WORKING

Manufacturing reactor is cylindrical reactors with dished bottom reactors. Products are manufactured by simple slow blending in a stirred reactor. The reactor is jacketed for heating. The your product manufacturing plant reactors are normally closed type and subjected to vacuum to avoid excessive foaming when foaming agent is added. For best results contra type rotating stirrer is best used for product manufacturing. CIP/ SIP nozzles is provided at the top of the reactor for cleaning. Suitable nozzles, manholes, valves etc are provided on the reactor. Manufacturing reactor can be subjected to full vacuum.

Reactor is provided with jacket for heating. Jacket can be steam heated or electrically heated as per client’s requirement. Suitable insulation and cladding is provided on the jacket. There is no need for any vacuum in this reactor. Normally the capacity of this reactor is 60 % the capacity of the main manufacturing reactor. Premix reactors can be 1 no or 2 nos as per the clients requirements and formulae of the product.

Ingredients are weighed or metered incrementally into the mixing reactor, with thorough mixing between each addition. A moderate amount of heat is used to reduce the viscosity and so facilitate ease of mixing. Some pearlising agents are waxy solids at ambient temperature and require melting in a premixing reactor before use.

Demineralized water is most commonly used in order to minimize contamination of the product. No further processing is required after blending, & perfuming and the product may be packed off directly from the mixing reactor. Or may be transferred to storage reactors from where they are transferred to the filling machines.

CONSTRUCTION

Stainless Steel Reactors (SSR) are made up of using SS 304, SS316, SS316 L etc., SS reactors are durable and performs efficiently for the longer period of time. SS reactors are generally jacketed or having limpet coil for cooling / heating purposes and mounted with different types of agitators such as propeller, Anchor, Turbine etc., SS Reactors are most commonly used reactors in Chemical process industry, Food Industry, Pharmaceutical Industry and Pesticide industry etc., SS reactors are also used for high pressure reactions by increasing the reactor vessel wall thickness.

Typical chemical reactors are connected with Cooling Water, Chilled water, Chilled Brine, Hot oil system, Steam / Hot water etc., to meet heating and cooling purposes during the reaction. Such reactors also connected with vapor column and then to a Condensor & receiver to perform reactions at high temperatures such as at reflux temperature or for solvent recovery after completion of reaction. These reactors are also used for solvent recovery by simple distillations although there may not be efficient separations without having proper distillation column with packing’s.

PREMIXING REACTOR

Premixing reactor is cylindrical reactors with dished bottom reactors. Top of the reactor is also dished end welded or can be provided with loose lid too. Agitator assembly in the premix reactor. Is high speed cowl/ saw cutter type agitator. In some cases high speed homogenizer are also provided. CIP/ SIP nozzles is provided at the top of the reactor for cleaning. Suitable nozzles, manholes, valves etc are provided on the reactor. Reactor is provided with jacket for heating. Jacket can be steam heated or electrically heated as per client’s requirement. Suitable insulation and cladding is provided on the jacket. There is no need for any vacuum in this reactor. Normally the capacity of this reactor is 60 % the capacity of the main manufacturing reactor. Premix reactors can be 1 no or 2 nos as per the client’s requirements and formulae of the product.

THE ADVANTAGES OF STEAM FOR JACKETED HEATING

In jacketed heating applications where processes require operating temperatures up to 350°F, steam and hot water serve as typical forms of heat transfer. Currently, an increasing number of process engineers are switching from steam to hot water for heating jacketed reactors or reactors. There are several basic reasons for this trend:· The temperature in the jacket can be controlled much more accurately with hot water than with steam. This higher degree of control protects against damage to or loss of product through over heating. Hot water ensures a better quality end product. This is particularly important in processes requiring very precise product temperature control. · Hot water distributes heat more evenly than steam. This eliminates hot spots which often cause product to bake onto the walls of the reactor, and at worst, ruin the entire batch.· In critical processes utilizing glass-lined reactors, steam can shock and damage the lining. Hot water allows smooth transitions from heating to cooling with no thermal shock.

In addition, many are switching to direct steam injection (DSI) systems to create the hot water for several basic reasons:· With an advanced-design steam injection hot water set, the temperature of the process can be adjusted at any predetermined rate on any desired time cycle.· A steam injection hot water system can be programmed to heat, then cool a process by stopping the heating cycle, then introducing cooling or tempered water into the jacket at any desired rate and temperature.· In this system the condensate leaves the loop through a back pressure relief valve at the lowest temperature after all the possible heat has been extracted. In a steam system, on the other hand, condensate at a much higher temperature is returned to the boiler in a condensate return line with its inherent heat losses. In this article, we will take an in-depth look at the advantages and disadvantages of steam and hot water for jacketed heating, and compare indirect and direct steam injection systems for making hot water. Then, we will review several specific applications now utilizing direct steam injection systems for jacketed heating.

PIPELINE

Interconnecting pipeline is provided for the plant as per the layout of the client’s room size. All pipelines are electro polished from inside and outside. All joints are DIN standards quick openable types. Pipelines are used for transferring the surfactants from storage tank to premix reactors, from premix reactors to manufacturing reactors and from mfg. reactors to storage reactor and from storage to filling line.

OTHERS

All reactors have CIP/ SIP nozzles & conical filters are provided at the discharge of the reactors. Entire plant is fully automatic and interconnected by suitable pipeline & requires only one operator for all the operations. Suitable working platform is provided for cleaning and maintenance. An integrated control panel fully automatic controlled by a PLC is provided. (Optional).

CONTROL PANEL & AUTOMATION

Control panel made in SS 304 Box (Weather Proof Enclosure) is provided with all the starters, overload relays, push buttons, lamps, Single Phase Preventer, circuit breakers etc. All hardware required for automatic operation of the shampoo mfg. plant is provided in the control panel.
Panel Internal Electrical accessories are largely of SCHNEIDER / SIEMENS / LT – Hager /Equivalent Make.

MAIN ADVANTAGES

• Complete Untouched Process to Avoid Contamination.
• Saving precious batch processing time.
• The entire plant can be operated by one operator & one helper, thus saving on manpower costs.
• Mixing and dispersing quality adjustable.
• Specially designed inline filters provided.

FEATURES

• Complete cover lifting arrangement to facilitate cleaning at the time of product change over.
• Especially semi-contra designed anchor stirrer with flexible Teflon or SS 304 scrapers.
• The main reactor is provided with a slow speed anchor agitator for mixing for emulsifying.
• Variable speed drive provided for main anchor stirrer assembly for different speeds.
• Jacketed reactors for heating / cooling processes.
• Inspection glass illumination.
• All Product Parts are of SS 304 Quality Material.
• All Pipelines are seamless & internally Electro-Polished.
• Documentation: DQ / IQ / OQ / PQ provided.