full-scale production: problems and solutions. (gleams & notions). - drum storage
A few years ago, my column detailed how to expand from lab recipes to pilot plant batches (
February 1991, p. 24).
This month, I will go through all kinds of technologies.
Some companies, mainly smaller ones, use the supplier's production chemicals "as is" to prevent espionage without changing tradenames.
Other companies use opaque paint to clear tradename before sending it to the processing zone.
These companies use code names for all raw materials.
Some even use code names in their R & D labs.
I work in a company that uses my name as the code for formaldehyde.
Unless the new chemist has access to the code table, he will make it blindly, because the code names of each company are different, so his previous development experience will be useless.
Dyes normally coded or not coded in small containers should be weighed by the laboratory in order to obtain more accurate weighing by using smaller scales.
Most chemicals are delivered in 55 gallons of barrels.
If the entire drum is not used in a batch, usually this is the case, the drum trolley can be used to allow the drum used in the part to be stored horizontally at a height suitable for pulling the contents into the weighing container.
Another useful device is the electric heating cover installed around the drum.
This prevents sticky raw materials from becoming more sticky or even strong in cold weather.
Using a heating chamber is another way to keep the liquid moist.
When large quantities of chemicals are frequently used, it may be more economical and convenient to purchase and store in storage tanks in bulk.
Some suppliers may install their own tanks with little or no long-term purchase agreement at all, and the use of tank eliminates the significant amount of work involved in handling materials, and save a lot of drum storage space.
One of the most important equipment used in the factory is the mixer.
Most cosmetic companies use stainless steel tanks, massage bathtubs with separate steam and cooling water channels.
It is sometimes overlooked that a careful design of the tank outlet valve is necessary.
In a closed position, the top should be flush with the inner surface of the mixing container.
Some containers have several inches of pipe under the mixed surface and above the valve, which can be filled with raw materials during processing.
This can cause a large number of unmixed products or raw materials to come out when the valve is first opened.
If the unmixed material is a pigment or wax, it will not be dispersed in the volume now cooled.
Another drawback of the Badvalve design is that microbial colonies can grow in an environment that is difficult to approach, which can lead to contamination of finished products.
The mixing device in the container should be generic.
It should contain high-speed mixing and slow mixing (paddle type)
Mix on the same axis.
When powder or gum concentrate, high speed propeller mixing is required at the beginning of the batch (Such as cabom)
Disperse or dissolve.
Low speed mixing is required to eliminate air when batch cooling becomes thicker.
This process should have enough heating, shear and the whole manufacturing time when producing the emulsion economically.
This can be achieved by keeping the oil phase above its melting point immediately before the emulsion.
If a wax melts at 70 [degrees]
Heating it to 85 [is a waste of time and effort]degrees]C.
Another way to reduce the cost of eating is to melt fat and wax with a small amount of oil and then add the rest of the oil.
Minimum amount of water (
At the same temperature as the oil)
Should be used to form emulsion.
Once sufficient emulsion is reached, the rest of the room temperature water is added.
This will eliminate a major part of the cooling cycle.
Cycle by passing the tap water through the housing of the mixing tank.
This technology is mainly applicable to oil. in-wateremulsions.
Other low-temperature lotions can be completed if there is no solid pro-fat component and the solid hydrophilic substance is easily soluble in water or water-soluble solvent.
Harvey Fishman owns a consulting firm at 34 Caso Avenue, Oakridge, NJ, Zip code: 07436.
Focus on cosmetic formula and new product ideas to provide tested finished products.
He has more than 30 years of experience and has served as research director in the halls of Bonte, Nestlé lemur and Turner.
He welcomed descriptive literature from suppliers, laboratory chemists and others in the field.