Emulsions are fundamental to a vast array of commercial products, yet they represent inherently unstable thermodynamic systems that require precise engineering. The successful development of an emulsion demands profound expertise in colloid chemistry, rigorous selection of surfactant systems, and highly controlled mechanical processing. Developing stable, high-performing emulsions—whether macroemulsions, nanoemulsions, or complex multiple emulsions—requires a partner who understands the intricate balance of interfacial tension, rheology, and droplet size distribution. BOC Sciences offers comprehensive emulsion formulation services, seamlessly bridging the gap between benchtop prototyping and large-scale manufacturing. From initial excipient screening and phase behavior mapping to process engineering and scale-up, we leverage advanced homogenization technologies to deliver robust, stable formulations. Our integrated approach helps clients across the chemical, personal care, food, and specialized materials industries overcome phase separation challenges, protect sensitive active ingredients, and achieve reliable commercial production.
BOC Sciences delivers technical excellence in colloid chemistry and process engineering, ensuring your formulations remain stable, uniform, and scalable.
BOC Sciences commands deep expertise across a variety of complex colloidal systems, tailoring the physical chemistry to match the specific delivery, texture, and performance requirements of your product.
Share your target product profile or current stability issues, and our formulation scientists will propose a customized strategy to perfect your emulsion.
Assess client requirements, define target physiochemical properties (viscosity, droplet size, appearance), and select candidate emulsifiers and processing methods.
Prepare laboratory prototypes, perform rigorous physical characterization, and iteratively adjust the surfactant system to prevent creaming, flocculation, or coalescence.
Translate mixing dynamics to pilot scale, optimize high-shear parameters, and subject the formulations to accelerated stability protocols to ensure long-term viability.
Deliver comprehensive formulation batch records, process validation data, or proceed to large-scale commercial manufacturing based on client preference.
Emulsions naturally tend to separate over time through Ostwald ripening, creaming, or coalescence. We address these thermodynamic challenges by meticulously designing the interfacial film using optimized surfactant blends, steric stabilizers, and electrostatic repulsion strategies. Our predictive stability models drastically reduce the time needed to formulate a robust product.
Achieving an ultra-fine, uniform droplet size is critical for product clarity, bioavailability, and texture. Standard mixing often fails to produce nanoscale droplets. We utilize advanced high-pressure homogenization and microfluidization platforms, fine-tuning pressure and pass cycles to consistently achieve targeted D50 and D90 metrics, even for challenging nanoemulsions.
A stable lab emulsion often breaks when transitioned to a 500L manufacturing vessel due to vastly different shear rates and heat transfer profiles. BOC Sciences applies rigorous chemical engineering principles, calculating tip speeds, shear stress, and cooling rates, to ensure that the exquisite texture and stability achieved in the beaker are perfectly replicated on the plant floor.
Many valuable compounds are prone to oxidation or hydrolysis when incorporated into biphasic systems. We specialize in designing multiple emulsions (W/O/W) and encapsulating matrices that shield fragile actives. By controlling the processing environment (e.g., vacuum mixing, low-temperature emulsification), we maximize the retention and efficacy of your key ingredients.
Our formulation scientists possess extensive academic and industrial experience in physical chemistry, enabling us to solve complex interfacial problems rather than relying on trial-and-error guesswork.
We do not just rely on visual observations. Our state-of-the-art analytical equipment provides quantifiable data on zeta potential, rheology, and droplet size, ensuring data-driven formulation decisions.
Because our development labs and production facilities are tightly integrated, the engineers responsible for scale-up are involved from day one. We offer processing capacities ranging from lab-scale prototypes to multi-ton bulk batches.
Every project is uniquely tailored to the specific raw materials and end-use requirements of the client. We provide complete transparency in our methodologies, transferring all optimized formulas and process parameters to you.
Client Needs: A functional beverage company required a transparent, water-soluble formulation for a highly lipophilic active compound. The formulation needed to remain optically clear and stable in acidic beverage bases for at least 12 months.
Challenges: Conventional emulsification resulted in a milky appearance and severe ringing (creaming) at the neck of the bottle after just two weeks of storage. Achieving optical clarity required reducing the droplet size well below the wavelength of visible light.
Solution: BOC Sciences designed a robust nanoemulsion system utilizing a specialized blend of food-grade, high-HLB emulsifiers. We employed high-pressure homogenization, optimizing the pressure to 15,000 psi across multiple passes. By precisely mapping the ternary phase behavior, we minimized the surfactant load while maximizing the active payload.
Outcome: The final nanoemulsion achieved a stable droplet size (D50 < 45nm) with a narrow polydispersity index. The resulting concentrate was completely transparent when diluted in water, exhibiting zero separation or turbidity after accelerated aging tests equivalent to an 18-month shelf life.
Client Needs: A skincare brand sought to develop a "water-burst" sensory cream that also provided sustained release of a sensitive, water-soluble antioxidant.
Challenges: The client's initial Water-in-Oil-in-Water (W/O/W) attempts failed entirely. The internal water droplets coalesced with the external water phase during the secondary emulsification step, leading to the immediate degradation of the active ingredient and loss of the unique texture.
Solution: Our physical chemists reformulated the primary W/O emulsion using a highly structured polymeric emulsifier to create a rigid interfacial film. For the secondary emulsification (W/O into W), we engineered a low-shear, controlled-addition process using a specialized agitator. This prevented the mechanical rupture of the primary emulsion droplets while evenly dispersing them into the external aqueous gel matrix.
Outcome: The W/O/W multiple emulsion remained structurally intact, verified via confocal microscopy. The active ingredient demonstrated a protected, sustained-release profile over 24 hours, and the client successfully launched a highly differentiated product with excellent sensory feedback.
Client Needs: A specialty materials company needed to scale up a high-viscosity, wax-based emulsion from a 5L laboratory scale to a 2,000L commercial batch size.
Challenges: The formulation had a steep temperature-viscosity curve. During initial scale-up attempts at the client's facility, uneven cooling led to localized wax crystallization and irreversible phase separation (breaking) before the emulsion could fully form.
Solution: BOC Sciences' engineering team conducted a thorough rheological profiling of the emulsion at various temperatures. We modeled the fluid dynamics to design a custom heating and cooling protocol. We transferred the process to our state-of-the-art vacuum emulsifying vessel equipped with counter-rotating sweep agitators and a bottom-entry high-shear homogenizer. This ensured intense, uniform energy dissipation and eliminated thermal dead-zones.
Outcome: The process was successfully scaled to 2,000L with 100% reproducibility. The commercial batches exhibited tighter droplet size distributions than the original lab samples, and manufacturing time was reduced by 30% due to the optimized cooling cycle.
BOC Sciences can handle oil-soluble, water-soluble, and lipid-based active ingredients, supporting oil-in-water (O/W) and water-in-oil (W/O) systems. We select suitable emulsifiers and dispersion methods based on material properties to ensure emulsion stability, uniform particle size, and consistent physicochemical performance for R&D and process development.
Emulsion stability depends on particle size distribution, surfactant combination, and dispersion energy. BOC Sciences adjusts emulsification parameters, shear forces, and temperature, combined with optimized formulation design, to achieve long-term uniform, phase-stable emulsions with consistent performance for downstream applications.
For poorly soluble or thermosensitive materials, we provide optimized solvent selection, low-energy emulsification, and temperature-controlled processes to preserve active ingredient structure and function while ensuring uniform, stable emulsion systems suitable for R&D and scale-up.
BOC Sciences’ emulsion platform flexibly supports laboratory-scale and pilot-scale batches. We design customized emulsification workflows and process parameters to ensure each batch maintains consistent particle size, viscosity, and stability, facilitating R&D validation and formulation optimization.
Using precision emulsification equipment, standardized process parameters, and online monitoring, BOC Sciences ensures each batch maintains consistent particle size, dispersion uniformity, and physical stability. Combined with formulation optimization and process documentation, this delivers reliable, reproducible emulsion performance for R&D and production.
Our internal team struggled for six months with a stubborn creaming issue in our new lotion base. BOC Sciences identified the root cause in just weeks through zeta potential analysis and completely stabilized the formula by adjusting the rheology modifiers. Their scientific depth is impressive.
— Dr. Richards, R&D Director, Personal Care Brand
Taking our microemulsion from the benchtop to a 1000L tank was our biggest fear. BOC Sciences managed the entire scale-up process meticulously. The transition was seamless, and the commercial batches match our lab prototypes perfectly in both appearance and performance.
— Mr. Davis, Operations Manager, Specialty Chemicals
We needed a highly transparent delivery system for a poorly soluble active. The nanoemulsion BOC Sciences developed exceeded our expectations—it's crystal clear and incredibly stable. They truly understand the nuances of high-pressure processing.
— Ms. Patel, Product Manager, Nutraceutical Co.
Working with their formulation team has been a pleasure. They provided comprehensive batch records, detailed stability data, and were always available to troubleshoot when we integrated the formulation into our final product line. A top-tier technical partner.
— Dr. Hughes, VP of Innovation, Agrochemical Producer
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