Batch at the limit?!. Current situation of the process capacity usage at the maximum optimized...
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![Page 1: Batch at the limit?!. Current situation of the process capacity usage at the maximum optimized processes standardized formulations limited capacities.](https://reader033.fdocuments.us/reader033/viewer/2022051517/56649f2b5503460f94c4558a/html5/thumbnails/1.jpg)
Batch at the limit?!
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Current situation of the process
capacity usage at the maximum optimized processes standardized formulations limited capacities concentration of production sites
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Current economic situation
potential of increasing the
productivity is limited cost pressure strong competition limited capacities
and how can we assist?
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Customer benefitscontinuous vs. batch
throughput increased by 25 % cleaning time optimised identical footprint maintenance efforts minimised time for maintenance reduced by 15%
substantial cost savings
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Cost benefit – example
batch machinepercentage material costs 80,0%percentage direct labour costs 10,0%percentage indirect production costs 10,0%
batch machine new plantworking hours per year 7.500 7.500output in liter per hour 4.000 5.000total output in liter per year 30.000.000 37.500.000 25,00%material costs per liter in Euro 1,00 1,00
cost annual output in Euro batch machine conti plantmaterial 30.000.000 37.500.000direct labour* 3.750.000 3.750.000indirect production* 3.750.000 3.750.000finished product unpacked 37.500.000 45.000.000 20,00%cost per liter 1,250 1,200 -4,00%savings per year 1.500.000
conti plantinvestment in plant 2.800.000payback period < 2 years
* amount remains the same at batch or conti
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Our solution:
continuous production
of toothpaste
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The process
Ingredients
Dosing
without pre-mixing directly from stock to
plant
fully automated exact control perfect, constant
quality
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The process
Wetting
De-aeration
Dispersing
revolutionary
powder-wetting less agglomeration
perfect particle size
perfect density
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The process
Additives
Control
in every phase of
production possible highest flexibility
full automation completely
reproducible
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The process
Quality con-
trol
in-line measuring of
viscosity, particle size,
density, flow rate,
pH-value, pressure and
temperature On-line quality control
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Storage and
filling:
The process
less storage before
filling necessary
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Continuous production meets your requirements
leading in technology higher output at lower costs
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together with you we want to combine products processes technology and automation
to be one step ahead!
Our intention
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Legend:1 density2 viscosity3 flow rate4 temperature5 particle size6 pressureVE de-aeratorPWM powder-wetting-machineM/DIL inline homogenizerFL filling line
The concept
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The concept
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Liquid sto- rage and
filling
Solid storage and filling
Continuous production
The concept
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The concept
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The concept
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The first trials: The complete plant
Liquid and dry phase
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Powder wetting machine
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The first trials
product outlet afterpowder wetting
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Product outlet after de-aeration
product outlet afterde-aeration
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Dosing: exact control, perfect and constant quality
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You have the knowledge of the product We have knowledge of machinery and
process technology Together we can find a new way of
processing toothpaste
Let‘s set a new milestone!
The vision