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Mazzoni LB S.p.A. Tel +39 0331 356111
Corso Sempione 212, bis Fax +39 0331 684511
21052 Busto Arsizio – ITALY e-mail: [email protected]
Mazzoni headquarter
Who we are?
Mazzoni was founded in 1946 by Mazzoni family and as from 1990 has been associated to the Ballestra Group. The core activity of Mazzoni has always been focused on innovative process technology to produce soap and glycerine.
Mazzoni has supplied more than 2,400 plants in over 130 countries: every year Mazzoni continuous saponification plants produce up
to 4,500,000 tons of liquid soap, and their finishing lines up to 14,000,000 tons of laundry soap and up to 4,500,000 tons of toilet soap. Mazzoni glycerine plants evaporate up to 2,000,000 tons of water and distillate over 200,000 tons of pharmaceutical grade glycerine.
All major multinationals are Mazzoni clients as Procter and Gamble, Colgate, Henkel, PZ Cussons, Reckitt Benckiser and Unilever as well as the most important soap manufacturers all over the world.
MAZZONI plants in the World.
Over 2400 process plants in 130 countries
Over 2400 process plants in 130 countries
Mazzoni technologies
Fats and OilsPretreatment
Saponification
Vacuum Drying
Finishing
Glycerine Refining
SGA: Bleaching Plants
SCNT: Continuous Neutral Fats/Oils Saponification PlantsSCT: Continuous Fatty Acids Neutralization PlantsSCT-C: Combined F.A. Neutralization & Drying PlantSSCT: Continu. Neutr. F/O Sapon. without Glycerine extraction
SC+C, SSCT+C: Integrated Saponification/Drying SystemsCL: Laundry Soap Drying PlantsEcodryers: Toilet Soap Drying Plants
LBC: Laundry Soap Finishing LinesLTC: Toilet Soap Finishing LinesSLB: Synthetic Soap Finishing LinesMP: Milling Plodder Finishing Lines
DCA: Spent Soap Lyes Treatment PlantsCSL: Industrial Glycerine PlantsDGA/GR: Pharmaceutical Glycerine Plants
Rim Blocks
RBL: Rim Blocks Manufacturing Lines
Mazzoni technologies
Beside the core soap plant business, Mazzoni has been involved over the year in the design and supply of plants for the production of:
- personal care and cosmetics;
- food processing;
so acquiring and excellent capability to engineer also a wide range of chemical and industrial plants, as well as the relevant offsites facilities (steam, cooling water, power distribution, tank farm, etc.).
Mazzoni shareholding
The Mazzoni shareholding is:80%: Sagittario S.p.A. 10%: Paolo Tovaglieri, Sales Director10%: Enrico Tovaglieri, Technical Director
Sagittario S.p.A. is the holding company which has developed and managed from 1990 up to 2007 the companies:
Ballestra S.p.A./Milan, today Desmet Ballestra S.p.A., world leader in the design and supply of plants for the detergents, surfactants, biodiesel and chemical industries, which presently owns a participation of 20% of Mazzoni;
CMB S.p.A./Rome, today Desmet Ballestra Oleo S.p.A., leader in design and supply of plants for the oleochemical industry, which is fully owned by Desmet Ballestra S.p.A.
Sagittario shareholders still retain important management position in Desmet Ballestra S.p.A.
Mazzoni world presence
Beside its own sale dept which coordinates all the sale activities providing also the necessary technical support, Mazzoni has a network or representative offices, the main ones in Russia and China, and the collaboration of Desmet Ballestra Group worldwide sales network.
China Russia
UK
Sudan
Sri Lanka
Venezuela
South Africa
Nigeria
Pakistan
Poland
Portugal
Algeria
Brazil
Bangladesh
Egypt
Indonesia
Japan
Mexico
Germany
Mazzoni network or representative offices Desmet Ballestra Group sales network
Mazzoni Organization Chart
CEO
Giuseppe di Carpegna
Controller Quality Assurance & IT
R&D Customer Service
Ferrari/Montanari
Sales dpt. Engineering dpt. Admin & Finance
P. Tovaglieri E. Tovaglieri E. Imperiali
Sales & Proposal Project mgt Admin/H&R
Marketing Purchase Dpt Export/Finance
Spare Parts Process Tech Health & Safety
Finish. line Tech
Automation Dpt
Workshop
Mazzoni Personnel
Mazzoni personnel includes 6 senior managers, 61 employees, 31 workers for an overall amount of 98 persons divided as follows.
23
8
69
12
31 9
PM, Tech Dpt., R&DSales & ProposalProcurementSpare parts & Customer ServiceManag., Admin. & Accounting WorkshopFood Division
Mazzoni turnover
€ x 1.000
Mazzoni has constantlymaintained a market share exceeding 50%.
2007 2008 2009 2010 20110
5,000
10,000
15,000
20,000
25,000
30,000
35,000
Production Distribution (geographic area)
Mazzoni sells yearly to customers located in over 100 different countries
EUROPE12%
ASIA30%AFRICA
31%
AMER-ICA27%
2007
EUROPE8% ASIA
28%
AFRICA28%
AMERICA36%
2008
EUROPE4%
ASIA39%
AFRICA33%
AMER-ICA24%
2009
Production Distribution (products)
Plants42%
Ma-chinery44%
Spare Parts14%
2007
Plants38%
Ma-chinery
49%
Spare Parts13%
2008
Plants31%
Ma-chinery
55%
Spare Parts14%
2009
Plants46%
Ma-chinery
40%
Spare Parts14%
2010
Research & Process Development
Process and detailed engineering
Feasibility studies
Products testing on Pilot Plants
Equipment fabrication and procurement
Supervision to plant installation and start up
Turn-key projects
Training of operators
Spare parts supply
After sale technical assistance
Plants revamping/upgrading/capacity increase
Project financing
Mazzoni services
· Troubleshooting.
· Plant performance (product quality, energy
consumption, plant operation reliability)
evaluation and optimization.
· Evaluation of plant equipment operating conditions for planned
maintenance (mechanical, electrical, instrumentation & control).
· Customer’s personnel training.
· Advisory services on new technologies, new equipment available on
the market, improvements of plant operation, safety ...
· Study and proposal for plant revamping and capacity increase.
Mazzoni after sale services
Saponification plants
The Tubular Reactor:
- Static multi tube reactor
- Saponification conditions: pressure (3-3.5 bar) and temperature (135/140 °C) .
-Holding time reduced to 8 min vs. 20/30 min. of the traditional reactor
-Easy formula changeover
-Versatility: the Tubular Reactor can saponify Neutral Fats/Oils and Fatty Acids
-Reduced maintenance and space requirement
39 Units installed world-wide.
R&D - Latest Innovations - Process
Saponification plants
Integrated Toilet Soap Plants “SCT + C” and “SSCT-C” the ideal solution for producing high quality soap noodles from Fatty Acids or from Neutral Oils/Fats (SWING).
The liquid soap is directly fed from the Tubular Reactor to the Vacuum Chamber allowing to manufacture all types of laundry and toilet soap noodles at the required final TFM content with a remarkable energy saving:
11 Units installed world-wide.
R&D - Latest Innovations - Process
Vacuum Dryers
”NO SPRAY” vacuum chamber with tangential soap injection vs. conventional Spray Nozzle system.
• Reduced soap fines formation by 50%
• Improved soap chips quality: less grits
• Overall equipment simplification: minimal maintenance
• Easy operations: all regulations outside the chamber
38 Units installed world-wide.
R&D - Latest Innovations
Soap Drier: VLS (Vapour Liquid Separator)
Pre-concentrate neat soap prior to the vacuum chamber
- 50% recovery of the steam generated in the dryer fro:- Drive the booster- Pre-heat of raw materials- Pre-heat liquid soap
- 40-50% reduction of water requirement to the barometric group
-Reduced fines formation (approx. 40-50%)
VLS is retro-fittable in existing dryers
Over 50 Units installed world-wide.
R&D - Latest Innovations
MRP Multi-refining Plodders
A-one-machine-configuration for toilet soap refining, homogenizing and extrusion substituting two duplex plodders (or rollmill) of conventional lines
• Process of all toilet soap bases (regular, translucent, syndet and combo)
• Quick and easy formulas changeovers
• 15-20% reduced energy requirement
• Reduced maintenance
• Reduced area required
• Reduced capital outlay
15 Units installed world-wide.
R&D - Latest Innovations - Finishing
“DTS” Direct Transfer SystemTo “pitch” discharge the stamped tablets into the pocketed belt of any packaging machine:
-flowpack – cartoners – wrappers
- “ONE TOUCH” transfer system: better finished tablets appearance
- Inbuilt on the stamper frame: simplified and compact unit’s design with easy operation and space saving
- 10-15% Higher production speed vs. solutions with timing systems
- >5% superior overall line’s efficiency
- Reduced capital outlay
R&D Joint development with ACMA.
22 Units installed world-wide
R&D - Latest Innovations - Finishing
• Completed installation of a 200KW Solar plant in Mazzoni roof size to produce 100% of workshop and offices power requirements.
• Ongoing Investment in increase of Mazzoni building heat efficiency as well as machinery cleaning water recovery.
• Plan to mitigate CO2 emissions related to personnel travelling through promoting and financing green projects in developing countries.
Environmentally Sustainable Production