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
