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Liquid Detergent, hand wash, Dish wash Manufacturing Plant

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Complete Liquid Soap Plant consists of following equipments

  1. Wax Phase Vessel
  2. Water Phase Vessel
  3. Manufacturing Vessel
  4. Batch Storage Vessel
  5. Twin Lobe type product transfer Pump
  6. Positive displacement type Transfer Pump
  7. Vacuum Pump.
  8. Interconnecting pipe line
  9. Integrated PLC based control Panel
  10. 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 Liquid Soap 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 Liquid Soap 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 Liquid Soap Manufacturing Vessel
01 GENERAL SPECIFICATIONS
A Function To prepare Liquid Soap
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 Liquid Soap
C Specific Gravity 0.9 gms/cc
D Fluid Handled in Jacket Steam / Hot Water / Raw water
E Service Preparation of Liquid Soap
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 Liquid Soap.
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 Liquid Soap
B Service Liquid Soap 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 CONENCTING 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 recirculation 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
  1. PUMP TYPE : TWIN lobe
  2. MODEL : Sanitary Design, GMP Model
  3. Contact Parts : SS 316
  4. Mounting : On Trolley with wheels.
H. POSITIVE DISPLACEMENT TYPE TRANSER PUMP
  1. PUMP TYPE : Positive Displacement Plunger type
  2. MODEL : Sanitary Design, GMP Model
  3. Contact Parts : SS 316
  4. Mounting : On Trolley with wheels.
I. WATER RING TYPE VACUUM PUMP
  1. PUMP TYPE : Water Ring type
  2. Model : Standard
  3. MOC : C. I.
  4. 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

  1. Main Drive motor ON OFF for wax phase vessel with motor ON indication.
  2. DTIC for wax phase vessel
  3. Main Drive motor ON OFF for water phase vessel with motor ON indication.
  4. DTIC for water phase vessel.
  5. Main Drive motor ON-OFF for manufacturing vessel with motor ON indication.
  6. POT for RPM variation for semi contra agitator.
  7. Main drives ON-OFF for homogenizer motor with motor ON indication.
  8. Timer for homogenizer motor.
  9. Vacuum pump ON OFF.
  10. Twin Lobe pump ON OFF.
  11. Positive displacement transfer pump ON OFF
  12. Steam ON-OFF selector switch for all jacketed vessels.
  13. Total process timer for Semi Contra agitator.
  14. Actual weight display for wax phae, water phase and main mixer.
SAFETY FEATURES
  1. Water flow sensor for mechanical seal of In Line homogenizer.
  2. Single phase preventer.
  3. Over Load relay for motor overloading protection.
  4. Heat Extraction fan and ventilation filter in power panel.
  5. 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. APPLEPACK can provide more than 10,000kgs capacity model also.
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