A standard semi-solid emulsion like shampoo manufacturing takes place in three different phase vessels - A water phase vessel, wax phase vessel and a main mixing vessel. Other components may include an emulsifier/homogenizer, a vacuum pump, Transfer pump, storage and buffer vessels and a CIP module. All our vessels are made of SS316L grade material and fabricated as per cGMP guidelines. The shampoo processing plant can be completely automated with pneumatically operated valves for aseptic manufacturing.

Water phase vessel

Water Phase Vessel All the aqueous phase mixing of ingredients is carried out in the water phase vessel with water or similar material as the solvent. The vessel could be jacketed for heating and cooling of the solution in the vessel. The temperature variation of the vessel could be achieved by steam & chilled water or electrical heating arrangement according to the availability of utilities at the customer’s facility. For uniform mixing, a propeller type stirrer is utilized along with baffles to prevent vortex formation. Product inlet into the vessel can be achieved via vacuum suction for minimum contamination. Similarly, solid ingredients can also be introduced into the solution at vacuum pressure. Solid ingredients can be introduced into the vessel via an additive hopper at the top of the vessel or a suction port situated at the bottom of the vessel. After obtaining the satisfied composition the contents of the vessel are transferred to the main manufacturing vessel.

Wax phase vessel

Wax Phase Vessel Similar to the water phase vessel, all oil/wax phase mixing is carried out in the wax phase vessel with wax as the main solvent. The vessel is usually jacketed for heating of the wax to improve solubility at elevated temperatures. The temperature variation of the vessel could be achieved by steam & chilled water or electrical heating arrangement according to the availability of utilities at the customers facility. For uniform mixing, a saw-tooth cutter type stirrer is utilized in this phase vessel. Product inlet into the vessel can be achieved via vacuum suction for minimum contamination. Similarly, solid ingredients can also be introduced into the solution at vacuum pressure. After obtaining the satisfied composition the contents of the vessel are transferred to the main manufacturing vessel.

Main Manufacturing vessel

Main Manufacturing Vessel The main mixing of the contents in the water phase vessel and the wax phase vessel is done in the main manufacturing vessel at appropriate temperature. The temperature variation of the vessel could be achieved by steam & chilled water or electrical heating arrangement according to the availability of utilities at the customers facility. Usually, the main mixing vessel is provided with a top mounted anchor type agitator to stir the product for uniform temperature transfer and minimizing lump formation. The agitator is also equipped with teflon scrapers for scraping of material from the walls of the vessels. Apart from the agitator, a homogenizer is provided at the bottom of the vessel for emulsification of the liquid-liquid mixture to a uniform composition. Propack technologies’ homogenizer is designed to reduce particle size to less than 5 microns. After attaining the desired composition and viscosity of the product, the contents are transferred into a storage vessel through a flush bottom diaphragm valve to minimize product holdup in the tank.

The operations of various pumps, pneumatically operated valves (in case of automated operation) and mixers is carried out through the main control panel. The panel is made out of SS304 grade material and consists of various safety lock systems like the Emergency stop and Mains supply indicators for safe work and extended component life. The vessels are connected to each other via interconnecting pipelines manufactured as per cGMP norms and connected with sealed tri clamp connection.

Features of Shampoo Plant & Equipment:

1. Uniform ingredient dispersion
2. No wall caking
3. Entire plant operation by one operator and one helper
4. Efficient heat transfer in the vessels
5. Particle size reduction less than 5 microns
6. Reduced batch processing time
7. Reduced change over time
8. Consistent product composition across different batches

1. All contact parts made of SS316L and non-contact parts made of SS304 grade material
2. Food grade silicone gaskets
3. Vessel design as per ASME guidelines
4. Torispherical, Hemispherical and Conical dish top customization availability
5. Hydraulic lid lifting arrangement for occasional cleaning
6. Static & Dynamic spray ball availability
7. VFD for motor rpm controls
8. Double cartridge mechanical seal along with cooling arrangement for Homogenizer shaft