Ambient-Temperature Mixing of Personal Hygiene Formulations
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Solution Overview
Problem
Conventional manufacturing of consumer personal hygiene products requires high energy input for mixing and heating, leading to environmental impact, chemical alteration of ingredients, and the formation of harmful compounds, compromising product efficacy and safety.
Innovation Solution
A low-energy manufacturing process that combines and mixes ingredients at ambient temperature, using propeller mixers and controlled mixing speeds to form personal hygiene products without significant thermal input, allowing for the use of natural and therapeutically efficacious ingredients.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If heating is applied during compounding to facilitate mixing and activation, then mixing efficiency and component activation are improved, but energy consumption increases and chemical alteration of ingredients occurs
Solution Approach 1:
The patent changes the temperature parameter from elevated heating conditions to ambient temperature, fundamentally altering the compounding process parameters to eliminate energy-intensive heating while maintaining effective mixing through modified formulation chemistry and extended mixing time
Solution Approach 2:
Ingredients are pre-formulated and pre-prepared to enable cold process mixing, where surfactants and other components are selected and prepared in advance to mix effectively at ambient temperatures without requiring thermal activation
2Ease of manufacture
If heating is applied during compounding, then mixing and activation of components are facilitated, but chemical alteration of ingredients and formation of harmful compounds occur
Solution Approach 1:
The patent fundamentally changes the temperature parameter from heated conditions to ambient temperature compounding, preventing thermal degradation and chemical alteration of sensitive ingredients while maintaining manufacturing effectiveness through formulated chemistry designed for cold process mixing
Solution Approach 2:
The patent converts the limitation of ambient temperature (slower mixing kinetics) into a benefit by selecting ingredients and formulations specifically designed for cold process mixing, where the lack of thermal energy is compensated by optimized chemical interactions and extended mixing time, ultimately preventing harmful thermal degradation
3Use of energy by moving object
If ambient temperature mixing is used, then energy consumption is reduced, but mixing time and process duration may increase
Solution Approach 1:
The patent changes the formulation parameters to enable effective mixing at ambient temperature, using specifically selected surfactants and additives that maintain low viscosity and high reactivity at room temperature, allowing for reduced mixing times despite the lower thermal energy input
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process maintains formulation homogeneity and efficacy while reducing environmental impact and avoiding chemical alterations, enabling the use of safer, natural ingredients.
Implementation Method 1
The mixing can be accomplished using a propeller mixer. In some embodiments, the propeller mixer can be rotated at a speed of greater than about 200 rpm during at least one of the mixing steps.
Data Source
AI summary
Embodiments described herein relate generally to apparatus, methods and systems for low energy processing of consumer personal hygiene products (PHPs) and formulations of the same. In some embodiments, a method of manufacturing a consumer PHP comprises combining a first material and second material at room temperature to form a first mixture, mixing the first mixture at room temperature, adding a third material at room temperature to form a second mixture; mixing the second mixture at room temperature, adding a fourth material at room temperature to form a third mixture; and mixing the third mixture at room temperature. In some embodiments, the third material and the fourth material can be mixed to form the second mixture and the first mixture and second mixture can be combined to form the third mixture. In some embodiments, the mixing can be accomplished using a propeller mixer. In some embodiments, the propeller mixer can be rotated at a speed of greater than about 200 rpm during at least one of the mixing steps. In some embodiments, the pH of the third mixture can be adjusted to between about 4.5 and about 6.5 using an acidifier. In some embodiments, the viscosity of the third mixture can be adjusted to between about 100 cP and about 25,000 cP using a thickener.