{"id":24057,"date":"2025-12-04T07:39:44","date_gmt":"2025-12-04T07:39:44","guid":{"rendered":"https:\/\/vakkimsa.com\/cat\/?p=24057"},"modified":"2026-07-22T08:07:21","modified_gmt":"2026-07-22T08:07:21","slug":"real-confidence-before-you-scale-pilot-plant","status":"publish","type":"post","link":"https:\/\/vakkimsa.com\/cat\/blog\/2025\/12\/04\/real-confidence-before-you-scale-pilot-plant\/","title":{"rendered":"Real confidence before you scale: Pilot Plant"},"content":{"rendered":"\n<p class=\"wp-block-paragraph\">In industrial processes where each product has unique characteristics, <strong>empirical validation can be essential<\/strong>. Agitation and mixing solutions present specific challenges depending on the application, and while in most cases process calculations and process simulations are sufficient to determine the result, on some occasions empirical testing is indispensable.<\/p>\n\n\n\n<blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\">\n<p class=\"wp-block-paragraph\"><strong>An incorrect selection of the agitator or mixer forces production stoppages and costly redesigns.<\/strong><\/p>\n<\/blockquote>\n\n\n\n<p class=\"wp-block-paragraph\">A \ud835\udde3\ud835\uddf6\ud835\uddf9\ud835\uddfc\ud835\ude01 \ud835\udde3\ud835\uddf9\ud835\uddee\ud835\uddfb\ud835\ude01 fully equipped with various agitation and inline mixing configurations to cover a wide spectrum of industrial processes, as is our case, <strong>allows reproducing real process conditions to validate solutions before industrial implementation<\/strong>, minimizing uncertainties and guaranteeing the technical viability of proposals.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">This functional testing environment includes:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Tanks of different volumes to adapt to different production scenarios<\/li>\n\n\n\n<li>Agitators with all types of impeller designs for all mixing processes<\/li>\n\n\n\n<li>Inline mixers with dispersion, emulsion and micro-emulsion capacity<\/li>\n\n\n\n<li>Viscometer, as a key tool to obtain fundamental parameters, and other data acquisition systems that allow studying the rheology of products and the conditions of the different process phases<\/li>\n\n\n\n<li>Measurement of key parameters such as mechanical stress, agitator energy consumption, pressure, temperature, &#8230;<\/li>\n<\/ul>\n\n\n\n<p class=\"wp-block-paragraph\">Testing at Vak Kimsa&#8217;s Pilot Plant \ud835\uddfb\ud835\uddfc\ud835\ude01 \ud835\uddfc\ud835\uddfb\ud835\uddf9\ud835\ude06 \ud835\ude03\ud835\uddf2\ud835\uddff\ud835\uddf6\ud835\uddf3\ud835\uddf6\ud835\uddf2\ud835\ude00 \ud835\ude01\ud835\uddf5\ud835\uddf2 \ud835\ude03\ud835\uddf6\ud835\uddee\ud835\uddef\ud835\uddf6\ud835\uddf9\ud835\uddf6\ud835\ude01\ud835\ude06 \ud835\uddfc\ud835\uddf3 \ud835\ude01\ud835\uddf5\ud835\uddf2 \ud835\uddfa\ud835\uddf6\ud835\ude05\ud835\ude01\ud835\ude02\ud835\uddff\ud835\uddf2, \ud835\uddef\ud835\ude02\ud835\ude01 \ud835\uddee\ud835\uddf9\ud835\ude00\ud835\uddfc \ud835\uddee\ud835\uddf9\ud835\uddf9\ud835\uddfc\ud835\ude04\ud835\ude00 \ud835\ude02\ud835\uddfb\ud835\uddf1\ud835\uddf2\ud835\uddff\ud835\ude00\ud835\ude01\ud835\uddee\ud835\uddfb\ud835\uddf1\ud835\uddf6\ud835\uddfb\ud835\uddf4 \ud835\ude01\ud835\uddf5\ud835\uddf2 \ud835\uddfd\ud835\uddff\ud835\uddfc\ud835\uddf0\ud835\uddf2\ud835\ude00\ud835\ude00 \ud835\uddf1\ud835\ude06\ud835\uddfb\ud835\uddee\ud835\uddfa\ud835\uddf6\ud835\uddf0\ud835\ude00, optimizing it and collecting valuable technical data that is integrated into engineering development.<\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\" \/>\n\n\n\n<h3 class=\"wp-block-heading\">\ud835\uddd4 \ud835\uddfd\ud835\uddff\ud835\uddee\ud835\uddf0\ud835\ude01\ud835\uddf6\ud835\uddf0\ud835\uddee\ud835\uddf9 \ud835\uddf0\ud835\uddee\ud835\ude00\ud835\uddf2 \ud835\ude00\ud835\ude01\ud835\ude02\ud835\uddf1\ud835\ude06<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">A company in the cosmetics sector needed to develop a new high-viscosity body cream with ingredients sensitive to temperature and shear. The formula combined aqueous and oily phases, stabilizers, emulsifiers and natural extracts, with the aim of achieving a stable, smooth and easy-to-apply texture.<\/p>\n\n\n\n<figure class=\"wp-block-image\"><img fetchpriority=\"high\" decoding=\"async\" width=\"1024\" height=\"606\" src=\"https:\/\/vakkimsa.com\/wp-content\/uploads\/sites\/2\/2026\/07\/1764772250352-1-1024x606.jpg\" alt=\"\" class=\"wp-image-24056\" srcset=\"https:\/\/vakkimsa.com\/cat\/wp-content\/uploads\/sites\/2\/2026\/07\/1764772250352-1-1024x606.jpg 1024w, https:\/\/vakkimsa.com\/cat\/wp-content\/uploads\/sites\/2\/2026\/07\/1764772250352-1-300x177.jpg 300w, https:\/\/vakkimsa.com\/cat\/wp-content\/uploads\/sites\/2\/2026\/07\/1764772250352-1-768x454.jpg 768w, https:\/\/vakkimsa.com\/cat\/wp-content\/uploads\/sites\/2\/2026\/07\/1764772250352-1.jpg 1488w\" sizes=\"(max-width: 1024px) 100vw, 1024px\" \/><figcaption class=\"wp-element-caption\">Vak Kimsa&#8217;s Pilot Plant<\/figcaption><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>The challenge:<\/strong> Initial industrial production presented unstable emulsions, inconsistencies in texture and viscosity between batches, and overheating of certain ingredients during mixing. This forced production to stop and the agitation system to be redesigned, with considerable added costs.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\ud835\udde7\ud835\uddf5\ud835\uddf2 \ud835\uddfd\ud835\uddf6\ud835\uddf9\ud835\uddfc\ud835\ude01 \ud835\uddfd\ud835\uddf9\ud835\uddee\ud835\uddfb\ud835\ude01 \ud835\ude01\ud835\uddff\ud835\uddf6\ud835\uddee\ud835\uddf9: The manufacturing process was reproduced in a 100L tank, equipped with a central agitator and variable shear disperser, combined with an inline mixing system for controlled addition of actives.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\ud835\udde7\ud835\uddf5\ud835\uddf2 \ud835\ude03\ud835\uddf6\ud835\ude00\ud835\uddf0\ud835\uddfc\ud835\uddfa\ud835\uddf2\ud835\ude01\ud835\uddf2\ud835\uddff \ud835\ude04\ud835\uddee\ud835\ude00 \ud835\uddf8\ud835\uddf2\ud835\ude06 \ud835\ude01\ud835\uddf5\ud835\uddff\ud835\uddfc\ud835\ude02\ud835\uddf4\ud835\uddf5\ud835\uddfc\ud835\ude02\ud835\ude01 \ud835\ude01\ud835\uddf5\ud835\uddf2 \ud835\uddfd\ud835\uddff\ud835\uddfc\ud835\uddf0\ud835\uddf2\ud835\ude00\ud835\ude00, being used before, during and after to monitor the evolution of viscosity as a function of time and temperature, the effect of shear on product stability, and the ideal operating limits to maintain the desired texture.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\ud835\udde5\ud835\uddf2\ud835\ude00\ud835\ude02\ud835\uddf9\ud835\ude01\ud835\ude00 \ud835\uddfc\ud835\uddef\ud835\ude01\ud835\uddee\ud835\uddf6\ud835\uddfb\ud835\uddf2\ud835\uddf1: Rheological data indicated that excessive agitation during the final emulsification phase reduced viscosity and affected stability. A critical temperature point was also detected, beyond which one of the actives lost effectiveness.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The tests allowed redesigning the agitation profile with defined and proven requirements, determining a necessary change in the ingredient incorporation sequence, and defining the key parameters to guarantee homogeneity and quality between batches.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\ud835\uddea\ud835\uddf6\ud835\ude01\ud835\uddf5 \ud835\ude01\ud835\uddf5\ud835\uddf6\ud835\ude00 \ud835\uddfd\ud835\uddf6\ud835\uddf9\ud835\uddfc\ud835\ude01 \ud835\uddfd\ud835\uddf9\ud835\uddee\ud835\uddfb\ud835\ude01 \ud835\ude01\ud835\uddff\ud835\uddf6\ud835\uddee\ud835\uddf9, \ud835\uddf5\ud835\uddf6\ud835\uddf4\ud835\uddf5 \ud835\ude01\ud835\uddf2\ud835\uddf0\ud835\uddf5\ud835\uddfb\ud835\uddf6\ud835\uddf0\ud835\uddee\ud835\uddf9 \ud835\uddee\ud835\uddfb\ud835\uddf1 \ud835\uddf2\ud835\uddf0\ud835\uddfc\ud835\uddfb\ud835\uddfc\ud835\uddfa\ud835\uddf6\ud835\uddf0 \ud835\uddff\ud835\uddf6\ud835\ude00\ud835\uddf8\ud835\ude00 \ud835\ude04\ud835\uddf2\ud835\uddff\ud835\uddf2 \ud835\uddee\ud835\ude03\ud835\uddfc\ud835\uddf6\ud835\uddf1\ud835\uddf2\ud835\uddf1. \ud835\udde7\ud835\uddf5\ud835\uddf2 \ud835\uddf1\ud835\uddee\ud835\ude01\ud835\uddee \ud835\uddfc\ud835\uddef\ud835\ude01\ud835\uddee\ud835\uddf6\ud835\uddfb\ud835\uddf2\ud835\uddf1 \ud835\uddf4\ud835\ude02\ud835\uddee\ud835\uddff\ud835\uddee\ud835\uddfb\ud835\ude01\ud835\uddf2\ud835\uddf2\ud835\uddf1 \ud835\uddee \ud835\ude00\ud835\uddee\ud835\uddf3\ud835\uddf2, \ud835\uddf2\ud835\uddf3\ud835\uddf3\ud835\uddf6\ud835\uddf0\ud835\uddf6\ud835\uddf2\ud835\uddfb\ud835\ude01 \ud835\uddf6\ud835\uddfb\ud835\uddf1\ud835\ude02\ud835\ude00\ud835\ude01\ud835\uddff\ud835\uddf6\ud835\uddee\ud835\uddf9 \ud835\ude00\ud835\uddf0\ud835\uddee\ud835\uddf9\ud835\uddf2-\ud835\ude02\ud835\uddfd \ud835\ude04\ud835\uddf6\ud835\ude01\ud835\uddf5 \ud835\uddf0\ud835\uddfc\ud835\uddfb\ud835\ude00\ud835\ude01\ud835\uddee\ud835\uddfb\ud835\ude01 \ud835\uddfe\ud835\ude02\ud835\uddee\ud835\uddf9\ud835\uddf6\ud835\ude01\ud835\ude06.<\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\" \/>\n\n\n\n<h3 class=\"wp-block-heading\">Why test in a pilot plant?<\/h3>\n\n\n\n<blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\">\n<p class=\"wp-block-paragraph\"><em>Because mistakes in production are expensive<\/em><\/p>\n<\/blockquote>\n\n\n\n<p class=\"wp-block-paragraph\">A pilot plant bridges the gap between lab theory and industrial reality. It lets you replicate actual production conditions, run hands-on trials, and observe product behavior in real time\u2014before any major investment.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The tests not only verify the viability of the mixture, but also \ud835\uddee\ud835\uddf9\ud835\uddf9\ud835\uddfc\ud835\ude04 \ud835\ude02\ud835\uddfb\ud835\uddf1\ud835\uddf2\ud835\uddff\ud835\ude00\ud835\ude01\ud835\uddee\ud835\uddfb\ud835\uddf1\ud835\uddf6\ud835\uddfb\ud835\uddf4 \ud835\ude01\ud835\uddf5\ud835\uddf2 \ud835\uddfd\ud835\uddff\ud835\uddfc\ud835\uddf0\ud835\uddf2\ud835\ude00\ud835\ude00 \ud835\uddf1\ud835\ude06\ud835\uddfb\ud835\uddee\ud835\uddfa\ud835\uddf6\ud835\uddf0\ud835\ude00, optimizing it and collecting valuable technical data that is integrated into engineering development.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Additionally at Vak Kimsa, analyses performed with ANSYS at fluid-dynamic level, together with mechanical and energy tests, constitute \ud835\uddee\ud835\uddfd\ud835\uddfd\ud835\uddf9\ud835\uddf6\ud835\uddf2\ud835\uddf1 \ud835\uddf8\ud835\uddfb\ud835\uddfc\ud835\ude04-\ud835\uddf5\ud835\uddfc\ud835\ude04 \ud835\uddef\ud835\uddee\ud835\ude00\ud835\uddf2\ud835\uddf1 \ud835\uddfc\ud835\uddfb \ud835\uddff\ud835\uddf2\ud835\uddee\ud835\uddf9 \ud835\uddf1\ud835\uddee\ud835\ude01\ud835\uddee \ud835\uddee\ud835\uddfb\ud835\uddf1 \ud835\uddf0\ud835\uddfc\ud835\uddfb\ud835\ude00\ud835\uddfc\ud835\uddf9\ud835\uddf6\ud835\uddf1\ud835\uddee\ud835\ude01\ud835\uddf2\ud835\uddf1 \ud835\uddf8\ud835\uddfb\ud835\uddfc\ud835\ude04\ud835\uddf9\ud835\uddf2\ud835\uddf1\ud835\uddf4\ud835\uddf2.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">This methodology marks the difference between a conventional solution and a truly efficient one.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">In short, the pilot plant is a validation and innovation space where theory is put to the test and where ideas are transformed into applicable solutions. It allows adjusting each proposal to the specific needs of each process and, above all, minimizing risks and \ud835\uddf4\ud835\ude02\ud835\uddee\ud835\uddff\ud835\uddee\ud835\uddfb\ud835\ude01\ud835\uddf2\ud835\uddf2\ud835\uddf6\ud835\uddfb\ud835\uddf4 \ud835\ude01\ud835\uddf5\ud835\uddf2 \ud835\ude00\ud835\ude02\ud835\uddf0\ud835\uddf0\ud835\uddf2\ud835\ude00\ud835\ude00 \ud835\uddfc\ud835\uddf3 \ud835\uddf6\ud835\uddfb\ud835\uddf1\ud835\ude02\ud835\ude00\ud835\ude01\ud835\uddff\ud835\uddf6\ud835\uddee\ud835\uddf9 \ud835\uddf6\ud835\uddfa\ud835\uddfd\ud835\uddf9\ud835\uddf2\ud835\uddfa\ud835\uddf2\ud835\uddfb\ud835\ude01\ud835\uddee\ud835\ude01\ud835\uddf6\ud835\uddfc\ud835\uddfb.<\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\" \/>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Do you want to see how it would work with your product?<\/strong> <a href=\"https:\/\/vakkimsa.com\/en\/contact-us\/\"><em>Contact us<\/em><\/a><em> and let&#8217;s talk about it.<\/em><\/li>\n<\/ul>\n","protected":false},"excerpt":{"rendered":"<p>\ud835\udde9\ud835\uddee\ud835\uddf9\ud835\uddf6\ud835\uddf1\ud835\uddee\ud835\ude01\ud835\uddf2 \ud835\uddef\ud835\uddf2\ud835\uddf3\ud835\uddfc\ud835\uddff\ud835\uddf2 \ud835\uddf6\ud835\uddfa\ud835\uddfd\ud835\uddf9\ud835\uddf2\ud835\uddfa\ud835\uddf2\ud835\uddfb\ud835\ude01\ud835\uddf6\ud835\uddfb\ud835\uddf4: \ud835\ude01\ud835\uddf5\ud835\uddf2 \ud835\uddf8\ud835\uddf2\ud835\ude06 \ud835\ude01\ud835\uddfc \ud835\uddee\ud835\ude03\ud835\uddfc\ud835\uddf6\ud835\uddf1\ud835\uddf6\ud835\uddfb\ud835\uddf4 \ud835\ude02\ud835\uddfb\ud835\uddf2\ud835\ude05\ud835\uddfd\ud835\uddf2\ud835\uddf0\ud835\ude01\ud835\uddf2\ud835\uddf1 \ud835\uddf0\ud835\uddfc\ud835\ude00\ud835\ude01\ud835\ude00 <\/p>\n","protected":false},"author":8,"featured_media":0,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"editor_notices":[],"footnotes":""},"categories":[85],"tags":[93,133,152,153,97,154],"class_list":["post-24057","post","type-post","status-publish","format-standard","hentry","category-article","tag-agitation","tag-cosmeticindustry","tag-cosmetics","tag-innovation","tag-mixing","tag-pilotplant"],"acf":[],"_links":{"self":[{"href":"https:\/\/vakkimsa.com\/cat\/wp-json\/wp\/v2\/posts\/24057","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/vakkimsa.com\/cat\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/vakkimsa.com\/cat\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/vakkimsa.com\/cat\/wp-json\/wp\/v2\/users\/8"}],"replies":[{"embeddable":true,"href":"https:\/\/vakkimsa.com\/cat\/wp-json\/wp\/v2\/comments?post=24057"}],"version-history":[{"count":1,"href":"https:\/\/vakkimsa.com\/cat\/wp-json\/wp\/v2\/posts\/24057\/revisions"}],"predecessor-version":[{"id":24058,"href":"https:\/\/vakkimsa.com\/cat\/wp-json\/wp\/v2\/posts\/24057\/revisions\/24058"}],"wp:attachment":[{"href":"https:\/\/vakkimsa.com\/cat\/wp-json\/wp\/v2\/media?parent=24057"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/vakkimsa.com\/cat\/wp-json\/wp\/v2\/categories?post=24057"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/vakkimsa.com\/cat\/wp-json\/wp\/v2\/tags?post=24057"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}