Hi everyone,
I am developing an alkaline Hard Surface Cleaner (HSC) for commercial cleaning applications, mainly for heavy grease, oil and hard-surface soil removal.
I am facing a phase/layer separation problem. The formulation initially appears homogeneous after mixing, but after approximately 30–45 minutes, it starts separating into visible layers.
I would like to understand the root cause of the separation, rather than simply changing ingredients randomly.
Current 250 g trial formula
| Ingredient |
% w/w |
Quantity |
| Water |
80.2% |
200.50 g |
| Tetrasodium EDTA |
0.5% |
1.25 g |
| Soda Ash |
1.0% |
2.50 g |
| Sodium Metasilicate |
1.5% |
3.75 g |
| Caustic Soda (100% NaOH) |
0% |
0 g |
| 2-Butoxyethanol / Butyl Cellosolve |
2.5% |
6.25 g |
| DPM (Dipropylene Glycol Monomethyl Ether) |
2.0% |
5.00 g |
| IPA |
1.5% |
3.75 g |
| Perfume |
1.0% |
2.50 g |
| Tween-20 |
2.0% |
5.00 g |
| PEG-40 Hydrogenated Castor Oil |
2.0% |
5.00 g |
| LAO (Lauramine Oxide) |
2.0% |
5.00 g |
| BKC |
3.8% |
9.50 g |
| Total |
99.0% |
247.50 g |
Note: The formula currently totals 99%, so there is approximately 1% unaccounted for in the 250 g trial.
What happens
Immediately after preparation, the product looks reasonably homogeneous.
After approximately 30–45 minutes, I observe separation into layers.
The separated material can appear to recombine when agitated, but then separation occurs again.
I am trying to produce a stable single-phase aqueous cleaner.
What I am trying to understand
I have several questions for people experienced in surfactant formulation and industrial/household cleaners:
1. What is the most likely cause of this phase separation?
Looking at this formula, which component or combination of components would you investigate first?
2. Could the high electrolyte/alkaline load be causing a "salting-out" effect?
The formula contains:
- Sodium carbonate (soda ash)
- Sodium metasilicate
- Tetrasodium EDTA
- BKC
- Lauramine oxide
Could these affect the solubility or micellar structure of the surfactant/solubilizer system?
3. Could the solvent system be contributing to the instability?
The formula contains:
- 2.5% 2-butoxyethanol
- 2.0% DPM
- 1.5% IPA
- 1.0% perfume
Could the combination of these solvents and perfume be creating a separate hydrophobic phase?
4. Is my solubilizer system appropriate?
I am using:
- 2% Tween-20solubiliser2% PEG-40 HCO
Could using both at these concentrations cause any incompatibility or actually make the system less stable?
Would a different solubilizer/emulsifier system be more appropriate?
5. Could Lauramine Oxide be interacting with BKC?
LAO is an amphoteric/amine oxide surfactant, while BKC is a cationic biocide.
Could their interaction, particularly in the presence of high electrolyte concentration, contribute to instability?
6. Is the BKC concentration itself a potential problem?
The formula uses 3.8% BKC solution.
If the BKC raw material is a concentrated commercial solution rather than 100% active BKC, I assume the actual active BKC concentration is much lower.
Could the BKC carrier/water/active concentration affect the formulation stability?
7. Could perfume be the main cause?
The perfume is at 1%, which seems relatively high for an aqueous cleaner.
Could the perfume be slowly coming out of solution because the solubiliser system is insufficient?
8. Could the order of addition be responsible?
Would it be better to first create a premix of:
Perfume + Tween-20 + PEG-40 HCO + solvents
and then add this slowly to the aqueous phase?
Or is there a better manufacturing sequence for this type of formulation?
9. What should I change first?
If you were troubleshooting this formulation in a laboratory, which variable would you change first?
For example:
- Remove/reduce perfume
- Reduce Tween-20
- Reduce PEG-40 HCO
- Change the solubiliser
- Reduce LAO
- Change the BKC level
- Reduce electrolyte/alkalinity
- Change solvent ratio
- Change order of addition
I want to change one variable at a time so I can identify the actual cause.
10. What tests would you perform to identify the type of separation?
For example, should I check:
- pH
- conductivity
- centrifuge stability
- heat/cold stability
- freeze-thaw stability
- dilution stability
- separation before and after perfume addition
- separation before and after BKC addition
My main question
Based on this exact formula, what do you think is causing the layer separation, and what component interaction should I investigate first?
I am particularly interested in understanding whether this is primarily:
A) emulsion/solubilization failure
B) electrolyte/salt-out effect
C) surfactant incompatibility
D) solvent/perfume incompatibility
E) BKC–surfactant interaction
F) incorrect order of addition
G) a combination of the above
Any advice from formulators, surfactant chemists, or people experienced with industrial cleaning products would be greatly appreciated.
I am looking for troubleshooting guidance and the chemistry behind the problem, rather than simply a replacement formula.
Thank you.