Dual asymmetric centrifugation to prepare cosmetic emulsions and creams: Physico-chemical and energy considerations.

OBJECTIVE: This study evaluates room-temperature dual asymmetric centrifugation (DAC) as an R&D scale alternative mixing technology for cosmetic oil-in-water emulsions and structured creams (200 g), compared with high-shear rotor-stator and thermo-mechanical processes, with a focus on product properties and energy requirements. METHODS: Formulations were characterized by visual assessment, conductivity and pH monitoring over 30 days. Physical stability was analysed by multiple light scattering. Flow and oscillatory measurements were performed, complemented by texture analysis. Specific energy consumption was evaluated at both scales. RESULTS: All systems exhibited homogeneous oil-in-water structures with no significant differences in pH evolution or physical stability. Shear-thinning behaviour was observed for all formulations, while creams showed dominant elastic behaviour (G' > G″), indicating structured networks independent of the mixing process. Texture properties were similar across technologies. Energy analysis revealed a scale effect: rotor-stator was more efficient for 30 g samples, while DAC became competitive at 200 g due to the absence of heating. Final product properties remained comparable across processes. CONCLUSION: DAC is a robust and energy-efficient alternative for cosmetic emulsions and creams, enabling comparable product properties while offering potential energy savings at larger scales, supporting more sustainable processing strategies.