How to Meet the Challenges of High-Viscosity Mixing

Summary:

• High-viscosity products like gels and ointments require more than conventional mixers.
• Manufacturers must overcome mixing power, dispersion quality, and operator safety concerns.
• Choosing the right equipment is essential to ensure efficiency, safety, and compliance

Understanding the Challenge 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 one may be more difficult than it first appears.

Why Conventional Mixing Options May Fall Short

Many conventional mixing options crowd the market today, including:

• Using multiple mixers or vessels
• Incorporating recirculating shear systems
• Other potentially limiting approaches

However, these systems have limitations when it comes to meeting the unique requirements of thick and highly viscous materials.

The Power Required for Mixing High-Viscosity Materials

Mixing systems for high-viscosity products (especially topically-applied products) must deliver significant power to move thick, heavy ingredients and achieve:

• Consistent blending
• Uniform product texture
• High-yield results

Dispersion, Emulsification, and Shear Rates Matter

In order to blend active ingredients correctly, high-viscosity products also demand:

• Thorough dispersion
• Complete emulsification
• High shear rates

Conventional mixers may only agitate a localized area around the mixing head, leading to uneven blending and inconsistent product quality.

Operator Safety Considerations

Operator safety is another major factor.

• Many topical products contain active ingredients in dry powder form.
• Mixing in a conventional open vessel can expose workers to airborne particles.
• This exposure increases the risk of inhalation-related health concerns.

To learn more about what it takes for successful high-viscosity mixing, download Mixing Topical Ointments, Gels and Lotions in High-Viscosity Applications. This guide covers:

• 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
  

Get the guide here.

Last Updated: 10/17/2025