Two Ways to Enter the Market
- As an ingredient producer: extract and supply seaweed or microalgae actives to cosmetic brands and formulators.
- As a finished-product manufacturer: turn algae extracts into creams, gels, serums, and masks under your own brand or for private-label clients.
Our plants can serve either model, or both.
Algae Extract Production for Cosmetics
Cosmetic-grade extracts need consistent quality, clarity, and controlled microbiological standards. A typical extraction line includes:
- Raw material preparation: washing and size reduction of seaweed, or preparation of microalgae biomass
- Extraction: aqueous or glycol-based extraction in jacketed, agitated vessels with precise temperature control
- Cell disruption (for microalgae): homogenizers and bead mills to release actives
- Clarification: centrifugation and multi-stage filtration for clear extracts
- Concentration and standardization: adjusting solids and active content to specification
- Preservation and packing: formulation into stable, ready-to-use cosmetic ingredients
Finished Product Formulation
This is where Wahal's cosmetic industry experience applies directly. Our formulation systems include:
- Vacuum emulsifying mixers: for creams and lotions, with high shear homogenization under vacuum to give smooth, air-free emulsions
- High shear mixers: for dispersing algae-derived thickeners such as carrageenan and alginate into gels and serums without lumps
- Powder blending systems: for alginate peel-off masks and other powder formats
- Storage and filling interface: holding tanks and transfer systems ready to connect to filling lines
Algae-derived hydrocolloids are hard to hydrate without lumps or "fish-eyes." Properly designed high shear dispersion solves this and cuts batch times, which is one of the most common problems we help cosmetic manufacturers fix.
Hygienic Design
Cosmetic production demands hygienic equipment. Our systems are built with:
- SS316L contact parts with polished internal finishes
- CIP-ready vessel and piping design
- Sanitary fittings and drainable layouts
- Documentation to support GMP-oriented operations
Plant Scales
- R&D and pilot systems: for formulation development and small-batch launches
- Production lines: batch formulation from small runs to multi-tonne capacity
- Integrated plants: extraction and formulation under one roof
Why Wahal Engineers
Wahal Engineers has long supplied mixing, homogenizing, and emulsifying equipment to cosmetic, pharmaceutical, and food manufacturers. We manufacture our core process equipment in Sonipat, India, and integrate it with the separation and filtration systems your process needs, delivering a single, commissioned plant.
Frequently Asked Questions
Can one plant handle both seaweed and microalgae?
Yes. Extraction lines can be configured for multiple raw materials, with cell disruption modules added for microalgae.
What products can the formulation section make?
Creams, lotions, gels, serums, and powder masks, using algae extracts and algae-derived thickeners.
Can you supply only the formulation equipment?
Yes. We supply individual formulation systems as well as complete turnkey plants.
Is the equipment suitable for GMP environments?
Our equipment follows hygienic design principles and comes with documentation to support GMP-oriented production.
