Troubleshooting Pro Polymer Gel Formation with Electrolytes

It appears you are having trouble fully dissolving Pro Polymer in your formulation, resulting in lumps. This is a common issue when working with gel makers like Pro Polymer in formulas containing high concentrations of electrolytes.

Your formula includes 10% Azelaic Acid, which is an electrolyte. Electrolytes can interfere with the gel-forming mechanism of Pro Polymer, making it harder to achieve a smooth, lump-free gel and potentially reducing the final viscosity.

The staff's suggestions are correct and address this specific challenge. Here's a breakdown of why this happens and how to improve your process:

Why Electrolytes Cause Issues

Pro Polymer creates a gel structure through a polymeric network. Electrolyte substances, which contain ions like Sodium, Magnesium, Calcium, or Potassium, can disrupt this network, preventing the polymer from fully hydrating and swelling, leading to undissolved lumps and a less viscous gel.

Recommended Solutions

Based on the nature of Pro Polymer and the presence of Azelaic Acid in your formula, here are the recommended approaches:

1. Use Appropriate Mixing Equipment: While you mentioned using a blender, ensure it is capable of providing sufficient shear to help disperse the Pro Polymer powder and break up any initial clumps, especially in the presence of electrolytes. However, be careful not to over-blend at high speeds (above 2500 rpm) once the gel starts to form, as this can damage the polymer structure.

2. Adjust the Mixing Procedure: This is often the most effective method when dealing with high electrolyte concentrations. Instead of mixing the electrolyte-containing ingredients (like Azelaic Acid) in the initial water phase, try this modified approach:

   • Create the gel base first by mixing Pro Polymer with the distilled water and other non-electrolyte water-soluble ingredients (like Lemon Peel Bioferment, Vitamin B3, n-acetyl glucosamine). Sprinkle the Pro Polymer powder slowly onto the water while stirring gently for 3-5 minutes to allow it to disperse. For best results and to avoid high-speed blending initially, you can let this mixture sit for up to 24 hours to allow the Pro Polymer to fully hydrate before blending slowly.
   • Once a thick gel base is formed, slowly add the electrolyte-containing ingredients (Azelaic Acid) and the oil phase ingredients (LipidSoft, Light Cream Maker) while continuing to mix. Adding electrolytes at this stage allows the gel structure to form first before being exposed to the disruptive ions.

3. Consider Increasing Pro Polymer Concentration: The product description for Pro Polymer notes that a higher amount (e.g., 2-3%) may be needed when the formula contains significant electrolytes to achieve the desired viscosity, compared to the usual 0.8-1% in formulas without electrolytes. You might consider slightly increasing the Pro Polymer percentage in your formula to compensate for the effect of the Azelaic Acid.

By adjusting your mixing technique, particularly by forming the gel before adding the Azelaic Acid, and ensuring proper dispersion of the Pro Polymer powder, you should be able to achieve a smoother, lump-free gel texture.