Post on 23-Nov-2015
description
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