Problem Solving
Efficient Production of Detergents in Batch Mode
The batch system for detergent production integrates raw material receiving, storage, dosing, weighing, and mixer feeding into a continuous process. Bulk components are supplied from silos or big-bag discharge stations and automatically transported to the conveyor scale according to the selected formula. This allows different raw materials to be supplied precisely and reproducibly for each batch.
Precise dosing for reproducible recipes
Frequency-controlled dosing screws and raw material-specific hold-up times in the vacuum conveying system ensure precise weighing of large and medium-sized components. Small components are pre-weighed separately and then fed into the closed process. This ensures that the required quantities of raw materials are reliably provided according to the formula, thereby creating the conditions for consistent product quality.
Flexible Mixing with Liquid Components
The weighed batch is emptied directly into the mixer. During the mixing process, perfume or other liquids can be sprayed onto the batch as needed. This allows liquid formulation components to be integrated into the batch process without interrupting the automated material flow.
Gentle product handling all the way through to filling
After the mixing process, the detergent is discharged into a receiving tank and, from there, gently conveyed— without separation —to two buffer tanks. These serve as a supply source for the subsequent filling process. This supports a continuous flow of material between production and filling.
Formulation Management and Process Control
The Kastor process control and visualization system controls the plant and integrates recipe management. This allows recipes to be retrieved as needed and ensures that the dosing, mixing, and filling processes are coordinated. The automated process control system supports the safe and efficient operation of the plant and its components.
