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Batch at the limit?!
Current situation of the process
capacity usage at the maximum optimized processes standardized formulations limited capacities concentration of production sites
Current economic situation
potential of increasing the
productivity is limited cost pressure strong competition limited capacities
and how can we assist?
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
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
Our solution:
continuous production
of toothpaste
The process
Ingredients
Dosing
without pre-mixing directly from stock to
plant
fully automated exact control perfect, constant
quality
The process
Wetting
De-aeration
Dispersing
revolutionary
powder-wetting less agglomeration
perfect particle size
perfect density
The process
Additives
Control
in every phase of
production possible highest flexibility
full automation completely
reproducible
The process
Quality con-
trol
in-line measuring of
viscosity, particle size,
density, flow rate,
pH-value, pressure and
temperature On-line quality control
Storage and
filling:
The process
less storage before
filling necessary
Continuous production meets your requirements
leading in technology higher output at lower costs
together with you we want to combine products processes technology and automation
to be one step ahead!
Our intention
Legend:1 density2 viscosity3 flow rate4 temperature5 particle size6 pressureVE de-aeratorPWM powder-wetting-machineM/DIL inline homogenizerFL filling line
The concept
The concept
Liquid sto- rage and
filling
Solid storage and filling
Continuous production
The concept
The concept
The concept
The first trials: The complete plant
Liquid and dry phase
Powder wetting machine
The first trials
product outlet afterpowder wetting
Product outlet after de-aeration
product outlet afterde-aeration
Dosing: exact control, perfect and constant quality
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