How to Meet the Challenges of High-Viscosity Mixing

Producing ointments, gels and other high-viscosity products is a challenging process. These stringently regulated products offer a high degree of difficulty for every manufacturer. 

Selecting the most efficient and cost-effective mixing solution can help you meet those challenges head on, but choosing the right mixing solution may be more difficult than it first appears. Many conventional mixing options crowd the market today, from using multiple mixers or vessels to incorporating recirculating shear systems and other similar mixing approaches. But each of these solutions has characteristics that limit their ability to meet some of the unique challenges of producing high-viscosity products. 

Powerful, robust mixing capabilities present the most fundamental challenge for high-viscosity product manufacturing. Topically-applied products in particular are among the highest viscosity manufactured products. Mixing systems for these products must have significant mixing power to move thick, heavy ingredients for consistent blending.

In addition, high-viscosity products require thorough dispersion, emulsification and high shear rates to properly blend the active ingredients. Consistent results can be difficult to achieve with conventional mixing methods, which can confine their mixing to a highly localized area around the mixing head.

Operator safety is also a key consideration in the production process for these products. Active ingredients for many topical ointments and other high viscosity products are often incorporated into the mix as dry powder. A conventional open vessel can expose operators to dust particle inhalation, which in turn can lead to adverse health effects.

Our new guide, Mixing Topical Ointments, Gels and Lotions in High-Viscosity Applications can help you understand these and other challenges common to these products. In this guide, you’ll learn:

• The unique challenges of a BioPharma product that affect the mixing process
• Why conventional mixing strategies may not adequately address these challenges
• How mixing systems specially designed for high-viscosity can produce superior results