2.8. Equpiment Specification

There are some equipments that needed for supporting the process

manufacturing of hair gel product. The equipment are choosen based on the need of

for the process and the maximum capacity production of the factory. The maximum

capacity for each equipment is basen on the market value. When we want to decide the

capacity of the process, we choose the minimum value that is near to the specification of

equipment capacity in the market. In hair gel production, these are some equipment

which are needed:

2.8.1. Storage Tank

The function of storage tank is to load the raw materials of the hair gel.

We use 2 storage tanks. The picture of the storage tank is shown below:

Table 1. Specification of Storage Tank

Capacity (L) Length (mm)

Width (mm)

Dimension (m2)

Maximum Height (m)

50 2900 2450 7.1 3.4300 3820 2870 11.0 3.4500 4035 3430 13.8 3.4

(Source: www.processequipments.com/tankvolumetricvessel)

Table 2. Storage Tank Capacity

Storage Capacity (L)

Ammount Feedstock Capacity (L/month)

500 1 Water 12789.744 300 1 Aloe Vera Extract  313.036

50 1

Carbomer  181.673Glycerin  57.674PVP K-30  363.345

Propylene Glycol  139.748

Polyquartenium 39  71.244

PEG-40 Hydrogenated Caster Oil

 25.769

Methylchloroisoizolinone  1.425

Surfactant  303.075Cytrus Essens  17.038Trietanolamine  204.502

(Source: www.processequipments.com/tankvolumetricvessel)

Figure 1. Storage Tank(Source: www.processequipments.com/tankvolumetricvessel)

2.8.2. Vessel

Vessel is usually used for the storage which the composition of feeds have

been calculated by the base of the phase feeds. We use four three vessel to load

the ingredient that have been calculated. The picture of the vessel is shown below:

Table 3. Vessel Specification

Capacity (L) Length (mm)

Width (mm)

Dimension (m2)

Maximum Height (m)

200 3640 2550 9.3 3.4(Source: www.processequipments.com/tankvolumetricvessel)

Table 4. Vessel Capacity

Vessel Capacity (L)

Ammount Stock Capacity (L/month)

200 1 Gel 13029.09 (Source: www.processequipments.com/tankvolumetricvessel)

Figure 2. Vessel(Source: www.processequipments.com/tankvolumetricvessel)

2.8.3. Mixer

In mixer, many additives such as PVP K-30, Propylene Glycol,

Polyquartenium 39, PEG-40 Hydrogenated Caster Oil, Methylchloroisoizolinone,

surfactant, neutralizer are mixed well. The picture of the mixer is shown below:

Table 5. Mixer Capacity

Input Volume (L)

Capacity (L)

Length (mm)

Width (mm)

Water 142.108200 3000 2530Carbomer 2.019

Glycerin 0.641Gel Based 144.768

200 3000 2530Additives 12.513PVP K-30 4.037

50 1540 950

Propylene Glycol 1.553Polyquartenium 39 0.792

PEG-40 Hydrogenated Caster Oil 0.286

Methylchloroisoizolinone 0.016Surfactant 3.367

Cytrus Essens 0.189Trietanolamine 2.272

(Source : https://www.qualtechproductsindustry.com/industrial-production- equipments/mixer-agitator/in-tank-mixer/ )

Table 6. Mixer Specification

Dimension (m2)

Maximum Height

(m)kWh Speed (rpm)

7.6 3 9.75 36001.7 1.2 6.25 3600

(Source : https://www.qualtechproductsindustry.com/industrial-production- equipments/mixer-agitator/in-tank-mixer/ )

(Source : https://www.qualtechproductsindustry.com/industrial-production- equipments/mixer-agitator/in-tank-mixer/ )

2.8.4. Heater

Heater is supply heat for the mixer to mix the additives. The picture of

heater is shown below:

Table 7. Heater Specification

Diameter (mm) Height (mm)

Dimension (m2)

kWh

12  712 1 2.4

2.8.5. Cooler

Cooler is supply heat for the mixer to mix the additives. The picture of

heater is shown below:

Table 8. Cooler Specification

Diameter (mm) Height (mm)

Dimension (m2)

kWh

12 712 1 2.4

2.8.6. Filling Jar Machine

This machine is used to fill the gel into the jar (package). The mass of the

hair gel jar is about 85 gr. The picture of filling machine is shown below :

Table 9. Filling Jar Machine Specification

Speed (units/min)

Length (mm)

Width (mm)

Height (mm)

Weight (kg)

Power (kWh)

Filling Weight (gr)

50 1000 700 1800 250 1.8 1-500(Source : http://www.alibaba.com/product-detail/Automatic-Powder-Filler-Machine-With-Inline_228058719.html?s=p)

Figure 3. Filling Jar Machine(Source : http://www.alibaba.com/product-detail/Automatic-Powder-Filler-Machine-With-

Inline_228058719.html?s=p)

2.8.7. Cleaning Machine

This equipment is suitable for clenaing the leaves of aloe vera. It is easy to

operate, convenient in maintenance and wiring. Here is the specification of the

machine :

Table 10. Cleaning Machine Specification

Max Capacity (T/h)

Length (mm)

Width (mm)

Height (mm)

Weight (kg)Power (kWh)

1 2600 1200 1500 375 1.5(Source: http://wzjimei.en.alibaba.com/product/60039290645-209501208/Aloe_leaf_washing_ Unit.html)

Figure 4. Cleaning Machine(Source: http://wzjimei.en.alibaba.com/product/60039290645-

209501208/Aloe_leaf_washing_ Unit.html)

2.8.8. Peeling Machine

This equipment is used to peel the aloe vera so we can get only the gel of the aloe vera. Aloe peeling machine is suitable for taking stabs off from leaves of aloe, cacti. The materials of this equipment is stainless steel.

Table 11. Peeling Machine Specification

Max Capacity (T/h)

Length (mm)

Width (mm)

Height (mm)

Weight (kg) Power (kWh)

1.5 1850 880 1360 275 0.75(Source: http://wzjimei.en.alibaba.com/product/60197449129209501208/Aloe_Vera_Peeling_ Cutting_Extract_Machine_.html )

Figure 5. Peeling Machine(Source: http://wzjimei.en.alibaba.com/product/60197449129209501208/Aloe_Vera_Peeling_

Cutting_Extract_Machine_.html )

2.8.9. Cutting Machine

This machine is used to cut and crush the aloe vera to make gel form. The

gel form of aloe vera make it easier to mix with gel based and the additives. Here is

the specification of the machine :

Figure 6. Cutting Machine(Source:

http://wzjimei.en.alibaba.com/product/257343277-209501208/Improved_ideal_Aloe_vera_Cutting_Machine.html )

Table 12. Cutting Machine Specification

Max Capacity (T/h)

Length (mm)

Width (mm)

Height (mm)

Weight (kg) Power (kWh)

1.5 1500 350 1300 225 0.75(Source: http://wzjimei.en.alibaba.com/product/257343277209501208/Improved_ideal_Aloe_ vera_Cutting_Machine.html )

2.8.10. Conveyor

This machine is used to transfer solid materials from the warehouse or

storage to another storage or process equipment. Aloe vera is transfer using

conveyor to cleaning machine and another process. Here is the specification of the

conveyor belt is :

Table 13. Conveyor belt specification

Speed (m/min) Length (mm)

Width (mm)

Thickness(mm)

2-10 8000 800 4(Source: http://wzjimei.en.alibaba.com/product/1668439035-209501208/Light_Type_Inspection_Conveyor_for_Diced_Aloe.html )

The specification of the conveyor is :

Table 14. Conveyor Specification

Length (mm)

Width (mm)

Height (mm)

Weight (kg) Power (kWh)

4000 900 900 250 0.63(Source: http://wzjimei.en.alibaba.com/product/1668439035-209501208/Light_Type_Inspection_Conveyor_for_Diced_Aloe.html )

Figure 7. Conveyor(Source:

http://wzjimei.en.alibaba.com/product/1668439035-209501208/Light_Type_Inspection_Conveyor_for_Diced_Aloe.html )

2.8.11. Centrifugal Pump

Table 15. Centrifugal Pump Specification

Speed (rpm) Capacity (m3/h)

Head (m)

Diameter (mm)

Weight (kg) Power (kWh)

2900 30 12 25 24 0.37

(Source: http://www.alibaba.com/product-detail/GPS-horizontal-centrifugal-pump-manufacturer_1097269497.html?s=p )

Figure 8. Centrifugal Pump(Source: http://www.alibaba.com/product-detail/GPS-horizontal-centrifugal-pump-

manufacturer_1097269497.html?s=p )

2.8.12. Rotary Pump

Table 16. Rotary Pump Specification

(Source: http://www.alibaba.com/product-detail/LQ3A-6-0-75kw-Stainless-Steel_492895885.html )

Figure 9. Rotary Pump(Source: http://www.alibaba.com/product-detail/LQ3A-6-0-75kw-Stainless-Steel_492895885.html )

2.9. Production Schedule

Factory Scheduling is the production management process by which

raw materials, intermediates and production capacity are efficiently allocated to

meet demand. Production scheduling also identifies many resources that use to

produce hair gel, anticipates problems that may occur, and estimates the time

which is needed to do an activities.

Process planning and scheduling makes the use of energy and other

resources in the process production are more effective. An efficient planning

and scheduling is really important. It can be a tool that directly contributes to the

company’s financial performances. Cash flow and profitability are essential, and

it depends on the efficient planning and scheduling of the process. Good

planning and scheduling can influence the company’s overall performance and

give more benefit and profit.

In manufacturing process, we use batch condition because the

characteristics of the material that we use and the limited addition tools of process

manufacturing. The duration of production of Zeus hair gel is based on all the

process. The operation time is about 21 hours per day. We produce about 1453 kg

of hair gel. We decide the amount of product based on demand in the market. The

time operation of our plant is 330 days per year. The plant will shut down for

maintenance, unexpected events, and national holiday for about 30 days per year.

The duration of production of Zeus hair gel is based on materials

weighting time; mixing time of gel based phase, mixing time of additives such as

PVP K-30, Propylene Glycol, Polyquartenium 39, PEG-40 Hydrogenated Caster

Oil, Methylchloroisoizolinone, surfactant, neutralizer, cytrus, ameroxol, time to

make aloe vera extract stratrs from cleaning the aloe vera, peeling, and cutting

until making a gel form of aloe vera. The duration time also depeded on time of

mixing the final component to make hair gel, filling the hair gel into jar, and

packaging time.

Based on the literature and our assumptions about the time of process, the

result is shown in table below :

Table 17. Summary of Overall Process and Times

No Process Time (minutes)

1 Gel based materials weighting process 152 Put raw materials into storage tank 15

3 Put material (gel based : water, carbomer, glycerin) into homogenizer (mixer 1)

15

4 Mix gel based materials in Mixer 1 105

5 Discharging the gel based from mixer 1 into vessel 1and quality control process

30

6 Additive materials weighting 30

7

Put material (additive : PVP K-30, Propylene Glycol, Polyquartenium 39, PEG-40 Hydrogenated Caster Oil, Methylchloroisoizolinone, surfactant, neutralizer, cytrus, ameroxol) into mixer 2

15

8 Mixing and heating process in mixer 2 609 Discharging the additives from mixer 2 into vessel 1 15

10 Clean the Aloe Vera in a machine 3011 Peel the Aloe Vera to get the gel inside 4512 Crush the gel to get a soft texture 4513 Filter aloe vera extract 30

14 Put the gel based, additive, aloe vera extract, and neutrilizer into mixer 3

15

15 Final mixing process 7516 Discharging final product into vessel 2 and quality control process 4517 Put gel into the jar 4518 Sealing and labelling process 3019 Packaging process 3020 Store product to warehouse 30

(Source: Author’s Personal Data)

From table above, we can use that data to make scheduling for one cycle.

The system use batch cycle, so to fulfill our production target, we have to use

more than one cycle. This batch cycle means that only some equipment that will

run continuously and the other will have to wait and not processed continuously.

The chart of tools and process scheduling for one cycle is shown below.

Table 18. Time Scheduling

No Process Time (minutes)

30 60 90 120 150 180 210 240 270 300 330 360 390 420 450

1 Gel based materials weighting process 15                                                            2 Put raw materials into storage tank 15                                                            

3Put material (gel based : water, carbomer, glycerin) into homogenizer (mixer 1)

15                                                           

4 Mix gel based materials in Mixer 1 105                                                            

5 Discharging the gel based from mixer 1 into vessel 1and quality control process

30                                                           

6 Additive materials weighting 30                                                            

7

Put material (additive : PVP K-30, Propylene Glycol, Polyquartenium 39, PEG-40 Hydrogenated Caster Oil, Methylchloroisoizolinone, surfactant, neutralizer, cytrus, ameroxol) into mixer 2

15                                                      

     8 Mixing and heating process in mixer 2 60                                                            

9 Discharging the additives from mixer 2 into vessel 1

15                     

                                    

10 Clean the Aloe Vera in a machine 30                                                            11 Peel the Aloe Vera to get the gel inside 45                                                            12 Crush the gel to get a soft texture 45                                                            13 Filter aloe vera extract 30                                                            

14 Put the gel based, additive, aloe vera extract, and neutrilizer into mixer 3

15                                                           

15 Final mixing process 75                                                            

16 Discharging final product into vessel 2 and quality control process

45                                                           

17 Put gel into the jar 45                                                            18 Sealing and labelling process 30                                                            19 Packaging process 30                                                            20 Store product to warehouse 30                                                            

(Source: Author’s Personal Data)