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Incorporation of Solids into Oil-Based Systems: Process Development and Pilot Solution for Industrial Formulations

Solids-into-Oil-Based

In the technical materials industry—from plastics to specialized coatings—incorporating fine solids into oil-based systems poses a key challenge in terms of mixing and product stability. When working with highly viscous raw materials such as polybutene (PIB) or mineral oils, achieving a homogeneous dispersion, without incorporated air and with guaranteed long-term stability, requires precise process design and equipment adapted to the demands of the product.

In response to this challenge, OLIVER + BATLLE partnered with a client in the industrial plastics sector to co-develop and validate a tailored solution. The goal was to assess the technical feasibility of incorporating up to 4% fumed silica into two different oil-based formulations, while maintaining product homogeneity and ensuring scalability for industrial production.

 

Project Goal: Incorporate Fumed Silica into Oil-Based Carriers

The objective of the project was to develop a mixing process capable of incorporating up to 4% fumed silica into two distinct oil-based matrices:

  • Polybutene 
  • Mineral oil 

Both matrices are characterised by high viscosity, which makes it particularly challenging to disperse low-density solids while avoiding aeration and phase instability.

The key goals were:

  • Confirm the compatibility of OLIVER + BATLLE‘s dispersion systems with the chosen raw materials
  • Verify the efficiency and uniformity of the dispersion process
  • Demonstrate process viability on a pilot scale as a step toward industrial application

Step-by-Step Technical Solution: From Lab Testing to a Custom Pilot Unit

To meet the project requirements, OLIVER + BATLLE proposed a three-phase strategy that combined in-house lab testing, the development of a custom-built pilot mixer, and a full validation of the mixing process.

Phase 1 – Laboratory Trials

The initial testing phase took place in OLIVER + BATLLE‘s technical laboratory using a planetary mixer designed for high-viscosity media.

  • Multiple trials were conducted using different dispersion parameters and dosing sequences.
  • All tests were recorded and shared with the client for remote review.
  • Results exceeded expectations, delivering a homogeneous dispersion with no air entrapment or visible separation.

Phase 2 – Design and Delivery of a Custom Pilot System

Based on the successful lab tests, OLIVER + BATLLE designed and manufactured a bespoke pilot solution:

  • MPVDV-30 planetary mixer, adapted to the rheological requirements of the formulation.
  • Integrated vacuum powder loading system, enabling clean, safe incorporation of solids.
  • Plug & play configuration, compatible with the client’s R&D lab environment.

This pilot system was built to simulate full-scale production conditions while maintaining flexibility and ease of operation.

Phase 3 – Joint Validation (FAT + SAT)

The pilot unit was temporarily installed at OLIVER + BATLLE’s facility to carry out joint validation sessions with the client (FAT and SAT).

  • A total of 8 real product batches were produced during this phase.
  • Dispersion performance, final product quality and vacuum loading efficiency were thoroughly evaluated.
  • The tests confirmed the robustness of the system and its suitability for further scaling.

Project Outcomes: Efficient Solid Dispersion Without Defects

The project successfully met all its defined targets, with the following key outcomes:

  • Full process validation with client raw materials
  • Efficient incorporation of solids without air or visible defects
  • Custom-designed pilot mixer tailored to product viscosity
  • Smooth transition from lab trials to industrial-scale production
  • Client now fully equipped to continue development in-house

Conclusion: A Reliable Mixing Solution for Oil-Based Systems with Fine Solids

This project showcases how a combination of technical expertise, in-house validation and tailored equipment design enables industrial clients to solve complex formulation challenges. The incorporation of fumed silica into high-viscosity oil carriers is not only possible-it can be done efficiently and repeatably with the right process design and dispersion system.

Thanks to this collaboration, the client is now equipped with a validated, reliable solution for continued product development under real operating conditions.