Batch at the limit?!

Current situation of the processcapacity usage at the maximumoptimized processesstandardized formulationslimited capacitiesconcentration of production sites

Current economic situationpotential of increasing the productivity is limitedcost pressurestrong competitionlimited capacities and how can we assist?

Customer benefitscontinuous vs. batchthroughput increased by 25 %cleaning time optimisedidentical footprint maintenance efforts minimisedtime for maintenance reduced by 15%substantial cost savings

Cost benefit example

cost benefit

batch machineconti plant

working hours per year7,500.007,500.00

output in l/h4,000.005,000.00

total output in litres per year30,000,000.0037,500,000.00

material costs per liter in Euro11

per total output in Europer 100 ml. in Euro

material30,000,000.00 37,500,000.00 0.10 0.10

direct labour900,000.00 900,000.00 0.00 0.00

indirect production3,000,000.00 3,000,000.00 0.01 0.01

finished product unpacked (fpu)33,900,000.00 41,400,000.00 0.11 0.11

output in l/hour100 ml./hcost fpu/h

batch machine4,000.0040,000.004,520.00

conti plant5,000.0050,000.005,520.00

raise per hour in %25.0025.0022.12

safed per 100 ml. in Euro0.00

safed per hour 4000 litres in Euro104.00

safed per year (7500 h) in Euro780,000.00

batch machineconti plant

costs of machine / plant1,000,000.00

depreciation (linear, 10 years)0.0100,000.00

maintenance costs57,000.00 20,000.00

costs per year in total57,000.00 120,000.00

safed funds per year0.0780,000.00

safed costs717,000.00

cost benefit HA

batch machine

percentage material costs80.0%

percentage direct labour costs10.0%

percentage indirect production costs10.0%

batch machinenew plant

working hours per year7,5007,500

output in liter per hour4,0005,000

total output in liter per year30,000,00037,500,00025.00%

material costs per liter in Euro1.001.00

cost annual output in Eurobatch machineconti plant

material30,000,00037,500,000

direct labour*3,750,0003,750,000

indirect production*3,750,0003,750,000

finished product unpacked37,500,00045,000,00020.00%

cost per liter1.2501.200-4.00%

savings per year1,500,000

conti plant

investment in plant2,800,000

payback period< 2 years

* amount remains the same at batch or conti

750024

312.5

Our solution:continuous production

of toothpaste

The processIngredients Dosingwithout pre-mixingdirectly from stock to plantfully automatedexact controlperfect, constant quality

The process Wetting De-aeration Dispersing revolutionary powder-wettingless agglomerationperfect particle sizeperfect density

The processAdditives Controlin every phase of production possiblehighest flexibilityfull automationcompletely reproducible

The processQuality con-trol in-line measuring of viscosity, particle size, density, flow rate, pH-value, pressure and temperatureOn-line quality control

Storage and filling:The process

less storage before filling necessary

Continuous production meets your requirements leading in technologyhigher output at lower costs

together with you we want to combine products processes technology and automation to be one step ahead!Our intention

Legend:densityviscosityflow ratetemperatureparticle sizepressureVEde-aeratorPWMpowder-wetting-machineM/DILinline homogenizerFLfilling lineThe concept

The concept

Liquid sto- rage and fillingSolid storage and fillingContinuous productionThe concept

The concept

The concept

The first trials: The complete plantLiquid and dry phase

Powder wetting machine

The first trialsproduct outlet after powder wetting

Product outlet after de-aerationproduct outlet after de-aeration

Dosing: exact control, perfect and constant quality

You have the knowledge of the productWe have knowledge of machinery and process technologyTogether we can find a new way of processing toothpaste Lets set a new milestone!The vision

Only marginal improvement possibleBatch and semi-continuous systems at the limit Higher output at lower costRaised product reproducabilityHigher capacitiesOnly marginal improvement possibleBatch and semi-continuous systems at the limit Higher output at lower costRaised product reproducabilityHigher capacities

We are seen as the main supplier for vacuum processing units to the mayor players in the tooth paste manufacture.

We have supplied more than 20 units bigger than 5000ltr. Batch volume which is a production volume of xxx ltr/h.You know how to produce toothpaste.

We try to be a step ahead of the requirements of our customers