Production 1.Organisations – departments and interconnections 2.Information transfer 3.Bulk Manufacturing – Processing 4.Product -Filling Equipment 5.Soap.

Slides:



Advertisements
Similar presentations
Drug Forms and Routes of Administration. Before FDA approval Rx company must clearly state in what form or forms the drug will be manufactured Rx company.
Advertisements

Contents: Cover
Packaging Materials Food Manufacture. Packaging Materials Cans Glass Containers Rigid plastic containers Flexible plastic packaging Paper & board Aluminium.
Generic Pressurized Water Reactor (PWR): Safety Systems Overview
WAREHOUSING MANAGEMENT
Pipe Cutting System The evolution of Patented products Designed in Finland pipe cutting.
Materials used in the external walls. Brick Bricks are probably the oldest manufactured material we have today. Although the method of production has.
Semi-Continuous Manufacturing of Personal Care Liquids Peter Divone Sr., P.E. Director, Process Development Global Skin Category R&D Prepared for the.
Providing the right technology for small/medium/large scale production of good quality BIODIESEL.
Shaving soap are originally prepared in bar or cake form. The bar shaving soap is resemble the ordinary bar toilet soap physically, but some changes must.
MGT Liquid & Process Systems Designing and manufacturing of custom-made, innovative stainless steel process solutions Privately owned 40 years of experience.
Chapter 39 Types of Packaging. Objectives Reasons for packaging (packing) products. Common types of packaging. Aseptic packaging.
Canning of Whole Tomato Next. Tomatoes may be preserved for long time by processing them in cans. The cans are made of tin plate with special lacquer.
Cooling As working temperatures rise, the strength of metals used reduces. This in turn will force manufacturers to use superior metals/alloys, which can.
Process Flow Paper Product user Ground wood Mechanical Pulping
Welcome to Disley Tissue. A brief history cotton mill built on current site Mid 19 th century - developed into a coated paper manufacturer 1993.
WHAT IS MANUFACTURING? Why do we study manufacturing?
HEAT EXCHANGERS in food process engineering Energy balance methodology used to design industrial equipments 1 FIP-DES Bertrand Broyart, Violaine Athès.
MECH152-L22-1 (1.0) - 1 Powder Metallurgy. MECH152-L22-1 (1.0) - 2 Typical Parts.
Harnessing Free Heat. The Energy Harness provides hot water using multiple heat sources, making the best use of low grade heat. It improves the efficiency.
Flexitank Introduction Philton Polythene Converters.
EMULSIONS Heterogeneous systems consisting of at least one immiscible liquid phase intimately dispersed throughout a second phase in the form of droplets.
Module 4: Storage and Dispensing Locations
YOUR PARTNER IN TEXTILE CHEMISTRY AVCO-BLANKINOL COM-LT BLEACHING AT LOW TEMPERATURE.
Operations Management
Nciples & Practice of Cosmetic Science, UK Society of Cosmetic Scientists, 21 – 26 February 2010 Processing and Manufacturing 1.Information transfer 2.Bulk.
Pharos University. جامعه فاروس Faculty of Engineering
Operation and Maintenance
The Supply Chain Management Guide
1 5 September, 2015 Different Retorts for Different Products & Packages by Rajiv Sood.
Yeast Propagation & Storage
Manufacturing Input Ingredients Process Mixing, chopping, baking
INDUSTRIAL ELECTRONICS CONTROL EET425/4 Lecturers Indra Nisja School of Electrical System Engineering Northern Malaysia University College of Engineering.
Cleaning & Sanitizing for Food Plants. 22 Dec 07Effective Cleaning2 Introduction All equipment must be cleaned and sanitized prior to use and following.
PRODUCTION LOGISTICS Production Process Slovak University of Technology Faculty of Material Science and Technology in Trnava.
Module 1, Part 3: Process validation Slide 1 of 22 © WHO – EDM – 12/2001 Validation Part 3: Process validation Supplementary Training Modules on Good Manufacturing.
Manufacturing is the changing of raw or processed materials into usable products. Manufacturing occurs in manufacturing plants, or factories.
Chapter 5: BIOREACTOR DESIGN & SCALE-UP
GROEN Product Presentation.
 Traditional concept of warehouse as store or go down  Development of modern concept of warehouse as facility Traditionally, consumer maintained his.
Turn Key Suppliers & Consultants For Samarthan Systems Pvt Ltd..
2K AIRMIX® PU2160 FLOWMAX® PU2160 Flowmax ® Technology for Total Reliability.
SC Project Review of NCSX, April 8-10, 2008 NCSX Cryogenics Systems WBS-62 Steve Raftopoulos NCSX Cryogenic Systems WBS(62) Manager.
Revolutionary Aseptic Production & Bulk Distribution System: An Economic Game Changer TRU ASEPTICS.
Migen SpA The The Italian Company of Specialized Services for Industry Plant Migen SpA The The Italian Company of Specialized Services for Industry Plant.
© British Sugar 2010 Case study: Bury St Edmunds factory How is sugar made? Bury St Edmunds factory is the United Kingdom’s largest milled sugar plant.
Paste Mixing Ashis Kumar Podder.
FLUID FLOW FOR CHEMICAL ENGINEERING
Air condition installation
Subject :- Mechanical Operation ( ) Branch :- Chemical Engineering Semester :- 5 Ribbon Mixer.
Planetary Mixer. Akshar Engineering Works was incorporated in the year We are a renowned Manufactured and Supplier of Industrial Products. Our organization.
Manufacturing systems Brian Russell. Exam expectations Issues associated with Manufacturing are regularly tested in the written paper. Questions often.
Maturing and cold smoking
BSB Biomanufacturing CHAPTER 2 Process Plant Design – Part III
Powdered Milk Plant Design
Processing and Manufacturing
SoluTube® THE PREFERED SURFACTANT DELIVERY METHOD
Lesson 2.1 Avenues for Contamination
Why do we study manufacturing?
What is Desuperheater Water heater and its Applications?
ICE CREAM Mrs. Schrewe August 25, 2017
Cold Process Soap, Lip Balms, Lotion Bars & Salves
The evolution of pipe cutting Patented products Designed in Finland Pipe Cutting System.
Chocolate Covered Cookies
Lesson 2.1 Avenues for Contamination
TRENTON Casing Filler Presentation
Cold Process Soap, Lip Balms, Lotion Bars & Salves
INTRODUCTION TO INDUSTRIAL PHARMACY
NEW ARISTON STORAGE BOILERS March, 2009.
FIRE SUPPRESSION SYSTEM.
Presentation transcript:

Production 1.Organisations – departments and interconnections 2.Information transfer 3.Bulk Manufacturing – Processing 4.Product -Filling Equipment 5.Soap Manufacture

Production Production and Interdepartmental relationship Marketing – National, Local Regional and Global Technical Group: Research Development Quality Operations Group: Manufacturing, Filling,, Assembly Warehousing, Engineering, Industrial Engineering Planning - National, Local Regional and Global Sales Purchasing - National, Local Regional and Global New roles – New Product Co-Ordinator & Value Stream Manager Outsourcing

Production Bulk Manufacturing – Scale Up Scale Up – defined as the successful duplication of the products primary characteristics over a range of increasing batch sizes and across a variety of manufacturing equipment or vessels of different sizes. The main factors that can influence the Scale Up Process : Heating and cooling times, Transfer and mixing times, High energy mixing (RPM) – homogenisation rotor/stator and type, Raw material addition rates or transfer times oil phase to water phase, Better still formulate with the factory production equipment in mind and use raw materials that do not require special treatment. Pilot equipment –using the pilot size vessel – 100 KG scale equipment such as the Becomix, Fryma and IKA which can be computer controlled. The manufacturing sequence can be transferred to the production size vessels. This helps to reduce the variability in the different parameters of heating, cooling, mixing and homogenisation.

Production Bulk Manufacture - Scale Up - Vessels Pilot equipment – using 100 Kg size vessel that does not represent the same type of mixing and cooling rates as used on a production vessel the scale up process is more complex due to the variability in the different parameters heating, cooling, mixing and homogenisation times. This can result in a product formulation having a different appearance to the standard agreed between R&D and Marketing. This is a common mistake and has been seen in number of different processing plants Outcomes from Pilot Batch: Temperature - heating graph & - cooling graph, Homogeniser and Mixer speed and timings, Viscosity adjustment graph, Rheology – profile, Ph adjustment – depending upon formulation, Particles size - depending upon formulation. With the software now available the batch data is collected and can then be used to programme the Production plant

Production Bulk Manufacturing Processing is the large scale mixing of raw materials - chemicals in a controlled way to produce a finished bulk. A batch of bulk can be from 50 to 25,000 kg depending upon product type powder, cream shower or shampoo Continuous processing of shampoo and shower gels. Before planning of a Works Experimental or Pilot batch a Risk Assessment must be carried out to identify and review all risks. Agree parameters with R&D which are the same as the Scale Up batch - viscosity, mixing and homogenisation speeds, heating and cooling temperatures and rates.

Production Bulk Manufacture – Equipment Selection The selection of equipment depends on the formulation and the manufacturing process, batch size, batch time, product fill, hot, cold, mixing or homogenisation and cooling rate. Detergent based formulations – propeller and vessel design – 70 % SLES dilution – homogeniser size. Vessel design height to diameter ratio, 1 to 2, Blade width 50% of vessel diameter and position on shaft about 0.80 meter from top and bottom, Blade design Emulsion formulation – new vessel design: Environmental issues are having a big impact on the design of new processing vessels: Electric power requirements; Heating and cooling cycle time; Steam and Water volume; Hot and cold emulsion processing; Wash cycle – CIP system in-vessel or in-line homogenisers for the formulation Guisti; Becomix; Fryma; IKA Powder formulations – Ribbon blender & hammer mill; Ribbon Blender & Turbo Mill or Plough Shear Blender which combines blender and mill in one unit

Production Bulk Manufacture – Equipment Selection GUISTI type – typical British design - flexible – pressure/vacuum vessel with in vessel homogeniser – rota/stator and contra rotating scraper blades. A recirculation pipe can be fitted to take bulk from the bottom of the vessel into the top of the vessel. Or a recirculation pipe can be fitted to in – line homogeniser like a Silverson which can have a greater power input able to homogenise thicker creams. Ideally fitted with load cells and computer control to ensure uniformity of manufacture. Becomix/Fryma/IKA type – typical European design – pressure/vacuum vessel with in vessel homogeniser – rota/stator and pump with a structured agitator mixing blade. With this design recirculation pipe not required. These type of mixing vessels are ideally suited to computer control which would include load cells, to ensure uniformity of manufacture and the recording of specified parameters. Secondary equipment: Phase vessel with stirrer – Oil or Water - steam heated, Powder inductor – in vessel or standard alone unit – Flash Blender type units –with Local extraction and ventilation units

Production Bulk Manufacturing - Bulk Storage This depends upon the type and quantity and hazards of the bulk to be stored. Typical examples are as follows: Shower Gels, Foam Baths, Shampoos and thin cream lotions - Storage Tank or bag in box Creams thick – Stainless Steel Drums or IBC, or Bag in Box: IBC stainless steel – require washout and sanitising before reuse. Wastage can be high due to design. Bag in Box Flow boxes which with the use of a mangle can reduce the wastage to a minimum. The advantage of Bag in Box is that they is no washout required of the storage container as with IBC. Drums with pump follower diaphragm - require washout and sanitising before reuse. Wastage can be high due to design. Powders – plastic bags in cardboard or plastic kegs or drums

Production Bulk Manufacturing - Bulk Raw Material Storage This will depend upon the raw material, quantity, hazards and the storage conditions recommended by the supplier. Typical examples are as follows: SLES – stored in insulated warmed storage tanks with a fail safe heating system – as it becomes to hot then you get thermal decomposition – big issue!!! All external storage tanks used for raw materials containing water should be insulated for frost protection and to reduce temperature shock if used in an emulsion Ethanol – stored in a tank that is intrinsically safe and fuller protected with fire fighting systems Water – storage tanks cleanable with CIP system – but depends upon water treatment process. All tank farms will need to be designed to meet local legislation.

Producting Filling and packaging All filling lines operate on the same principle: Filling; Capping; Labelling with coding; Pack to secondary packaging carton, tray & shrink wrap Pack to outer; Pack to pallet. The filling and packing of cosmetics and toiletries is a complex operation driven by volume and market. Plus the cost of equipment can be very high and delivery times up to 9 months. An new automatic filling line to fill toiletries can cost £1 to 3.0 million depending how much automation is installed. The use of pucks has become standard due to its flexibility – able to fill different size containers. Filling and packaging - Filling Machines There is a variety of filling machines available from simple hand operated to highly complex multi headed computer controlled automatic filling, capping, labelling and packaging. The viscosity, rheology and any product foaming, primary components - tube, pot, jar or toggle will dictate the filling method. So you will need decide the cost of filling? A manual line may run at 30 to 45 units per minute A fully automatic filler that runs at 120 to 340 units per minute

Production Filling and packaging Secondary packaging These are cartons, leaflets, trays, shrink film, shippers Straight on Trays normally hold 6 or 12 units depending upon how many facings on shelf. Shrink film – applied my healing sealing machine and heat tunnel to shrink a round pack. Shelf Ready Packaging – this is the latest idea but know clear design. Industry meeting later in year to seek agreement. But has big implication for industry because until format agree design of automatic loading equipment is not possible. Pallet Layout – important for high street stores as all pallets delivered into the warehouse are scanned in as proof of delivery. Therefore units/packs per pallet is a key issue for the stores and it costs to load and verify data on to the computer systems.

Production SOAP Soap is one of the oldest known toiletry products and there have been many attempts to change it. We have types ranging from the normal hard toilet soap to versions of clear glycerine soaps which are softer and gentler to the skin. Glycerine soap production is very different from normal soap production and requires specialised equipment (some formulations may be covered by patents). The typical constituents of toilet soap are soap base noodles, colours and pigments, conditioning agents, perfume and extracts. The original raw materials used for the production of soap form the basis of many emulsifiers and detergents used in the cosmetics and toiletries industry today. It is therefore important to understand these chemical and production processes. George Whalley’s three articles entitled Soap Story (from the SPC April – June 1995, reproduced by kind permission) gives a good overview of the chemistry of soap making, the drying and final finishing of the soap bar.

Production Soap There are three basic soap manufacturing routes: a. Direct saponification of oils and fats – the Neutral Fat Route b. Neutralisation of fatty acids – the fatty acid route c. Saponification of fatty methyl esters The production of all finished toilet soap bars follows a common flow pattern – blending and pre-treatment of oils and fats, their conversion into soap, the recovery of glycerine, cooling and partial drying of a liquid soap into a noodle form, and the conversion of soap noodles into a finished bar – known as toilet soap finishing. The Soap noodle can be dried in two different ways – vacuum drying and band drying these two methods will produce soap of different appearance due to their crystalline structure. So what goes into a bar of toilet soap - skin conditioning additives, fragrance, opacifiers, colours, fluorescent brighteners, lather modifiers, emollients such as oils, fats, waxes, laolin and fatty acids.