Cosmetics Processing

Cosmetics-processing-industry-cosmetics-manufacturing-powder-bulkinside

The cosmetics industry is a global powerhouse, encompassing an expansive array of products designed to enhance beauty, promote skin care, and provide personal care solutions. Beyond its aesthetic appeal, the cosmetics sector is a dynamic and rapidly evolving industrial domain with a profound impact on economies, research and development, and manufacturing.

The cosmetics manufacturing industry can be described as an industry that manufactures cosmetics.

These cosmetics include:

  • Color cosmetics, for example, mascara and foundation,
  • Skincare cosmetics, for example, cleansers and moisturizers,
  • Haircare products, for example, shampoos, conditioners, and hair colors,
  • Toiletries, for example, soap and bubble bath.

A small number of multinational corporations dominate the cosmetics manufacturing industry.

The cosmetics manufacturing industry is a science-driven and highly innovative sector. Research and Development programs delve into all imaginable aspects of beauty and well-being, from investigating consumer behavior and beauty aspirations, the biology of skin, hair, teeth, and oral cavity, to new innovative technologies and bettering sustainable development methods.

Thanks to new markets and customer groups, the demand for cosmetic products is growing. As a result, new players are entering this competitive environment.

In this race for market share, time-to-market and flexibility in manufacturing are decisive factors. This calls for modern, fully automated processing technology that also takes advantage of the latest digital technologies.

The cosmetics processing industry exhibits high innovation, particularly within organic and prestige product lines.Cosmetics Processing and Manufacturing - Cream manufacturing

Cosmetic powders have been used since ancient times, for example, as makeup. The role of powders as and in cosmetics has developed from crudely pulverized natural powders to highly sophisticated nanomaterials, with powder manipulation processes growing in their complexity and sophistication.

An essential advantage of cosmetic powders is the many stability-related benefits to the final product.

Cosmetic powders are usually marketed as loose (flow) powders or compacted (pressed) powders.

They are used to provide adhesiveness, slipperiness, absorbance, smoothness, and the bloom effect they provide to the skin or hair.

Technical, scientific knowledge brings significant advantages to the formulator in the increasingly competitive and technological area.

Most cosmetic powder products are similar and standardized concerning their ingredient composition.

Typically, cosmetic powders contain these ingredients:

  • Fillers, for example, talc, kaolin, calcium and magnesium carbonate, metallic stearates, silica, and silicates,
  • Colors, for example, pigments, lakes, mica, bismuth oxychloride,
  • Preservatives,
  • Perfume,
  • Binding agents include mineral oils, fatty esters, lanolin and derivatives, gums, and emulsifying agents.

The composition of these ingredients, along with their particle size and physical properties, impacts the technical quality of the final powder formulation.

GEMCO-Tumble-Blender-with-Pneumatic-Conveying-VAC-U-MAX-Cosmetics
Picture: GEMCO Tumble Blender with VAC-U-MAX Pneumatic Conveying System

As the global cosmetics industry evolves and grows with new styles, trends, and innovations, processed cosmetics must also be modernized.

Powders form a substantial part of the base materials needed for cosmetics.

Cosmetic powders processing requires screening, mixing, milling, drying, and agglomeration technology.

In cosmetic powders processing, it is crucial to effectively and cost-efficiently achieve superior hydrophobic (waterproof) and other material properties and better distribution of active ingredients.

Specialized process equipment is also crucial to effectively blend cosmetic powder and enrobe it in a hydrophobic coating.

While hydrophobic materials are not new in the cosmetics and personal care industry, optimizing the process is essential to create high-performance, powder-based products ranging from makeup and mascara to sunblock.

In manufacturing cosmetic products, precision drying is often required as well.

A cosmetic powder improves the appearance of the skin and increases the softness and smoothness.

Essential process equipment for the formulation of powder cosmetics includes:

Even during a financial crisis, the global cosmetics industry continued to grow. This is partly because of substantial innovations in all aspects of this industry, including the use of powders and powder-based cosmetic products.

Improved coating technology, such as fluid bed coating, helps avoid pigment degradation and enhances resistance to interaction with naturally present skin oiliness, extending product efficiency.

There is also an increasing development of microspheres with a soft-focus effect and coated and micronized pigments that help to provide good skin coverage.

The powder presence in cosmetic formulations can grant a perfect finish to makeup products and provide good sensorial properties.

Innovations in the cosmetics industry are not short-term, and it can take over five years of innovative research and formulation to bring a new product to the market.

Innovations are also not static. Every year, a quarter of all cosmetic products on the market are improved or are entirely new.

Although innovation in our industry is a constant process, revolutionary breakthroughs are rare.

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Experts for Cosmetics Processing

Travis has over 20 years of experience in the dry bulk solids industry and is the President at Vortex, an engineering and manufacturing company that specialises in process valves and loading solutions specifically for solids handling. Travis has worked on solution-driven installations across six continents and has a strong knowledge of market-specific regulations and requirements within the industry.
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Tim Llewellyn is the Global Projects & Applications Engineering Manager at Flexicon Corporation, a world leader in the design and manufacture of bulk handling equipment and custom-engineered systems. He has over 20 years of experience managing and delivering complex global projects within the bulk material handling industry, including expertise across multiple sectors, including food, chemical, pharmaceutical, nutraceutical, and plastics. Tim has a proven track record of building and managing teams focused on helping clients solve their powder handling challenges. Tim holds a Bachelor of Science degree in Mechanical Engineering from Lehigh University.
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Alex McCans is National Sales Manager for HammerTek Corporation, manufacturer of the innovative Smart Elbow Deflection Elbow. With over 10 years of experience in mechanical and pneumatic conveying of bulk solids, Alex leads the HammerTek sales team to solve conveying challenges for customers around the world. His expertise and dedication have helped establish HammerTek as a trusted leader in the industry.
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Malcolm has an extensive background as a Mechanical Engineer in Material Handling and Sieving Technology and has been working on Vibratory Sifter Technology for well over 40 years, with the last 21 years at Kason Europe. Malcolm currently holds the role of Technical Sales Engineer. He handles all the technical aspects of providing the Regional Sales Managers with the quotations they require to sell the AMP/AHS range of equipment globally. He also assists the RSM’S with customer queries and final deal negotiations as well as liaising with the Engineering team to ensure a smooth transition between sales and GA approval. His vast knowledge means that he also offers and provides training where required on the AMP product range of equipment across the European Sales group.
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Gareth Meese works as Regional Sales Director – EMEA (Europe, the Middle East, India, and Northern Africa) for Eriez-Europe, a global leader in several key technology areas, including magnetic separation, metal detection, and material handling equipment. With nearly 20 years of experience in continuously-evolving positions, Gareth is well versed in bulk material handling applications. When Gareth joined Eriez as an Export Sales Engineer, he led several Eriez teams tasked with expanding business throughout Scandinavia, the Baltic States, and the Czech Republic. Later, as Export Sales Manager, he concentrated on growing Eriez-Europe in Russia, Europe and Northern Africa. His recent promotion expands his geographic responsibilities further with the addition of the Middle East and India. Gareth has been instrumental in pursuing Eriez’ vision and holds a Bachelor of Science in Physics from Cardiff University. Gareth is more than prepared to discuss and recommend a tailored solution for any unique bulk material handling application.
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Robert brings over 25 years of experience for bulk material handling and material processing equipment to Material Transfer. At MTS, he is responsible to fostering new business opportunities while nurturing account relationships. His depth of experience and industry knowledge allows our Team to meet the growing needs of our customers as we continue to provide the highest quality systems to the marketplace.
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Tim Porco is the the President of Erie Technical Systems Inc. He oversees the company’s day-to-day operations, ensuring top-notch solutions for customer needs. He holds a Chemical Engineering degree from Case Western Reserve University and is an active member of the Flexible Intermediate Bulk Filling Association (FIBCA). With an extensive background in technical sales, product management, and sales management within the powder solids handling industry, Tim applies his diverse skills to develop economical solutions for clients. Tim is committed to listening carefully to customer requirements and translating them into effective applications of Erie Technical Systems equipment.
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Design Engineer, Project Manager, Territory and Sales Manager with 40+ years of experience in capture at source designs, sales and installation projects for high and low vacuum and dust collection and filtration systems and explosion and fire mitigation in dust collection systems.
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Matthew Bailey – Technical Lead

Matthew is a mechanical engineer holding an honours degree from the Auckland University of Technology and has been responsible for BFM® Global’s product development, testing and compliance programme for almost 5 years. Matt’s experience is centered on the powder handling industry with a specific focus on flexible connectors, and all the compliance requirements around them. From food to pharmaceutical and all industries in between, Matt works with our Distributor partners, end users and OEMs from Europe, Asia and the Americas to solve application challenges. He regularly attends industry tradeshows around the world and understands the complex requirements of each different market.
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More than 35 years’ experience in development and realisation projects as a project manager for feed, aqua feed and petfood. Working at Dinnissen for 25 years as account manager in feed, aqua feed and petfood division. Specialist in developing major projects with added value focussing on pneumatic conveying, mixing, drying, grinding and coating with liquid and powder systems.
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