Complete Liquid Soap 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 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
- 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. APPLEPACK can provide more than 10,000kgs capacity model also.