66 brix sugar solution at ambient temperature, representing considerable reduction in costs and production time. We look forward to building out the video library so that the full range of Silverson mixers’ capabilities can be viewed by current and potential users.”

Speed and convenience

The video demonstrates how Silverson’s range of high-shear mixers rapidly break down the sugar granules as they pass through the rotor/stator workhead, exposing the largest surface area of sugar to water. This greatly accelerates the solubilization process and can cut mixing time by up to 90%. Silverson offers in-tank mixers for small batches and powder – liquid mixing systems for bulk production. These offer additional advantages because the sugar can be loaded into the hopper at floor level, so there’s no need for a conveyor system to get the sugar to the top of a large tank.

The result is sugar syrup preparation in a much faster process time at a reduced cost for sanitary applications in the food and pharmaceutical industries. When complete, Silverson’s “How-To” video collection will feature dozens of high-quality, easy-to-understand videos, all housed on Silverson's Website How-To Video Library.

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Silverson mixers offer clear advantage in Carbopol dispersion

Industry-leading technology creates rapid, predictable and uniform mix every time

Silverson Machines has released “How to Mix Carbopol,” the latest in its new series of “how-to” videos which can be found in a growing, informative and easily accessible online library outlining the company’s solutions to challenging and complex mixing applications.

“Our new videos show the clear advantages of Silverson mixers in a wide variety of industrial applications,” says Matt Smith, International Sales Director. “For the cosmetic industry, we are illustrating how our mixers can eliminate the difficulties often experienced when dispersing Carbopol, a key thickening ingredient found in many personal-care gels, creams and lotions. As the video demonstrates, Silverson’s powder/liquid mixing systems can cut processing time by up to 90 percent and provide a uniform mix every time.”

Reduced time, predictable results

Dispersing Carbopol effectively is a challenging task, because the powder tends to float on the surface of the liquid and needs vigorous agitation to incorporate it into the water – while keeping aeration to an absolute minimum. A degree of high shear is also required to properly disperse and hydrate the Carbopol, to ensure an agglomerate-free dispersion and obtain a clear, bright gel after neutralization. “How to Mix Carbopol” draws from Silverson’s 75 years of experience in helping clients with challenging mixing applications. The video demonstrates a range of options for Carbopol dispersion – from in-tank mixers for small batches to the latest powder/liquid mixing systems for bulk production. 

With a Silverson Flashmix, the powder is fed into the hopper, and then rapidly incorporated into the liquid stream. It then passes into the precision-engineered rotor/stator workhead, where the materials are intensively mixed before being returned to the vessel by the self-pumping mixer. This allows for the rapid dispersion and hydration of the powder without forming agglomerates, and with minimized aeration. After a short recirculation period, the Carbopol is fully hydrated, uniform and agglomerate free, all in a fraction of the time taken by convention agitators. Silverson also offers a range of in-tank mixers for smaller volumes – such as the Ultramix, which is ideal for rapid incorporation of Carbopol, and can handle higher-viscosity mixes.

When complete, Silverson’s “How-To” collection will feature dozens of high-quality, easy-to-understand videos, all housed on Silverson's Website How-To Video Library.

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Silverson launches Informative “How-To” Video Library

High-definition series showcases industry leader’s multiple mixing solutions

Silverson Machines has produced the first set of “how-to” videos in what will become an informative and easily accessible library outlining the company’s solutions to challenging and complex mixing applications. When complete, the series will feature dozens of high-quality, easy-to-understand videos, all available on the Silverson website — silverson.com/us/resource-library/videos/#how-to-videos.

“With many applications, mixing is the critical step in the production process,” says Matt Smith, International Sales Director. “Silverson has developed multiple solutions to common — and not so common — mixing applications. We are producing these high-definition videos so that our solutions can be seen in action, which is much more dynamic than just seeing a product photo, or seeing a presentation on how it works.”

Expanding product showcase

One of the first videos, “How To Disperse Titanium Dioxide,” shows Silverson’s small and large scale solutions for successful dispersion of this commonly used pigment in the chemical, personal care and pharmaceutical industries. In less than three minutes, viewers see precision-engineered Silverson mixers at work, rapidly dispersing and deagglomerating the powder into water and creating a uniform end product that’s ready for the production line.

The first videos in the series are: 

“We’re very excited about this opportunity to show what we can do and look forward to building out the library over the coming months,” Smith says.

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Silverson introduces High-Viscosity In-Line Mixer

Eliminates need for auxiliary feed pump for high-viscosity processing

The new Silverson Ultra Sanitary High-Viscosity In-Line mixer is engineered to process higher viscosity products in the food, pharmaceutical, cosmetic and chemical industries. The HV In-Line is based on the EHEDG and 3-A Certified UHS series of mixers, which comply with FDA and cGMP guidelines. The difference is the new mixer’s unique pumping rotor design, which substantially increases its flow capacity as well as providing the ability to process higher viscosity mixes. “The flow rate of the mixer remains high as product viscosity rises,” says Matt Smith, international sales director, Silverson Machines, “this has opened up a whole new range of products to the advantages of Silverson high shear mixers."

Capital savings
Because the HV In-Line maintains its flow rate as product viscosity increases, there is no need for an additional feed pump when processing higher viscosity products, such as gels and creams. “Eliminating the requirement for a feed pump is a significant savings for a manufacturer in terms of capital outlay," says Smith. "It also reduces power requirements, maintenance and cleaning costs too. But one of the biggest advantages is simplicity. Balancing an In-Line mixer's flow rate with that of a feed pump can be a compromise; with our new HV In-Line a single machine does the job.  It's much simpler and much more efficient."

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New Testing Centre - Apprentice Program

Silverson Machines has always operated a “try before you buy” policy - offering demonstration mixers for on-site trials, and by maintaining an on-site Test Centre where clients can bring in their ingredients and test a full range of mixers under actual production conditions. 

Taking this service to a new level, in October Silverson opened the doors to a new purpose-built testing facility.  The facility encompasses three testing bays and is equipped with laboratory, pilot scale and bulk production units for in-tank and in-line mixing processes, and a full range of new Flashmix powder/liquid mixers.

Alongside the practical testing area the facility incorporates a laboratory, showroom and conference area.

The new test center is co-located with Silverson’s award-winning Training School, where apprentices spend the first year of a five-year apprenticeship getting a solid grounding in all aspects of mechanical engineering. Back in September, Silverson took on six new youngsters, taking the number of apprentices in the scheme to 10. 

The Training School and Test Centre have been brought together under one roof to highlight the technology and professionalism visible in Silverson’s production facilities and the people who work there, reinforcing the company’s position as a high quality manufacturer and market leader. In addition, the apprentices will assist with trials, gaining an appreciation of how high shear mixers are used in a wide range of industrial applications.

If you have new mixing applications or would like to see how Silverson can improve your mixing process, contact Silverson to arrange a trial in the new facility.

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New generation Flashmix revolutionizes powder/liquid mixing

The latest Silverson Flashmix powder/liquid mixer is now two times faster. Large volumes of powder are dispersed and hydrated, consistently and agglomerate free at a rate of up to 500lbs/min. The Flashmix incorporates breakthrough technology that allows it to bring the benefits of high shear mixing to new applications. “We’ve really broken new ground here,” explains Matt Smith, international sales director, Silverson Machines. “The Flashmix can be used at higher temperatures and with higher viscosity mixes, than was previously possible. This opens a whole new area of processing for high shear mixing.”

The engineering difference

Unlike most powder/liquid mixers, which use vacuum to pull in powders, the Flashmix literally forces powder into the liquid stream - there's no venturi, no vacuum. A specially modified Silverson In-Line mixer recirculates liquid from a process vessel through the Flashmix at high velocity with minimal aeration. Since the powder and liquid components are introduced directly into the high shear zone of the mixer, they are subjected to intense mechanical and hydraulic shear, which instantaneously combines them, producing a homogeneous product without agglomerates. “The Flashmix is uniquely suited for mixing higher concentrations of gums and thickeners,” adds Smith.

The Flashmix is built upon a base of an EHEDG and 3-A Certified sanitary In-Line mixer. Because of its modular construction, the Flashmix can be customized to accommodate numerous applications and batch sizes. “The real beauty of the Flashmix is its simplicity,” says Smith. “No additional pump is needed; it requires only low power; and it’s easy to install, operate and clean. From an operational perspective, this is hugely beneficial.”

View more information about Flashmix powder/liquid mixers.

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Silverson Conversion App Now Available on Android Platform

Volume calculation tool for processors

Silverson Machines, Inc. announces release of the Android-based version of the company’s latest app – Silverson Conversion Tools – available for free download on Google Play. The Android version of the app contains the same versatile set of conversion and calculation tools as the original iOS platform app. “The app is suitable for use in almost any process environment as a quick reference tool for engineers and operations personnel,” explains Harold Rothman, CEO, Silverson Machines. “Now with the Android version available, all smartphone users should be able to take advantage of the multiple functionalities within our free app.”

In addition to the tank volume calculator for determining the volume of most types of cylindrical or rectangular tanks, there are additional conversion tools built into the app to assist users in calculating and converting length, flow, motor power, pressure, temperature, volume and fine measurement. The app allows the user to move between U.S. and metric measurements and includes helpful links to the entire range of Silverson high shear mixers and processing application expertise.

In addition to the Android platform, the Silverson Conversion Tools app is also available on the iOS platform for iPhones, iPads and other devices.

To learn more or to download the app, visit either Google Play or the Apple App Store and search under “Silverson” or “Silverson Conversion Tools.”

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Silverson Debuts Conversion App

Volume calculation tool for processors

Silverson Machines, Inc. recently launched a new app – Silverson Conversion Tools – available in Apple’s App Store. The new app contains a versatile set of conversion and calculation tools suitable for use in almost any process environment. “We built this free app as a quick reference tool for engineers and operations personnel, so they could easily calculate the volume of any vertical tank, based on varying parameters,” explains Harold Rothman, CEO, Silverson Machines. “Our app even allows users to share their volume calculation results via email with colleagues.”

In addition to the tank volume calculator for determining the volume of most types of cylindrical or rectangular tanks, there are additional conversion tools built into the app to assist users in calculating and converting length, flow, motor power, pressure, temperature, volume and fine measurement. The app allows the user to move between U.S. and metric measurements and includes helpful links to the entire range of Silverson high shear mixers and processing application expertise.

Initially available on the iOS platform for iPhones, iPads etc., Silverson plans on releasing an Android-based version later this summer, according to Rothman.

Download the app or if you prefer, go to the Apple App Store and search under “Silverson” or “Silverson Conversion Tools.”

Silverson in the news:
PowderBulkSoilds.com

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Mobile Batch mixer keeps production moving

Manufacturer attributes success to reliability and versatility

Silverson medium-range High Shear Batch mixers offer unrivaled efficiency, flexibility and reliability - day after day, year after year. For more than 15 years, a specialty coatings manufacturer in Kansas has had a Silverson mixer in constant service. During this time the company estimates they’ve produced well in excess of a million U.S. gallons of product - which is no small feat for an entrepreneurial company in a niche market. Batch sizes vary, usually around 50 gallons but sometimes up to 200, with a typical process time of between 30 to 45 minutes for the mixing stage of their production process. “Clearly, there hasn’t been a lot of downtime in all those years and the mixer has given ‘exceptional service,’” explains Matt Smith, Silverson sales director. “Our customer developed their entire product range using this particular mixer, and it’s become central to their manufacturing operation - the versatility and reliability of their Silverson Batch mixer has been key to their success.”

The versatility of the Silverson Batch mixer is such that a single machine can carry out a wide range of duties - blending, emulsifying, disintegrating, dissolving and homogenizing - through the use of easily interchangeable workheads and screens, available for each mixer. This flexibility is further enhanced by the use of a mobile hydraulic floor stand (local safety regulations permitting) for mixers in the small to medium range - models up to 25 hp. This allows the mixer to be easily moved from vessel to vessel and raised and lowered during operation to optimize performance - for example to create a vortex for wetting out powders with a tendency to float or ‘raft’ or, conversely, to minimize aeration. Robust, simple construction ensures Silverson Batch mixers are easy to operate, easy to maintain and easy to clean.

The Batch mixer has certainly been part of a winning formula in Kansas, where the manufacturer has just recently placed an order for another identical mixer from Silverson. “It’s a pleasure doing business with professionals who make our job easier,” says their president, adding the decision to purchase was easily justifiable based on the performance and reliability of their existing Silverson mixer.

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Silverson Ultramix in-tank mixing

Production floor workhorse offers exceptional mixing even in tight spots

Innovative design makes the Silverson Ultramix a must-have when mixing in problematic environments, such as the difficult vessel geometry of IBCs and tote bins. Designed for shear-sensitive applications, requiring mixing capabilities beyond the scope of conventional agitators, the Ultramix produces a highly efficient in-tank movement. Because of the small diameter of its single piece dynamic workhead, the Ultramix can provide effective high shear mixing even in vessels with narrow openings.

Offering one of the cleanest methods of in-tank mixing available on the market, the Ultramix also provides superior performance; rapid blending, dispersion and dissolving of ingredients for a wide range of applications within the food, pharmaceutical, personal care and chemical industries. The Ultramix can process volumes from laboratory scale up to 1,800 gallons, depending on viscosity, with larger units available upon request. This mid-range mixer is also suitable for bulk powder dispersion, deagglomeration, gelation, reaction acceleration, suspension and processing high-viscosity mixes.

Well matched
The Ultramix product range includes a series of production models and a laboratory scale unit compatible with the Silverson L5 Series lab mixers. This allows users to accurately reproduce the performance of production mixers in the laboratory, for more predictable scale-up testing, research & development and QA procedures.

The Ultramix is equally suited to aggressive chemical service and the most demanding sanitary standards—the unit complies with 3A, USDA and cGMP requirements and is designed for clean-in-place (CIP) operation with sterilize-in-place (SIP) as an option.

For more information about the Ultramix and all of Silverson high shear mixers, click here to contact us.

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Silverson mixers for Cleanroom processing

High shear mixers made to order with complete documentation

Silverson mixing equipment for use in Cleanroom manufacturing doesn’t just meet the requirements of regulatory bodies such as the U.S. Food and Drug Administration; in many cases, it exceeds them. Silverson is a pioneer in the concept of Ultra Sanitary mixing equipment, and offers a range of options for mixing under sterile conditions. Every unit for Cleanroom use is designed and built to the exacting standards of Silverson engineers, and customized to meet specific customer manufacturing requirements. “Because customer needs vary widely by what is being manufactured, the method of sterilization being used and so on, our Cleanroom systems are generally made to order,” explains Peter Matthews, Silverson Machines’, technical manager. “Documentation and traceability are also a necessity for Cleanroom equipment, so we plan accordingly during our manufacturing process.”

Cleanroom manufacturing equipment background
The many standards and regulations applicable in this field cover a range of criteria. Essentially, process equipment must be easily cleaned, maintained and inspected; it must not contaminate the product either physically, chemically or microbiologically, nor must the equipment allow the product to contaminate other aspects of the process. Some standards also cover the selection of materials - for example, FDA requirements state that equipment must only be constructed from materials on the FDA master list.

Silverson High Shear mixers available for Cleanroom operation include In-Line, Bottom Entry, Top Entry and Flashblend powder/liquid mixing systems. To achieve the above criteria, a number of modifications would be incorporated.

These include:

 

Silverson has provided mixers for a range of duties in Cleanroom installations, including use under laminar flow and units for Class 100 Cleanrooms. Typical applications include manufacture of tablet coatings, pharmaceutical syrups and dispersion of active ingredients and excipients for injectables and inhalants. More demanding applications such as the production of sterile suspensions and dispersion of sterile powders into sterile liquids are also carried out using specially modified units.

For more information on Silverson custom manufactured mixers and the full range of Silverson high shear mixers, click here to contact us.

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New Silverson Verso

Streamline scale-up with pilot-scale In-Line mixer

Going from the lab to production scale has always been a challenge. With the new Silverson Verso, it’s become less of one. “The Verso reproduces what we can do on a production scale,” explains David Rothman, Director of Silverson Machines. “It gives clients the ability to start scaling accurately with smaller volumes than they were able to previously.”

A bench top In-Line mixer, the Verso is ideal for pilot-scale or laboratory applications. Controlled from a digital operating touch pad, it offers excellent reproducibility when scaling up, and with a tachometer, ammeter and programmable timer, it provides an accurate and easy method of forecasting the performance of larger In-Line mixers under full-scale conditions.

The Verso complements Silverson’s lab range of equipment, providing the next step in the scale-up process. The 1 hp machine has a self-pumping flow rate of 6.5 U.S. gallons per minute (depending on product viscosity). “We developed the Verso as a direct response to customer requests. Our customers wanted an interim size machine that could allow them to streamline their scale-up process,” says Rothman. “Our production scale UHS Series In-Line Mixers can be used with single or multistage rotor/stator configurations, so we have included that option with the Verso as well.” A full range of interchangeable workheads is available for the Verso, allowing it to perform the widest range of mixing duties, including blending, emulsifying, homogenizing, solubilizing, suspending, dispersing, particle size reduction and reaction acceleration.

For more information on the Verso or other Silverson mixers, click here to contact us.

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Silverson leads in customizing mixers

When just any mixer won’t do

The engineers at Silverson Machines understand that every manufacturing environment is different, and that every mixing process is different. And because every mixing process is different, one mixer does not meet everyone’s needs. Sometimes a mixer needs to fit into a difficult space; sometimes hazardous or aggressive chemicals need to be mixed without risk to the operator or damage to the equipment; and also sanitary applications present a wide range of challenges. Applications such as these are increasingly common, and they call for a customized solution. “This is one of our strengths,” says Matt Smith, VP of Sales, Silverson. “We are more than willing to customize our mixers, which means we can solve unique mixing problems for our customers. Rather than try to change someone’s mixing methods, we’ll change our mixer to adapt to the needs of our customer.”

The customization process begins with research. Silverson’s engineers start by gathering all the information they can on what is being mixed, all the end-product specifications, where it will be mixed, etc. All this information is then used to choose the appropriate mixer and to customize it to the unique demands of the mixing process. Practical testing of modifications and prototypes frequently forms part of the design process. “It’s a true partnership,” says Smith. “While we know our mixers, we depend on our customers’ knowledge of their process. We marry the two to create a customized mixer.” The Silverson philosophy is based on being customer-focused rather than mass-producing a set product design.

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Taking hygiene to the next level

Silverson introduces new line of Ultra Sanitary In-Line Mixers

No manufacturer wants to be part of the next food safety scare or product safety recall. In taking measures to avoid this, manufacturers are stepping up their sanitation standards and practices and looking for equipment that helps them to do just that. Silverson’s Ultra Sanitary In-Line Mixers are one such product. The Ultra Sanitary Mixers meet the advanced CIP (clean-in-place) and SIP (sterilize-in-place) requirements demanded by today’s pharmaceutical and food industries. They are designed to comply with FDA, cGMP standards and are 3A TPV (Third Party Verification) and EHEDG Certified.

The Ultra Sanitary In-Line Mixers offer all the qualities and flexibility of Silverson’s standard multipurpose In-Line machines, but include many additional features; self-draining tangential outlet, single-piece inlet plate and stator, and hygienic EHEDG Certified mechanical shaft seals; all wetted parts are in 316L stainless steel with crevice-free construction. Stainless steel motors are available as an optional extra.

The design of the Ultra Sanitary In-Line mixer makes it impossible for any materials - liquid or solid - to pass from the inlet to the outlet without being subjected to intense mechanical and hydraulic shear as they pass through the workhead. Bypassing is impossible. The hygienic construction shortens the required CIP/SIP cycle time and minimizes the use of cleaning chemicals. Dismantling for manual cleaning is not required, significantly reducing downtime and operating costs.

Efficient and rapid in operation, the Ultra Sanitary In-Line Mixer accepts any of Silverson’s interchangeable rotor/stator workheads and screens, which offer great versatility, allowing any machine to perform a wide range of mixing operations. These include emulsifying, homogenizing, disintegrating, suspending, dissolving, solubilizing, dispersing, blending, particle size reduction, de-agglomerating and reaction accelerating.

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In-tank mixing cleans up

The new Silverson Ultramix offers cleanest available method of in-tank mixing

Ultramix is the newest addition to the Silverson mixing line. It is a mid-range machine designed for shear-sensitive applications that require mixing capabilities beyond what is offered by a conventional agitator.

The new Silverson Ultramix features a unique, single-piece dynamic mixing head for one of the cleanest methods of in-tank mixing available on the market. In addition, the Ultramix offers superior mixing for rapid dispersion and dissolving of ingredients for a wide range of applications within the food, pharmaceutical and petrochemical industries.

The Ultramix can process capacities from laboratory scale up to 1,800 gallons depending on viscosity. Larger units are available upon request. With its single shaft, no frame arms and small diameter mixing head, the Ultramix is ideal for tanks or vessels with narrow openings, such as tote bins. This mid-range mixer is also suitable for bulk powder dispersion and for processing high-viscosity mixes.

Typical applications include:

 

The Ultramix product range includes a series of production models and a laboratory scale unit compatible with Silverson’s L5 Series lab mixers. This allows users to accurately reproduce the performance of production mixers in the laboratory, for more predictable scale-up testing, Research & Development and QA procedures.

The Ultramix is equally suited to aggressive chemical service and the most demanding sanitary standards—the unit complies with 3A, USDA and cGMP requirements and is designed for clean-in-place (CIP) operation with sterilize-in-place (SIP) as an option.

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Silverson goes digital

Launches new L5 Series of laboratory mixers

Silverson’s new generation L5 Series laboratory mixers move processing into the digital age. The state-of-the-art L5M model offers a high level of instrumentation and automation via a digital touch screen. Its functions include a programmable timer, infinitely variable speed control with “speedlock,” an integral ammeter and digital tachometer, providing excellent repeatability when performing quality assurance runs or other repetitive, standardized testing.

In addition to the functional advantages, the touch screen offers increased cleanliness and reliability. Mechanically the L5 Series offers a number of refinements including a redesigned rise and fall mechanism which eliminates overrun, further increasing reliability and operating precision.

The L5 Series includes the basic L5R, the L5T (with tachometer), the multifunctional L5M and some additional models for specialized applications. More than 40 interchangeable mixing units are available for use with the new L5 range; options include tubular assemblies for narrow necked or small containers, Ultramix assemblies, twin-headed Duplex Disintegrator units and a special In-Line assembly. With a capacity range from 1 milliliter to 12 liters, and In-Line flow rates of up to 20 liters/minute, the new generation of laboratory mixers offers unrivalled efficiency and versatility in all day-to-day laboratory and small scale production duties.

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Flashblend fuels the need for speed

Silverson powder/liquid mixing system improves operating efficiencies

Claims for great speed mean nothing unless the highest quality standards back-up the manufacturing process. Customers can rely on Silverson for technologically advanced equipment that performs beyond expectations. Silverson, the company that sets industry standards for quality in high shear mixing equipment, introduces a new manual version of the Flashblend powder/liquid mixing system that can rapidly disperse ingredients in a fraction of the time normally assigned to conventional powder/liquid blending equipment. The high shear action overcomes the problems associated with incorporating even the most difficult powders within the food, pharmaceutical, cosmetics, toiletries and chemical industries.

The new Flashblend mixing system contains a specially modified Silverson high shear In-Line mixer coupled with a powder injector system and low-level powder feed hopper. During operation, powder is loaded into the low-level powder feed hopper, separated from the powder injector assembly by a manually operated valve.

The self-pumping Flashblend draws liquid from the process vessel, and forces it through the powder injector assembly at great velocity, creating a vacuum that is boosted by the action of the specially modified high shear mixer. Once the valve is opened, powder is drawn from the hopper into the injector system where it is instantly dispersed into the fluid stream. The powder/liquid mix passes immediately into the high shear rotor/stator mixer, which subjects the materials to intense, but focused mechanical and hydraulic shear, producing a totally agglomerate-free dispersion.

The entire operation concludes in a fraction of the time normally assigned to this type of mixing process. The Flashblend helps improve processing efficiencies, rapidly dispersing ingredients with varying levels of viscosity for any number of applications within the food, pharmaceutical, cosmetics, toiletries and chemical industries.

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The ultimate in hygienic standards

Silverson Ultra Hygienic In-Line Mixers set new hygienic standards

Product safety continues to be a top consumer concern worldwide. A seemingly endless stream of news stories chronicling product safety issues—toxic toothpaste, tainted peanut butter, unsafe toys—has heightened consumer awareness, making many manufacturers more interested than ever in trying to ensure that their products are produced as safely and hygienically as possible. One step in that process is using equipment that is designed to the highest sanitary standards.

Silverson’s new Ultra Sanitary In-Line Mixers are the most sanitary machines on the market today. Mixers designed for food use in the United States must comply with 3-A sanitary standards. Silverson’s range of Ultra Sanitary In-Line Mixers not only meets 3-A standards, it surpasses them. Every mixer is designed to meet the European Hygienic Engineering & Design Group (EHEDG) standard – the toughest in the world – as well. The EHEDG is considered the international benchmark for sanitation because its standards set forth stringent bacterial contamination level parameters for equipment to achieve after cleaning. Silverson is the only manufacturer in the world today producing mixers that meet both of these standards.

“With more food scares here and abroad, people now have much higher expectations for their equipment, especially those who work in multinational environments,” says Silverson Managing Director Harold Rothman. “The desire for higher levels of cleanliness goes beyond food and pharmaceutical manufacturers. Makers of personal care products and other consumer product industries are seeking it, as well.” It wasn’t that long ago when machines were stripped down weekly and steam or liquid was forced through the system for cleaning. Today more and more manufacturers are demanding equipment that is clean-in-place or sterilization-in-place, and lines and equipment are being cleaned more frequently.

When the Ultra Sanitary In-Line Mixers were conceived and built, this changing marketplace concern was taken into consideration. This new generation of mixers was built to meet this higher global standard.

“The 3-A series of standards is set down for how a machine is constructed, but it does not cover any sanitary conditions,” explains Rothman. “The EHEDG standard doesn’t care how the machine is constructed; it is concerned with the level of sanitation that can be achieved. To meet the standard, a machine must be as clean as a three-foot length of a sanitary pipe.” If a machine has a higher bacterial count than the pipe after cleaning, it does not meet the standard. By building its machines to the specifications of both the 3-A and the EHEDG standards, Silverson ensures its Ultra Sanitary In-Line Mixers deliver the highest level of sanitation on the market today.

For more than 75 years, Silverson has been helping the world’s largest manufacturers solve their most difficult mixing challenges. The development of a range of Ultra Sanitary In-Line Mixers continues this heritage. In addition to their superior level of sanitation, the Ultra Sanitary In-Line Mixers are extremely versatile. The mixers are available with single or multi-stage rotor/stator configurations that let the user fit them to individual process requirements. Also mixers can be equipped with Ultra Sanitary Single Mechanical Shaft Seals or easily converted to Ultra Sanitary Double Mechanical Shaft Seals.

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Just-in-time mixing

Silverson Flashblend mixing system improves production

Silver Spring Soft Drinks is the largest independently owned soft drinks manufacturer in the UK. In addition to their own brands, they manufacture own-label products for all of the major UK food retailers and export throughout Europe.

Established in 1870, Silver Spring has always embraced and pioneered new technology and their twelve acre site in Folkestone is one of the most technologically advanced in the industry. One of the latest improvements has been in the syrup production process, where a Silverson Flashblend powder/liquid mixing system has been installed for dispersing and hydrating functional ingredients. These are prepared in concentrated solutions, however the long mixing times previously required to produce each batch meant that it was a race against time to keep up with the rest of production. “We needed to begin making up gum solutions hours in advance to get a head start, because it sometimes took over an hour to complete a batch,” explains Tom Geldard, syrup room team leader. “With the Flashblend, we can make a batch twice the size in about seven minutes. Gum solutions can now be prepared on a just-in-time basis and we can use the unit for other ingredients such as aspartame, citric acid and maltodextrin.”

Silverson Machines designed the Flashblend for high speed entraining and instant dispersion of powders into liquids, especially problematic ingredients such as gums and thickeners, caseinates, flour, starches, powdered milk, etc. An agglomerate-free, homogeneous dispersion can be produced in a single pass, with powder incorporation rates of up to 15,000Kg/hr. The range includes 3 production models and a pilot-scale unit. Silverson also has the capacity to customize mixers to individual customer’s needs, and the model supplied to Silver Spring incorporates a number of special features specifically designed for their process.

At Silver Spring, the Flashblend has taken the strain off one of the critical stages in manufacturing. “These ingredients are only a very small percentage of the finished product but the improvements to the process make a huge amount of difference,” comments Tom Geldard. “The Flashblend gives us the flexibility to react quickly to the needs of production.” And when production exceeds a million liters per day, that’s quite an advantage.

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