{"id":20958,"date":"2025-09-20T10:29:44","date_gmt":"2025-09-20T08:29:44","guid":{"rendered":"https:\/\/staging.oliverbatlle.com\/?p=20958"},"modified":"2026-01-21T19:05:42","modified_gmt":"2026-01-21T18:05:42","slug":"incorporation-of-solids-into-oil-based-systems-process-development-and-pilot-solution-for-industrial-formulations","status":"publish","type":"post","link":"https:\/\/oliverbatlle.com\/en\/incorporation-of-solids-into-oil-based-systems-process-development-and-pilot-solution-for-industrial-formulations\/","title":{"rendered":"Incorporation of Solids into Oil-Based Systems: Process Development and Pilot Solution for Industrial Formulations"},"content":{"rendered":"<p><strong>In the technical materials industry\u2014from plastics to specialized coatings\u2014incorporating fine solids into oil-based systems poses a key challenge in terms of mixing and product stability.<\/strong> 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.<\/p>\n<p>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.<\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"font-size: 28px; font-weight: 600; letter-spacing: 0px;\">Project Goal: Incorporate Fumed Silica into Oil-Based Carriers<\/span><\/p>\n<p>The objective of the project was to develop a mixing process capable of incorporating up to <strong>4% fumed silica<\/strong> into two distinct oil-based matrices:<\/p>\n<ul>\n<li><strong>Polybutene\u00a0<\/strong><\/li>\n<li><strong>Mineral oil\u00a0<\/strong><\/li>\n<\/ul>\n<p>Both matrices are characterised by high viscosity, which makes it particularly challenging to disperse low-density solids while avoiding aeration and phase instability.<\/p>\n<p>The key goals were:<\/p>\n<ul>\n<li>Confirm the compatibility of <strong>OLIVER + BATLLE<\/strong>&#8216;s dispersion systems with the chosen raw materials<\/li>\n<li>Verify the efficiency and uniformity of the dispersion process<\/li>\n<li>Demonstrate process viability on a pilot scale as a step toward industrial application<\/li>\n<\/ul>\n<h2><\/h2>\n<h2>Step-by-Step Technical Solution: From Lab Testing to a Custom Pilot Unit<\/h2>\n<p>To meet the project requirements, <strong>OLIVER + BATLLE<\/strong> 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.<\/p>\n<h3>Phase 1 &#8211; Laboratory Trials<\/h3>\n<p>The initial testing phase took place in <strong>OLIVER + BATLLE<\/strong>&#8216;s technical laboratory using a planetary mixer designed for high-viscosity media.<\/p>\n<ul>\n<li>Multiple trials were conducted using different dispersion parameters and dosing sequences.<\/li>\n<li>All tests were recorded and shared with the client for remote review.<\/li>\n<li>Results exceeded expectations, delivering a homogeneous dispersion with no air entrapment or visible separation.<\/li>\n<\/ul>\n<h3>Phase 2 &#8211; Design and Delivery of a Custom Pilot System<\/h3>\n<p>Based on the successful lab tests, <strong>OLIVER + BATLLE<\/strong> designed and manufactured a bespoke pilot solution:<\/p>\n<ul>\n<li><strong>MPVDV-30 planetary mixer<\/strong>, adapted to the rheological requirements of the formulation.<\/li>\n<li><strong>Integrated vacuum powder loading system<\/strong>, enabling clean, safe incorporation of solids.<\/li>\n<li><strong>Plug &amp; play configuration<\/strong>, compatible with the client&#8217;s R&amp;D lab environment.<\/li>\n<\/ul>\n<p>This pilot system was built to simulate full-scale production conditions while maintaining flexibility and ease of operation.<\/p>\n<h3>Phase 3 &#8211; Joint Validation (FAT + SAT)<\/h3>\n<p>The pilot unit was temporarily installed at OLIVER + BATLLE&#8217;s facility to carry out <strong>joint validation sessions with the client<\/strong> (FAT and SAT).<\/p>\n<ul>\n<li>A total of 8 real product batches were produced during this phase.<\/li>\n<li>Dispersion performance, final product quality and vacuum loading efficiency were thoroughly evaluated.<\/li>\n<li>The tests confirmed the robustness of the system and its suitability for further scaling.<\/li>\n<\/ul>\n<h2><\/h2>\n<h2>Project Outcomes: Efficient Solid Dispersion Without Defects<\/h2>\n<p>The project successfully met all its defined targets, with the following key outcomes:<\/p>\n<ul>\n<li><strong>Full process validation with client raw materials<\/strong><\/li>\n<li><strong>Efficient incorporation of solids without air or visible defects<\/strong><\/li>\n<li><strong>Custom-designed pilot mixer tailored to product viscosity<\/strong><\/li>\n<li><strong>Smooth transition from lab trials to industrial-scale production<\/strong><\/li>\n<li><strong>Client now fully equipped to continue development in-house<\/strong><\/li>\n<\/ul>\n<h2><\/h2>\n<h2>Conclusion: A Reliable Mixing Solution for Oil-Based Systems with Fine Solids<\/h2>\n<p>This project showcases how a combination of technical expertise, in-house validation and tailored equipment design enables industrial clients to <strong>solve complex formulation challenges<\/strong>. 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.<\/p>\n<p>Thanks to this collaboration, the client is now equipped with a validated, reliable solution for continued product development under real operating conditions.<\/p>\n<p>&nbsp;<\/p>\n\n\t\t\t<div\n\t\t\tclass=\"hs-form-frame\"\n\t\t\tdata-region=\"eu1\"\n\t\t\tdata-form-id=\"318b29b5-e207-4d3e-912d-1102a4a108e7\"\n\t\t\tdata-portal-id=\"147556243\"\n\t\t\t >\n\t\t\t<\/div>\n\t\t\t\n","protected":false},"excerpt":{"rendered":"<p>In the technical materials industry\u2014from plastics to specialized coatings\u2014incorporating 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 [&hellip;]<\/p>\n","protected":false},"author":15,"featured_media":20959,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"content-type":"","footnotes":""},"categories":[50518882,50518883,50518886],"tags":[],"class_list":["post-20958","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-blog-en","category-mixing","category-process"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v25.1 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Incorporation of Solids into Oil-Based Systems: Process Development and Pilot Solution for Industrial Formulations - Oliver + Batlle Incorporation of Solids into Oil-Based Systems: Process Development and 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