Optimal design and experimental validation of emulsified cosmetic products: A multiscale approach

There is an increasing demand for sustainable and cost-effective chemical products, such as eco-friendly emulsified products, contributing to a resource-efficient economy and a reduction in our ecological footprint. This new paradigm challenges the chemical industry due to a lack of accurate predictive models and understanding of emulsified systems. This study presents an optimization strategy to design cosmetic emulsions through a multiscale approach, which represents an opportunity to boost and improve the design of these products. The study employs a model-based design approach considering operating conditions, product formulation, economic performance, consumer preference, and the emulsions properties at different scales. At the macroscopic scale, rheological and textural properties are considered and coupled with a Population Balance Model, which estimates the drop size distribution (i.e., microscopic scale). The optimal emulsion formulation is established for consumer preference and product profit maximization scenarios. According to the economic model, a higher level of consumer preference is expected to lead to increased product sales. However, the results also indicate that consumer preference maximization may not necessarily correlate with higher profits. Thus, the profit maximization scenario offers a better balance between consumer preference and economic performance. Also, experimental validation was performed for the product properties and operating conditions.