How to Scale the Production of Dispersions

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Tal Shechter
Nov 18, 2016
min read
How to Scale the Production of Dispersions

Increasing the scale of production is a challenge that many industries – including pharmaceutical, biotech, and cosmetic – face on a continuous basis. In the growing world of dispersions, cell lysis, micronization of particles, and other applications requiring the use of a homogenizer, bridging the gap between R&D and manufacturing is a costly and often unsuccessful challenge.

BEE International has extensive experience in the field of development and production of homogenization equipment, suitable for virtually any application, beginning from the early stages of planning, research and development work, and scale up, all the way to final implementation and production.

Scaling the production of dispersions is an event that takes much preparation, foresight, and planning, but with proper preparation, knowledge, and tools, it is a satisfying and profitable endeavor.

Replicating dispersion in a large-scale production environment that has been successfully implemented in a smaller laboratory setting can be difficult. Even when a satisfactory particle size has been achieved, when produced on a larger scale, it may not have the same qualities and characteristics as what was created in the laboratory setting. Inconsistencies can be observed in many areas, including (but not limited to):

  • Differing size and/or densities of media
  • Differing throughput rates of media
  • Mill wear and changes in millbase viscosity
  • Dispersion at differing speed/rate/power

The process of dispersion requires a high level of attention to detail, accurate input variables, and consistent design criteria. Pion offers high quality laboratory systems that address and standardize all of the numerous factors that can affect a scaled up dispersion process. Our BEE brand homogenizers, including the Nano DeBEE 45-2, Micro DeBEE 45, and Mini DeBEE 30, are built for reliability and repeatability, and are able to keep up with the high pace of a full-scale 24/7 manufacturing environment.  

Our BEE brand pilot plant homogenizers, designed for scaling up homogenization, micronization, and dispersion from the R&D stage all the way to full-blown production, can be customized to fit your schedule, production needs, and budget.  Our homogenizers include key features for successful  scaling of dispersions, including:

  • Low-High operating pressure from 5,000-45,000psi
  • PLC panel to control process pressure, temperature, and other parameters
  • Constant process pressure
  • Custom process configurations to enable control of shear and impact
  • Adjustable back pressure
  • Heat exchangers for cooling of product
  • Guaranteed scale up from R&D to manufacturing

Pion's DeBEE 2000, our pilot scale high pressure homogenizer, contains a 10 horsepower motor which converts hydraulic power through high pressure cylinders. The unit is capable of reaching up to 45,000psi and is suitable for the scale up needs of most major manufacturing industries.

Contact us for more information on our pilot plant homogenizers and other equipment to meet your dispersion scale up needs.

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