A.) WAX/OIL PHASE & WATER VESSEL SPECIFICATIONS

Material of construction:

B.) MANUFACTURING VESSEL

Material of construction :

C.) PRODUCT PIPE LINE :

Pipe line will cover the following :
1) Water phase vessel to Mixing vessel thru pump
2) Wax phase vessel to Mixing Vessel thru pump & conical filter
3) Mixing Vessel for re-circulation
4) Mixing vessel to Storage Vessel through lobe pump.
5) Storage vessel to hopper of filling machine through transfer pump.

All pipe are seamless & electropolished from inside and outside. Fittings are DIN standard with silicon gasket.

D.) ELECTRIC CONTROL PANEL :

It shall consist of
a Main isolator
b DOL starter for Anchor drive
c DOL starter for HSE motor
d Machine light switch for main Mixing Vessel
e Electrical Digital temperature indicator for all vessel
f. Fuses for all motors
g. Ammeter for anchor and HSE motors
h. Indicating lamps for main ON & OFF with selector switch.
i. DOL starters for propeller agitators of Wax & water Phase vessels
j. DOL Starters for all the pumps

E.) PUMPS:

CENTRIFUGAL PUMP
Rate : 400 Ltrs/Hr
MOC : SS 316Q
Inlet & Outlet : DIN fitting with T connection at inlet & outlet
Above pump is used to transfer wax & water to the main mixing tank.

BUMP PUMP :
Above pump is used to recirculate final mixed cream for intense mixing & to transfer finished cream from Mixing vessel to storage vessel. Other details are as below.
1) Type : Twin BUMP
2) Design : Sanitary
3) Drive : suitable HP, 200 RPM gearbox & motor
4) Seal : Teflon bush
5) Mounting : Trolley mounted , MOC – SS304Q
6) Inlet & outlet : DIN fittings / triclover at inlet & outlet.
7) MOC : SS 316Q for contact parts

TRANSFER PUMP – RECIPROCATING TYPE, POSITIVE DISPLACEMENT & METERING TYPE
Above pump is used to transfer CREAM/OINTMENT from storage vessel to hopper of filling machine.

a) Type : Reciprocating Plunger type
b) Capacity : 1000 LtR./Hr
c) Drive : suitable HP, 1440 RPM
d) Head : 2.5 Mtr.
e) Mounting : Trolley mounted , MOC – SS304Q

The above pump doses metered quantity of cream into the hopper of filling machine which suits filling rate of filling machine. There is control feed back system between Filling machine & pump.

VACUUM PUMP :
Above pump is suitable HP & capacity depending on the capacity of the ointment plant vessel . watering / oilring type with silencer & non return valve.

F.) STORAGE TANK:

The vessel shall be in SS 316Q having cylindrical conical bottom. The vessel will be provided with 40mm ball valve. Shell portion will be flanged from top & bolted to top dish with gasket in bet-ween. All joints are fusion free argon arc welded & inside mirror finished.
The vessel will be supported by 4 nos. cladded ‘C’ class 3” pipe and to maintain 450mm ground clearance. Vessel has 50mm inlet nozzle for finished product entry & vent.

G.) WORKING PLATFORM :

This platform will cover both tanks & with AL dimpled plate and SS counter sunk screw. SS 304 Q railing on either side. There is provision of steps on either side.

General

Shampoos are typically viscous liquids, either clear or opaque (pearlised), containing 20–40% solids, adjusted to approximately pH 5.5. Most, but not all, have viscosities in the ratio of 500–1500 centipoise. A hair shampoo may be defined as a detergent specifically formulated for the washing of hair, and packaged in a user-convenient form. Typically, a shampoo must clean well, rinse easily, impart gloss to the hair, minimise tangle and not damage the hair structure, or the scalp or the eyes.

MANUFACTURING PROCESS

Shampoos are manufactured by simple slow blending in a stirred vessel. The vessel may be jacketed for heating. Vessels are normally closed type and subjected to vacuum to avoid excessive foaming when foaming agent is added. For best results contra type rotating stirrer is best used for shampoo manufacturing.
Ingredients are weighed or metered incrementally into the mixing vessel, with thorough mixing between each addition. A moderate amount of heat is used to reduce the viscosity and so facilitate ease of mixing.
Some pearlising agents are waxy solids at ambient temperature and require melting in a premixing vessels before use. Demineralised water is most commonly used in order to minimise contamination of the product.
No further processing is required after blending, & perfuming and the product may be packed off directly from the mixing vessel. Or may be transferred to storage vessels from where they are transferred to the filling machines.
Many companies make the bases for the shampoos where they do all the premxing of surfactants, sles, other ingredients and sell the same to major industries These industries are mainly called the formulators and in this second level processing will involve only the addition of water, colour and fragrance. In case of ayurvedic or herbal shampoos, they add their propriety formulae ingredients themselves so that no one knows the exact nature of ingredients and its details.

VESSELS REQUIRED FOR A SHAMPOO PLANT

MAIN SHAMPOO MANUFACTURING VESSEL
Manufacturing vessel is cylindrical vessels with dished bottom vessels. Top of the vessel is also dished end welded. Agitator assembly in the manufacturing vessel., slow speed Anchor agitator is provided in the manufacturing vessel. However for best results contra rotating or semi contra rotating agitators are normally preferred by most of the manufacturers for excellent quality of the shampoo produced. CIP turbo disk is provided at the top of the vessel for cleaning. Suitable nozzles, manholes, valves etc are provided on the vessel. Vessel can also be provided with jacket which can be used for both heating and cooling if required by the client. Manufacturing vessel can be subjected to full vacuum.

PREMIXING VESSEL

Premixing vessel is cylindrical vessels with dished bottom vessels. Top of the vessel is also dished end welded or can be provided with loose lid too. Agitator assembly in the premix vessel. Is high speed cowl/ saw cutter type agitator. In some cases high speed homogenizer are also provided. CIP turbo disk is provided at the top of the vessel for cleaning. Suitable nozzles, manholes, valves etc are provided on the vessel. Vessel is provided with jacket for heating. Jacket can be steam heated or electrically heated as per client’s requirement. Suitable insulation and cladding is provided on the jacket. There is no need for any vacuum in this vessel. Normally the capacity of this vessel is 60 % the capcity of the main manufacturing vessel. Premix vessels can be 1 no or 2 nos as per the clients requirements and formulae of the shampoo.

STORAGE VESSEL

Storage vessel is simple vessel used to store shampoos. It is cylindrical type of vessel with dished bottom, loose top lid. Bottom valve is provided with din fittings to facilitate the pipeline connection. Its capacity is the same as the manufacturing vessel. Normally storage tanks are more in number so that different types of shampoos can be manufactured and stored. Filling is then done as per the requirement & market demands.

SLES/ SURFACTANTS STORAGE VESSEL

In manufacturing of shampoos the SLES/ surfactants form a major ingredients. Hence it has to be stored in large quantities. Also if drums of 200 kgs are bought it will turn expensive for the manufacturers. Hence most of the manufacturers but one entire tanker of surfactants and store the same. Normally one weeks/ months usage of surfactants are normally kept stored to ensure continous production. Hence the capacity of this storage tank will be taking into consideration of the storage requirements of the client. This tanks are vertical tanks with big heights with flat bottom. Top is also closed with suitable manhole and nozzles for effective loading into the vessel through pumps. Similarly outlet is also provided at the bottom where the surfactants are tansfered from the storage vessel into the manufacturing vessel or premix vessel through pumps.

PUMPS

Transfer pumps are used to transfer material from premix vessel to the manufacturing vessel only if the mfg vessel is not under vacuum. If it is under vacuum the premix is automatically transferred into the main vessel through vacuum. Transfer pumps are required for the following
o Transfering surfactants to premix / main vessel
o From main vessel to storage vessels
o From storage vessel to filling machine.

PIPELINE

Interconnecting pipeline is provided for the plant as per the layout of the clients room size. All pipelines are electropolished from inside and outside. All joints are DIN standards quick openable types. Pipelines are used for transferring the surfactants from storage tank to premix vessels, from premix vessels to manufacturing vessels and from mfg vessels to storage vessel and from storage to filling line.

OTHERS

All vessels have CIP/ SIP nozzles & conical filters are provided at the discharge of the vessels. Entire plant is fully automatic and interconnected by suitable pipeline & requires only one operator for all the operations. Suitable working platform is provided for cleaning and maintainence. An integrated control panel fully automatic controlled by a PLC is provided. (Optional)

CONTROL PANEL & AUTOMATION

Control panel is provided with all the starters, overload relays, push buttons, lamps, ckt breakers etc. all hardware required for automatic operation of the shampoo mfg plant is provided in the control panel.
Various automation is available as per clients requirements to name a few

o PLC of any brand and configuration.
o Load cells under each vessel
o Pneumatically operated valves
o Any Other custom built automation

Capacities of shampoo manufacturing plants manufactured

200 Ltrs to 20000 ltrs / batch

OTHER TYPES OF SHAMPOO PLANTS AVAILABLE

Shampoo plants are also available in economic range where open type with agitator vessels are provided with various cheaper options to suit every budget.

GENERAL

Hair Oil are typically viscous liquids, either clear or opaque. They come in various types from normal hair oils, ayurvedic, herbal, medicinal, etc and cater to different types of hairs.

MANUFACTURING PROCESS

Hair oils is one of the most simplest to manufacturer. Hair oil is manufactured in simple stirring type vessel at slow speed. The different type of oil bases are mixed as per the formulae and then active ingredients are added. Perfuming is done and then directly taken for filling.

VESSELS REQUIRED FOR A SHAMPOO PLANT

Oil Manufacturing Vessel
Manufacturing vessel is cylindrical vessels with dished bottom vessels. Top of the vessel loose lid Agitator assembly in the manufacturing vessel., slow speed Anchor agitator or paddle type agitator. Bottom outlet is provided. No additional gadgets are required for manufacturing hair oil

Storage Vessel
Storage vessel is simple vessel used to store Hair Oils. It is cylindrical type of vessel with dished bottom, loose top lid. Bottom valve is provided with din fittings to facilitate the pipeline connection. Its capacity is the same as the

OPERATION

The RIBBON BLENDER is an efficient and versatile blending machine for mixing of dry granules & powders homogeneously. Approximate two third of the volume of the container of Ribbon Blender is filled to ensure proper mixing. The Ribbon Blender gives best result for mixing of dry powder & granules due to the design and shape of the mixing ribbon and product container. It can be used for Pharmaceutical, Food, Chemical and Cosmetic products etc.

Material should be charge from the top side. There are port/ports should be provided on the top cover to charge the material as well as for air vent. One discharge valve provided at the bottom side at center of the container. The discharge height could be adjust as per the requirement, so that material gets discharge in the other container directly, so that material handling time for discharge is nil and the operation is dust free.

In Ribbon Blender the powder moves from center to the end of container and end of container to the center of container. Hence requirement of total mixing time is very less and the RPM required are also very less.

The dry material gets sufficient contineous movement due to the shape & movement of ribbon & shape of the container., which moves material for good quality of blending.
The unit is consist of one electrical motor, one worm reduction gear, belt drive between motor and gear, couple drive between gear to ( ribbon ) mixing stirrer. Container having four nos. of legs with discharge valve & top cover. Both end of mixing shaft is sealed with bush & PTFE gland housing & safety guards are provided on all moving parts.

SALIENT FEATURES :

• The shape of container and mixing stirrer gives sufficient contineous movement to the powder / granules, result in good quality.
• All contact parts are made out of SS304/SS316 quality material.
• Maximum care has been taken to ensure safe operation of the unit.
• Inching facility for stirrer for discharge of material.
• Full cover on top side of the container.
• Discharge height must be adjusted, if confirm with order.
• Operating panel provided for safe operation of blender.
• Centrally located material Discharge valve.
• Dust proof top cover with window provided.
• General structure completely made out of mild steel & painted in Standard Model & the same is claded with SS304 in GMP model.
• Safety Guards & Covers made out of SS304 in GMP Model & made out of mild steel in Standard Model.
• Legs made out of M.S & painted in Standard Model & same will be claded with SS304 in GMP Model.
• Automatic control Panel provided with the machine.

TOOTHPASTE MANUFACTURING MIXER consists of a Main Manufacturing Vessel also known as Contra Mixer. Contra Mixer as the name suggest works on the principle of Contra rotation of Blades for simultaneous beating and scraping operation. The mixer is highly versatile and mostly used for manufacturing Tooth Paste, Creams, Cosmetics and other viscous products.

The Mixing Assembly consists of series of paddle type blades of appropriate shape to move the material back towards the centre of the container. The paddle type blades are provided on the central shaft which runs through a hollow shaft on which other sets of blades are welded. Both the sets of blades intermeshes with each other and rotates in clockwise and anti-clockwise direction respectively and one sets also scraps the container wall for thorough and uniform mixing of the material.

The mixer is so designed to withstand high vacuum applied during the process for optimum mixing. Contra Mixer is provided with a jacket for cooling or heating as per the application. The vessel shall have a shell of suitable thickness with a hemispherical bottom and flanged top dish made out of S.S. 316 plate. The vessel shall be jacketed with MS jacket ( SS304 jacket provided on extra cost on demand, if required ) of suitable with stiffeners suitable for steam pressure of 4 to 5 Kg/cm2. The jacket shall be insulated with 50 mm thick glass wool insulation and shall be cladded with 16 SWG M.S. or SS304 material. The vessel shall be suitable for 600 to 700 mm of Hg vacuum and internal pressure of 3 Kgs / cm2.

The top lid of the Mixer m/c shall be provided with hydraulic lifting and lowering arrangement, if required. Hydraulic arrangement will consist of : ( Optional at extra cost )
a. Hard Crome plated HYDRAULIC CYLINDERS ( 2 Nos. )
b. Limit switches at upper and lower limits
c. Power pack with direction control valve by actuated

SPECIAL FEATURES

• All contact parts are made out of SS 304 / SS 316 quality material.
• Compact design requires comparatively smaller floor space.
• Product container mounted on mounting lugs or legs as required by customer.
• Hydraulic power pack with cylinders are provided for lowering and lifting movement of top cover with stirrers drive assembly. Lowering and lifting movement of drive assembly will be achieved through hydraulic lifting system for easy of cleaning and changeover of products. (OPTIONAL - Provided On Demand)
• Fixed product container for safe operation during mixing.
• Product container having hemispherical shape bottom.
• As stirrer is a top driven and sealing doesnt comes in contact with product, there isnt any black particle contamination problem.
• Steam circulation jacket for mixing bowl, to heat the product during operation & water circulation facility to cool the product during or after mixing. ( made out of mild steel or SS304, as per customer requirement )
• All Non contact parts (general structure) made out of mild steel (SS304 provided on demand, on extra cost) and claded with SS304 or crome plated or made out of SS304 in GMP Model.
• Contact parts are polished to the mirror finished and noncontact parts are polished to the matt finished in GMP Model. All safety guards & covers made out of SS304 material in GMP model & made out of mild steel & painted in standard model.
• General structure & all non contact parts are made out of Mild Steel & same will painted in Standard Model.
• Digital temperature indicator provided to indicate the temperature of the product. (Temperature controller for steam heating is not in our scope of supply.)

SPECIAL FEATURES

• Machine design as per the vacuum application for de-airation of mixing container, to remove air bubbles from the product during mixing for GEL products. ( Vacuum System) vacuum pump is not in our scope of supply.
• Insulation will be provided on jacket of container. The insulation will be covered with M.S. material in standard model and SS304 material in GMP model.
• Material discharge from bottom. Flush bottom valve provided for material discharge.
• M/C provided with Light glass, Sight glass, material inlet, water inlet, steam & washing water inlet, air suction valve for vacuum, vacuum gauge etc...
• Mixing assembly have two speed facility. Variable speed drive facility for mixing assembly will be provided on extra cost, as a OPTIONAL facility.
• Digital Timer for Batch time setting.
• Ampere Meter for main motor.
  

OPTIONAL

• "PLC" based operating panel for automation.
• Variable speed drive for main motor for variable rpm of mixing assembly.
• Online sampling port to take sample of product during mixing.
• Inline homoginizer or Colloid mill

IMPORTANT SPECIAL FEATURES

1. Capability to handle a large range of tube sizes
2. Automatic cap tightening
3. No-tube-no-fill device
4. Automatic tube infeed
5. Adjustable filling pump and several optional attachments
6. Can handle tube diameters from 10 mm to 40 mm and lengths from 40 mm to 200 mm. ~ Automatic tube infeed with cassette loader.
7. Simultaneous accessibility of many tube holders in case of manual infeed.
8. Tube cleaning device for dust removal (particularly required for pharmaceutical and~ food products)
9. Adjustable filling pump with different volumes:. - Ease in removal of pump components for cleaning and changeover. -Contact parts are corrosion resistant, - No-tube-no-fill device, - Blow off device to cut "Rat tail" of highly viscous products.- Photo-electric tube registration for automatic positioning of tube orientation. - Multiple folding stations for tube closure. - Code marking on the closure with digits and/or letters. -Transportation of filled tubes forward and backward.

SPECIFICATIONS:

• Output, tubes per hour 2400-3600 depending upon tube size and product
• Attendance 1 operator
• Power consumption 1 KW
• Floor space occupied 1.2 x 0.7 m
• Height, including paste container 1.7 m; ( 5' - 7" )
• Height, excluding paste container 1.1 m. ( 3' )
• Net weight 550 kgs (1200 Ibs)
• Gross weight 750 kgs (1650 Ibs)
• Shipping volume 3m³ (100 cu.ft)