Shampoo Manufacturing Plant

Shampoos are categorized as viscous liquids that may be clear or opaque with a pearlized look and manufactured at approximately the pH of 5.5. It is known to contain 20- 40 % solids and most of the shampoos have viscosities in the range of 500–1500 centipoises if not all of them. They can be termed as detergents that are uniquely and specially crafted for the washing and cleansing of hair. They come in attractive packages which are very convenient to be used. The properties of a good shampoo include cleansing well, being able to be rinsed off with ease, imparting a flawless gloss to the hair, and minimizing any tangles present in the hair. Importantly a shampoo should not harm the hair structure, scalp, or eyes.

Our Supply Range Include-

Main Shampoo Manufacturing Vessel
The manufacturing vessels are cylindrical ones that are dish bottomed. The top of the vessel is also dished and welded and has an agitator assembly. A slow agitator is inherent in the assembly system though the contra-rotating or semi contra-rotating agitators are preferred as their usage is preferred by most manufacturers due to the excellent quality of shampoo produced by it. The shampoo manufacturing vessel has a CIP turbo disk on top of the vessel for cleaning purposes. The other components included in it are the Suitable nozzles, manholes, valves that are present on the vessel. Upon client specification and requirement a jacket can also be provided for heating and cooling. They are resistant enough to be subjected to complete vacuum exposure.

Pre Mixing Vessel

The pre-mixing vessels are cylindrical vessels with dished bottom and a dished top with welding. The top is provided with a lid and the agitator assembly has a high-speed cowl or resembles a saw cutter type agitator. Optionally a high-speed homogenizer may also be provided. The CIP turbo disk is also provided at the top for cleaning purposes. There are Suitable nozzles, manholes, valves that are provided on the vessel. The vessel is provided with a jacket for heating and the same can be steam heated or heated electrically as per customer specification. The jacket also provides excellent insulation and cladding eliminating the need for any vacuum in the vessel. The capacity of this vessel is almost 60% of the main manufacturing vessel and the client’s formula of the shampoo and other requirements determine the premix vessel’s quantity. It could be used in the count of one or two numbers.

Storage Vessel

The storage vessel is a simple cylindrical vessel required to store shampoos. It has a dished bottom and a loose top lid. To facilitate the pipeline connection, a bottom valve with din fittings is provided. It possesses the same capacity as the manufacturing vessel. The storage tanks are usually more in number as the shampoos require to be manufactured and stored. Subsequently, the filling is done as per the requirements of the market.

SLES/ Surfactants Storage Vessel

The SLES and the Surfactants constitute a major ingredient in shampoos and require to be stored in large quantities. Buying large quantities like 200 kg drums could turn out to be very expensive for the manufacturers and that is why they prefer purchasing an entire tanker of surfactants and storing the same. They ensure a backup of weeks or a month and store it to ensure seamless production. They are vertical tanks heightened and having a flat bottom. A suitable manhole and nozzle close the top so that loading into the vessels can be enabled through pumps. Also, the outlet is provided at the bottom so that the surfactants can be transferred from the storage vessel into the manufacturing ones or the premix vessels through pumps.

Pumps

The transfer pumps are efficient in transferring material from the prefix vessel to the manufacturing vessel when not under vacuum conditions. Under vacuum, the premix is transferred to the main vessel automatically. Transfer pumps play a key role in transferring the surfactants from –

• The storage tanks to the premix vessels
• The premix vessels to the manufacturing vessels
• The manufacturing vessels to storage vessels
• The storage line to filling line

Pipeline

The plant is provided with an interconnecting pipeline depending on the client’s room size. The interior and exterior of the pipeline are electropolished. The joints are reopenable and the standardized DIN types. The Pipes are used to transfer the surfactants from-

• The storage tank to premix vessels
• Premix vessels to manufacturing vessels
• Manufacturing Vessels to storage vessels
• Storage to the filling line

Others

The Vessels have CIP and SIP nozzles as well as conical filters for the discharge of the vessels. The complete plant is interconnected by a suitable pipeline and can be manned by a single operator. An optional PLC control with a fully automatic integrated control panel is provided and a suitable working platform is provided for cleaning and maintenance.

Control Panel and Automation

The control panel has all the features that are required for the automatic operation of shampoo manufacturing. It includes the starters, overload relays, pushbuttons, lamps, ckt breakers, and much more. The hardware is designed to suit customer specifications and a few automation are listed below

• Integration with a PLC based automation
• Load Cells underneath each vessel
• Valves that are operated Pneumatically
• Other Custom Built automation are included
• The capacity of the various shampoo manufacturing plants
• Range of 200 Ltrs to 20000 Ltrs / batch

The basic Components-

• Completely enclosed tanking system to ensure optimality in production procedures
• Comprehensive conforming with the CGMP requirements of the FMCG industry
• Presence of an anchor agitator for efficient mixing
• A well present heating and cooling mechanism through the presence of jacketed vessels
• Provision of Mechanical Seals for a leak-free operation
• A bottom entry homogenizer for adequate homogenization
• Presence of an electric panel for controlling various parameters
• Optional load cells for an online weighment
• Optional pre-blending tanks for efficacy
• The capacity of 500 Ltrs to 10,000 Ltrs in batch sizes

Salient Features:

• All vessels manufactured remain compliant with the CGMP requirements
• Any product transfer is done through vacuum operation
• Vessels are well jacketed for heating and cooling
• Insulation of all the vessels for minimizing heat loss
• Provision of a perforated anchor for optimum mixing of the main vessel
• Mechanical Seals that are vacuum rated are provided in the operation
• CIP system enablement for a shorter cleaning cycle
• A comprehensive central control panel for operating the whole plant
• The optionality of a contra rotary agitator system
• Optional Load cells for online weighing provision
• Optional PLC based system with pneumatic valves for automatic operation
• The capacity of 50 Ltrs to 3000 Ltrs present

Complete SHAMPOO Plant consists of following equipments

• Wax Phase Vessel
• Water Phase Vessel
• Manufacturing Vessel
• Batch Storage Vessel
• Twin Lobe type product transfer Pump
• Positive displacement type Transfer Pump
• Vacuum Pump.
• Interconnecting pipe line
• Integrated PLC based control Panel
• Working Platform

A. Wax Phase Vessel

Sr. no.	Description	Specifications
	TAG	Wax Phase Vessel
01	GENERAL SPECIFICATIONS
A	Function	To prepare wax phase require for SHAMPOO manufacturing
B	Code	Built as per Good Engineering Practice and to comply cGMP standard
C	MOC	SS 316 contact parts and SS 304 non contact parts. Heavy parts and structures shall be cladded with SS 304 materials.
D	Type	Cylindrical Vertical with welded bottom dish and top dish. Vacuum compatible.
E	Mounting	Vertical on Legs with load cell
02	PROCESS DETAILS & OPERATIONAL DATA
A	Operation Type	Batch
B	Fluid Handled in vessel	Client to confirm
C	Specific Gravity	0.9 gms /cc
D	Fluid Handled in Jacket	Steam / Hot Water / Raw water
E	Service	Mixing
F	Operating Temperature	20-80 deg. C
G	Operating Pressure	FV – ATM
H	Operating pressure in Jacket	3.0 Kgs/cm2
I	Minimum Steerable Volume	20 % of gross Volume
J	Min. Temperature sensing Volume	20% of working Volume
03	MATERIAL OF CONSTRUCTION
A	Shell / Bottom / Top dish	SA 240 Gr. 316
B	Jacket	SA 240 Gr. 304
C	Stirrer Mounting Pad	SA 240 Gr. 316
D	Stirrer Shaft	SS 316
E	Gasket	Food grade Silicon
F	Nozzles	SS 316, Seamless pipes
G	Mechanical Seal Type	Double Cartridge water cooled type
H	Baffles	SS 316
I	Monkey Ladder	SS 316
J	Legs Pipe	SS 304
K	Base plate	SS 304, suitable for load cell mounting
L	Hardware – Internal	SS 316
M	Hardware – external	SS 304
N	Product outlet Valve type / MOC	Sanitary Design with 1 side flange an 1 side TC connection / SS 316
04	INSULATION AND CLADDING
A	Type of insulation	Mineral wool
B	Insulation Thickness	50 mm
C	Insulation cladding	SS 304, full welded
05	DRIVE AND AGITATOR DATA
A	Type of agitator	Rotor Stator type homogenizer
B	Agitator Entry	Top Entry.
C	No. of Impeller	01
D	Impeller Dia	As per design
E	Shaft Dia.	As per design
G	Shaft Type	Solid
H	RPM	1440 RPM
I	No. of Baffles	01 No.
J	Motor Type	TEFC/Non FLP / 3Ph/415V/AC
K	Transmission	Direct Mounting
06	SURFACE FINISH
A	Product Contact Parts	220 grit mirror finish. Surface roughness

B. Water Phase Vessel

Sr. no.	Description	Specifications
	TAG	Water Phase Vessel
01	GENERAL SPECIFICATIONS
A	Function	To prepare water phase require for SHAMPOO manufacturing
B	Code	Built as per Good Engineering Practice and to comply cGMP standard
C	MOC	SS 316 contact parts and SS 304 non contact parts. Heavy parts and structures shall be cladded with SS 304 materials.
D	Type	Cylindrical Vertical with welded bottom dish and top dish. Vacuum compatible.
E	Mounting	Vertical on Legs with load cell
02	PROCESS DETAILS & OPERATIONAL DATA
A	Operation Type	Batch
B	Fluid Handled in vessel	Client to confirm
C	Specific Gravity	0.9 gms /cc
D	Fluid Handled in Jacket	Steam / Hot Water / Raw water
E	Service	Mixing
F	Operating Temperature	20-80 deg. C
G	Operating Pressure	FV – ATM
H	Operating pressure in Jacket	3.0 Kgs/cm2
I	Minimum Steerable Volume	20 % of gross Volume
J	Min. Temperature sensing Volume	20% of working Volume
03	MATERIAL OF CONSTRUCTION
A	Shell / Bottom / Top dish	SA 240 Gr. 316
B	Jacket	SA 240 Gr. 304
C	Stirrer Mounting Pad	SA 240 Gr. 316
D	Stirrer Shaft	SS 316
E	Gasket	Food grade Silicon
F	Nozzles	SS 316, Seamless pipes
G	Mechanical Seal Type	Double Cartridge water cooled
H	Baffles	SS 316
I	Monkey Ladder	SS 316
J	Legs Pipe	SS 304
K	Base plate	SS 304, suitable for load cell mounting
L	Hardware – Internal	SS 316
M	Hardware – external	SS 304
N	Product outlet Valve type / MOC	Sanitary Design with 1 side flange an 1 side TC connection / SS 316
04	INSULATION AND CLADDING
A	Type of insulation	Mineral wool
B	Insulation Thickness	50 mm
C	Insulation cladding	SS 304, full welded
05	DRIVE AND AGITATOR DATA
A	Type of agitator	Propeller type
B	Agitator Entry	Top Entry.
C	No. of Impeller	01
D	Impeller Dia	As per design
E	Shaft Dia.	As per design
G	Shaft Type	Solid
H	RPM	1440 RPM
I	No. of Baffles	01 No.
J	Motor Type	TEFC/Non FLP / 3Ph/415V/AC
K	Transmission	Direct Mounting
06	SURFACE FINISH
A	Product Contact Parts	220 grit mirror finish. Surface roughness

C. Manufacturing Vessel

Sr. no.	Description	Specifications
	TAG	SHAMPOO Manufacturing Vessel
01	GENERAL SPECIFICATIONS
A	Function	To prepare SHAMPOO
B	Code	Built as per Good Engineering Practice and to comply cGMP standard
C	MOC	SS 316 contact parts and SS 304 non contact parts. Heavy parts and structures shall be cladded with SS 304 materials.
D	Type	Cylindrical Vertical with welded bottom dish and flanged top dish. Hydraulic Lifting of top drive assembly. Max. Lift will be 500 mm OR according to site condition.
E	Mounting	Vertical on Legs with (Optional) load cell mounting
02	PROCESS DETAILS & OPERATIONAL DATA
A	Operation Type	Batch
B	Fluid Handled in vessel	SHAMPOO
C	Specific Gravity	0.9 gms/cc
D	Fluid Handled in Jacket	Steam / Hot Water / Raw water
E	Service	Preparation of SHAMPOO
F	Operating Temperature	10 to 90 Deg. C
G	Operating Pressure	FV to ATM
H	Operating pressure in Jacket	3.5 Kgs/cm2
I	Minimum Steerable Volume	20 % of gross Volume
J	Min. Temperature sensing Volume	20% of working Volume
03	MATERIAL OF CONSTRUCTION
A	Shell / Bottom / Top dish	SA 240 Gr. 316
B	Jacket	SA 240 Gr. 304
C	Agitator Mounting Pad	SA 240 Gr. 304 with SS 316 bushing
D	Agitator Shaft	SS 316
E	Gasket	Food grade Silicon
F	Nozzles	SS 316, Seamless pipe, Sch. 40
G	Mechanical Seal Type	Single Dry Mechanical seal – Hi-Fab or Leak Proof make.
H	Baffles	SS 316
I	Monkey Ladder	N/A
J	Legs Pipe	SS 304
K	Base plate	SS 304
L	Hardware – Internal	SS 316
M	Hardware – external	SS 304
N	Product outlet Valve type / MOC	Sanitary Design with 1 side flange an 1 side TC connection / SS 316
04	INSULATION AND CLADDING
A	Type of insulation	Mineral wool
B	Insulation Thickness	50 mm
C	Insulation cladding	SS 304, full welded
05	DRIVE AND AGITATOR DATA
A	Type of agitator	Semi Contra Type with bottom entry homogenizer. OR Semi Contra Type Inline Homogenizer
B	Agitator Entry	Top Entry for Semi Contra & bottom entry for Homogenizer.
C	No. of Agitator	01
D	Agitator Design	As per design
E	Shaft Type	Solid
G	RPM	10- 40 for Semi Contra Agitator ( Variable through VFD) & 2800 for Homogenizer
H	No. of Fix Baffles	As per design
I	Motor Type	TEFC/Non FLP / 3Ph/415V/AC / IE 3
J	Transmission	Rigid Coupling for shaft joint inside the vessel and Flexible coupling for gear box – agitator shaft. Motor to Gear Box – direct couple
K		Direct couple for homogenizer motor
L	Transmission	Rigid Coupling for shaft joint inside the vessel and Flexible coupling for gear box – agitator shaft. Motor to Gear Box – direct couple
M	Gear Box for Main Drive	Worm reduction / Heli Bevel type
N	Bearing Housing	CI / MS Bearing housing with heavy duty Taper roller bearings – 02 nos. Covered with SS 304 cover.
O	Drive Stool assembly	MS / CI stool with 20 thick Flanges, covered with SS 304 cover.
P	Agitator PAD Plate	Solid SS 304 with SS 316 bushing
Q	Scrapper Blades	02 Nos. Floating type PTFE scrapper blades shall be provided to cover total wall surfaces of the mixing vessel.
R	TOP Dish Lifting	By means of 02 nos. hydraulic cylinders and power pack unit.
S	Host Burst check valve	Will Be provided which will not allow the lifted load to come down in case the hydraulic hose pipe burst or any leakages from hose pipe / joint.
T	Scrapper Blades	02 Nos. Floating type PTFE scrapper blades shall be provided to cover total wall surfaces of the mixing vessel.
06	SURFACE FINISH
A	Product Contact Parts	220 grit mirror finish. Surface roughness

D. Batch Storage vessel without jacket

Sr. No.	Description	Specifications
1.	GENRAL DESCRIPTION
A	Function	Storage of SHAMPOO .
B	Code	Built as per Good Engineering Practice and to comply cGMP
C	MOC	SS 316 contact parts and SS 304 non contact parts. Heavy parts and structures shall be cladded with SS 304 materials.
D	Description	Vertical, cylindrical with conical bottom Loose Top Lid. Leg Supported Without any jacket & agitator
E	Vessel Type	Cylindrical vertical with Conical bottom & Loose top Lid.
2.	Process and Operation Data
A	Fluid Handled in Vessel	SHAMPOO
B	Service	SHAMPOO Storage
C	Design Temp.	100 Deg. C
D	Operating Temp.	AMB
E	Operating Pressure of Vessel	ATM + Static
F	Operating Type	Batch
	SURFACE FINISH
A	Internal Finish	Mirror 240 Grit. Surface roughness

E. INTER CONNECTING PIPE LINES

Inter connecting pipe line provided as under;

• From wax phase vessel to manufacturing vessel through inline type conical filter
• From water phase vessel to manufacturing vessel through inline type conical filter
• From Manufacturing Vessel’s outlet to re-circulation nozzle through Lobe Pump
• From manufacturing vessel to batch storage vessel through lobe pump.
• From Batch storage vessel to inlet of positive displacement type plunger pump inlet.
• From plunger pump to filling machine hopper ( Max. length 3 Mtrs. With 2 bend)

All interconnecting pipe lines are internally electro polished and with TC joints for easy in cleaning.

F. WORKING PLATFORM

SS 304 working platform manufactured out of SS pipes and Angles. Platform top shall be of 18 swg dimpled plate. SS 304 pipe railing as a safety railing shall be provided for safe working of operator.

Platform shall be suitable to cover wax phase, water phase and manufacturing vessels & Storage Vessel. Operating panel shall be mounted on the working platform at suitable location.

G. TWIN LOBE TYPE TRANSFER PUMP

• PUMP TYPE : TWIN lobe
• MODEL : Sanitary Design, GMP Model
• Contact Parts : SS 316
• Mounting : On Trolley with wheels.

H. POSITIVE DISPLACEMENT TYPE TRANSER PUMP

• PUMP TYPE : Positive Displacement Plunger type
• MODEL : Sanitary Design, GMP Model
• Contact Parts : SS 316
• Mounting : On Trolley with wheels.

I. WATER RING TYPE VACUUM PUMP

• PUMP TYPE : Water Ring type
• Model : Standard
• MOC : C. I.
• Mounting : On SKID

5. INTEGRATED CONTROL PANEL

Mild Steel powder coated PLC based power panel, which shall be mounted on service floor consisting of require switch gears and fuses, with SS 304 colour touch HMI based Operating panel mounted near the equipment inside the production area, consisting of following controls

• Main Drive motor ON OFF for wax phase vessel with motor ON indication.
• DTIC for wax phase vessel
• Main Drive motor ON OFF for water phase vessel with motor ON indication.
• DTIC for water phase vessel.
• Main Drive motor ON-OFF for manufacturing vessel with motor ON indication.
• POT for RPM variation for semi contra agitator.
• Main drives ON-OFF for homogenizer motor with motor ON indication.
• Timer for homogenizer motor.
• Vacuum pump ON OFF.
• Twin Lobe pump ON OFF.
• Positive displacement transfer pump ON OFF
• Steam ON-OFF selector switch for all jacketed vessels.
• Total process timer for Semi Contra agitator.
• Actual weight display for wax phae, water phase and main mixer.

SAFETY FEATURES

• Water flow sensor for mechanical seal of In Line homogenizer.
• Single phase preventer.
• Over Load relay for motor overloading protection.
• Heat Extraction fan and ventilation filter in power panel.
• Emergency OFF in operating panel.

Note : Cable between power panel to control panel and from power panel to respective motors are not in our scope of supply.

01	GENERAL POINTS
A	All product contact parts shall be of SS 316 & non-contact parts shall be of SS 304, unless otherwise specified.
B	All electrical shall be of non FLP construction.
C	All electrical switch gears shall be of C&S / L&T / Siemens make
02	DOCUMENTS
A	FDS	Provided immediate up on receipt of order
B	DQ	Provided immediate up on receipt of order
C	Drawing for approval	Provided immediate up on receipt of order
D	Final As built Drawing	Provided along with machine dispatch
E	IQ / OQ / PQ	Provided along with machine dispatch
F	O&M Manual	Provided along with machine dispatch
G	MTR	Provided along with machine dispatch
H	RM test certificates	Provided along with machine dispatch
I	Bought out items test certificates	Provided along with machine dispatch
J	Electrical Diagram	Provided along with machine dispatch
K	Internal Trial report	Provided along with machine dispatch
L	Warrantee Certificate	Provided along with machine dispatch	In our format
M	FAT file / report	Provided before FAT
N	SAT file / report	Provided along with machine dispatch

Batch Size

• Available model 20 KG to 10,000KG working Capacity.
• Working capacity is customized as per customer’s requirement. Abster can provide more than 10,000kgs capacity model also.

A. Shampoo is a hair care product that is used for removal of oils, dirt, dandruff, environmental pollutant & other contaminant particles that gradually built up in hairs.

B. Shampoo is a clear / opaque viscous liquid.

C. Normal Viscosity of Shampoo is in the range of 500 – 1500 centipoise.

D. It contains approx… 20 – 40 % solids & Ph value is around 5.0 to 5.5

E. Classifications of Shampoo

a. Based on use or functions,

• Conditioning shampoo
• Antidandruff or Therapeutic Shampoo
• Baby Shampoo
• Balancing Shampoo
• Clarifying Shampoo

b. Based on appearance

• Cream Shampoo
• Oil Shampoo
• Medicated Shampoo

F. General Manufacturing process flow diagram is

G. Shampoo Manufacturing Plant consists of

• Base / Phase preparation Mixer/s
• Shampoo Mixer
• Storage Vessel
• Transfer pumps
• Working platform
• Integrated control Panel

H. SALIENT FEATURES

• Capacities available from lab scale 50 ltrs. To 10000 Ltr / batch
• Good Engineering Practice follows for manufacturing.
• Stainless Steel 316 / 316 L grade wetted parts and Stainless Steel 304 or mild steel painted non-wetted parts.
• Variable speed of agitator to suit different process conditions.
• Different heating modes like steam, electrical, Thermic Oil , Hot water
• Electrical control panel with require controls and safety interlocks.
• Disperser blade agitator for phase vessel and Pitch Blade Turbine type agitator for Shampoo Mixer.

I. OPTIONALS

• Fully automatic operation with PLC + HMI panel.
• All valves will be pneumatically operated.
• Utility control accessories for mixer and phase vessel
• Load cell for weight measurement.
• Data logger with printer facility
• SCADA connectivity
• Tailor made construction

J. GENERAL LAYOUT

K. TECHNICAL SPECIFICATIONS

BATCH CAPACITY IN LTR.	PHASE VESSEL WORKIIG VOLUME IN LTR.	MIXER VOLUME IN LTR.	TOTAL CONNECTED POWER LOAD	SPACE REQUIRE IN MM.
				LENGTH		WIDTH	HEIGHT
50	35	50	3.75 HP
100	70	100	4.0 HP
250	175	250	7.5 HP
500	350	500	10.0 HP
1000	700	1000	16.0 HP
1500	1050	1500	20.5 HP
2000	1400	2000	25.5 HP
3000	2100	3000	28.0 HP
5000	3500	5000	42.5 HP
10000	7000	10000	57.5 HP