Glatt’s cutting-edge technology and Merck’s expertise have come together to revolutionise the production of special effect pigments using Dryflux technology, to meet the evolving demands of the cosmetics industry.
On 30 June, a completely new type of production plant for special effect pigments was officially commissioned at the Glatt Technology Centre. The Dryflux technology is suitable for numerous powder applications.
Pigment specialists at Merck and the technology and production experts at Glatt are working together to produce an innovative range of cosmetic pigments using completely new technology. Merck Group requested the development and construction of a plant based on chemical vapour deposition (CVD) after successful joint trials at Glatt’s Technology Centre in Weimar, Germany.
Since September 2022, the patent-pending Ronaflux pigments have been produced by Glatt in Weimar for the Darmstadt-based science and technology company, Merck. Glatt was commissioned by Merck to develop the plant technology and install the complete production facility, which is owned by Merck. Glatt then fulfilled its role as a contract manufacturer of Ronaflux pigments for Merck. Construction of the plant began in 2020. It spans 74m2 of floor space and 2.5 floors.
Strong technical capabilities
Merck and Glatt have enjoyed a successful partnership for many years, during which time Glatt has been manufacturing systems for Merck’s Healthcare and Life Science sectors.
Special quality and purity standards are needed to manufacture the Ronaflux pigments.
In recent years, investment grants from the Thüringische Aufbaubank have made it possible to create the ideal conditions for these processing requirements at Glatt’s Technology Centre. This allowed Glatt to expand its technological portfolio to include the development and application of high-temperature process technology based on fluid bed and powder synthesis. The necessary infrastructure was already in place at Glatt, and it could be expanded quickly and cost-effectively. As a plant and process specialist, Glatt has the corresponding know-how required to set up a production plant for the Ronaflux pigments.
A first for this system and scale
Dr Michael Jacob, head of process technology food, feed & fine chemicals at Glatt, says: “There is no other CVD system of this scale and no other plant like it. It was also developed, designed, built and commissioned in a relatively short time.”
Dr Jacob attributes some of the success of this project to the interplay of strengths within Glatt: “Not only were we able to draw on outstanding R&D resources, but also the technological synergies from high-temperature process engineering and our many years of expertise in plant engineering. The basic technology was already available through successful R&D activities.”
Among other things, Glatt benefits from the results of a joint project of the regional development cluster Thuringian Particle Design pades, which was funded by the Federal Ministry of Education and Research. Dr Jacob continues: “This development would not have been possible without our expertise in pharmaceutical engineering for the planning and realisation of cleanroom projects for GMP production, as well as in the cosmetics industry. We are not only plant constructors, but also operators and producers. We are problem solvers too, with the challenges involved with the commissioning quickly identified and resolved thanks to great teamwork. The cooperation with Merck is characterised by trust, constructive cooperation and partnership.”
A flexible technology
Dryflux technology creates a new class of special effect pigments, which are very colour intensive and have a metallic shine. These unique effects are based on thin carbon layers on the pigment surface. The technology is flexible and universally applicable to many powdered materials to meet customised customer requirements.
First, the pigment powder is stirred vigorously in the reactor with an inert gas and heated to the required reaction temperature. Then the formation of thin carbon layers around the powder particles begins with the introduction of a carbon-containing gas into the reactor, that is then decomposed. Once all the powder particles are evenly coated with a carbon layer, the product is cooled, sieved and packaged under strict hygienic conditions.
A second validation phase for other products is currently underway, in which the fluidisation behaviour of new raw materials will be evaluated and supporting parameters, such as pulsation, adjusted to the respective product.
