Divone UnileverICB 13AQ Sunday
Divone UnileverICB 13AQ Sunday
Divone UnileverICB 13AQ Sunday
ABSTRACT
In many personal care product liquids applications, batch manufacturing has been replaced by
continuous or semi-continuous processes. When moving from batch to continuous processing,
coordination between formulation development, process development, supply chain and manufacturing
quality control is mandatory. R&D commitment to support the semi-continuous platform is a prerequisite
for wide spread adoption and long term progression.
Unilever has adopted and adapted semi-continuous processing for its personal care liquids
manufacturing. With multi channel systems from 4 liters/minute to 400 liters/ min., we have installed ,
commissioned and validated units in 10 countries. A review of scale-up practices, machine design
(including hygienic considerations) and practical considerations are outlined in the presentation.
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Agenda
Plant Design
Summary
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Introduction: Overview of Technology
Flow Diagram
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Introduction: Overview of Technology
Water
Oil Minors Neat
Premix Water
Rework
Premix tank
To Storage
Tank
In-line Mixer
Phases flow
Finished product flow
Semi-Continuous Processing of Personal Care Liquids
Oil Ingredients
Premix
Minor
Premix
PRODUCTION
180 to 270
kg/min
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Benefits : Semi- Continuous vs. Batch Mixing
Cost Comparison
Experience to Date
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Benefits : Semi-Continuous vs Batch
BATCH Process
- Capacity 45 kgs/min
- Capital - $1.2M (0.8M EU)
SEMI-CONTINUOUS Process
- Capacity - (270 kgs/min)
- Capital - $1.9M (1.3M EU)
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Benefits : Semi-Continuous vs Batch
Experience to date:
70% Capacity increase
Allows the use of concentrated premixes for further capacity increase ( 3X for
HBLs and up to 10X for shampoos)
Smaller Footprint
Easier to Clean and Changeover
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R&D Integration and Scale-Up
Formulation Breakdown
Pilot
Plant Data Acquisition and
Measurement Tools
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R&D Integration Scale-Up
Formula Development: SCA L E UP CONDIT I ONS DOVE L OT I ONS
O/W Skin Cream Emulsion WATER PHASE 32C
OIL PHASE 73C
Oil Phase 4000 kgs PRESSURE 180 PSI / 12 BAR
CODE Material % Kgs Temperature 73
FLOW RATE 140 KG/MIN
50184 Pristerene 4911 2.2900 91.6000 Bomb No.2
50049 Cerasynt IP 1.3500 54.0000 % 12.1910 ORIFICE 0.096 IN 2
50327 Monoestearato de Glicerilo 0.6300 25.2000
50637 Alcohol Cetlico 0.3610 14.4400
51566 Petrolato 1.0000 40.0000
51634 Myrj 59 1.1600 46.4000 In-Line Mixer
SONOLATOR
20150 Neobee M-5 2.0000 80.0000
50333 Silicon 50 cts 2.000 80.0000
50106 Metilparaben 0.2000 8.0000
50159 Propilparaben 0.1000 4.0000
50970 Acetato de Vitamina E 0.1000 4.0000
ORIFICE 0 .0 96
50165 Silicon 245 1.0000 40.0000
12.1910 487.6400
& 250
orifice =
Stress (Pa)
150
100
50
0
0 100 200 300 400 500 600 700 800 900 1000
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R&D Integration Scale-Up
Understanding Hydrodynamic Cavitation
SI Units US Units
Q=Throughput water like fluid (L/min) Q=Throughput water like fluid (gal/min)
k= SI Orifice Coeffecient
(67) k= US Orifice Coeffecient (30)
A= orifice area (cm^2) A= orifice area (in^2)
P= Pump-to-orifice Pressure (bar) P= Pump-to-orifice Pressure (PSI)
Q*= Throughput water like fluid SG=1 Q*= Throughput water like fluid SG=1
(kgs/min) (lbs/min)
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Plant Design
Layout Considerations
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Plant Design : Controls and Software
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Plant Design: Layout Considerations
WATER
PHASE
OLEIC OLEIC
PHASE PHASE
OLEIC
PHASE
UMF1
Mixer
SONOLATOR
PURGE TANK
Pneumatic
Pump
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Plant Design: Layout Considerations
Location with Adequate Space
- adequate room to work on wet end of pumps
Pumps
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Plant Design: Maintenance & Repair
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Plant Design: Valves & CIP
Check-valves on all streams leading into mixing chamber
CIP around in-line mixer
Pressure relief valves
(Bardiani or Tuchenhagen Q)
or rupture discs
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Summary
14 SEMI-CONTINUOUS SYSTEMS GENERATE 30% OF
ALL THE PCL TONNAGE PRODUCED BY UNILEVER,
OVER 200 BATCH PLATFORMS PRODUCE THE REST OF
THE VOLUME
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It takes Dedicated Teamwork and Focus to
move from batch to continuous processing !
Thank you
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