Product Integrity is Key!

Transcription

1 Product Integrity is Key! Gentle and Pure Processing of Detergent Powders DETEX 2018 Le Royal Hotel Amman, Jordan April 10-11,

2 Agenda Introduction 1. Our Technology: Mixing Impregnating 2. Your Detergents: Key characteristics and challenges 3. Our Machines: Special features and sizes 2

3 Introducing Bastiaan Soeteman MSc. Mechanical Engineering TU DELFT, The Netherlands Managing Director/Owner Lindor, The Netherlands Director Winkworth, UK Board member of Wecycle (recycling of electric appliances) 3

4 Lindor offices with large manufacturing area Founded in 1963 in Dordrecht, the Netherlands The first Gentle Touch mixer build in 1989 Well over 400 mixers installed worldwide Production of mixers each year Testing facilities in NL, UK, India, Japan World wide agent and support network Planckstraat GS Dordrecht (close to Rotterdam) The Netherlands Tel: +31 (0) Enquities: Service & spare parts: 4

5 Our Technology: Gentle Mixing & Impregnating 7

6 Mixers are used to make a homogeneous blend of the powders and liquid additives Spray tower Spray tower Dry Liquid Dry Liquid Ready for packaging Ready for packaging 8

7 There are many choices for a type of mixer each with their own characteristics UT Mixer (Ribbon) RT Mixer (Ploughshare) TS Mixer (Paddle) Gentle Touch Mixer (Lindor) Conical Mixer Vertical Ribbon DC Blender (Bi-Conical) IBC Blender 9

8 These eight types of mixers each use one of three mixing mechanisms Convection Mixing Diffusion Mixing Forced Flow Mechanical Fluidisation Gravity Flow Particles are PUSHED by a tool like ribbon or blade which move some particles who move others. Particles are WHIPPED in the air by a fast plough shear or paddle. These particles collide with others, creating a cloud. Particles are lifted and DROPPING/SLIDING on the rest, redistributing coninuously. Each partcle undergoes the same force (G). Examples: 10

9 The mixing mechanism defines to a degree the amount of shear inflicted on the product ~ W/kg ~ 5 10 W/kg ~ 1 2 W/kg High Shear Low Shear High shear force on product No shear force on product Possible breakage No breakage Static Low Static Heat No heat High energy - >>> kw! Low energy - <<< kw! Product Inegrity: As long as possible use as little shear as possible 11

10 Rotary vessel mixing allows the product to be dispersed with no mechanical agitation, thus very low shear 12

11 By slowly rotating drum the fixed scoops lift the product up so that gravity takes over creating a thorough mixing action 13

12 As is demonstrated by this 3D simulation 14

13 The mixing action results in a homogeneous product in a short time typically between 2 and 5 minutes conductivity [ S/cm] min mixing time [s] 3 min. Sample 200kg of product base (roller dried rice cereal) plus NaCl in Lindor L750 15

14 Due to this mechanism, gravity is doing most of the work so power used is low Total Power Use (kw) Bulk Density 0,3 kg/dm3 0,5 kg/dm3 0,7 kg/dm3 Installed Power based on SEW (kw) Type - size L500 0,2 0,4 0,5 2,2 L750 0,4 0,6 0,8 2,2 L1000 0,5 0,8 1,1 2,2 L1500 0,7 1,2 1,7 2,2 3,0 L2000 1,0 1,5 2,2 2,2 3,0 4,0 L3000 1,7 2,9 4,0 5,5 7,5 11,0 L4000 2,3 3,8 5,4 5,5 7,5 11,0 L5000 2,7 4,8 6,7 5,5 7,5 11,0 L6000* 2,9 4,9 6,8 2 x 5,5 L7000* 3,4 5,7 8,0 2 x 2,5 2 x 7,5 L8000* 3,9 6,5 9,1 2 x 5,5 2 x 7,5 L10000* 4,9 8,1 11,4 2 x 5,5 2 x 7,5 2 x 11,0 L12000* 6,7 11,2 15,7 2 x 5,5 2 x 11,0 2 x 15,0 L14000* 7,9 13,1 18,3 2 x 11,0 2 x 15,0 Used motordrives (SEW): 2,2 kw 3,0 kw 4,0 kw 5,5 kw 7,5 kw 11,0 kw *: 2 motordrives used per mixer Note: Angle of repose 35, use of single lip seals 16

15 Characteristics of rotary vessel process technology offer process integrity Key Process Characteristics Excellent homogeneity Short mixing time (~ 2 5 min.) No breakage particle integrity Excellent liquid dosing Quick and easy to clean Self-emptying (typ. > 99,9%) No frictional heat generatin Variable batch size (10-100%) Very low energy consumption Low maintenance 17

16 Precious products each with their own challenges are processed in this way Chemicals: Detergents Polymers, compounds Minerals, metal powders Ceramics Super Adsorbent Powders Catalysts Food: Instant Drinks Breakfast Cereals Snacks, Nuts, Dried Fruits Baking Powders Baby Nutrition, Milk Powder Tea, Herbs Flavours, Spices and Salts 18

17 Your Detergents: Key characteristics and challenges 19

18 Your powder quality is defined by its raw materials, formulation and process integrity Key Parameters Particle size Agglomeration Powder homogeneity Liquid repetition Key Challenges Dust/fines formation Lumps Long process cycles Loss of ingredient activity 20

19 and then more challenges Cross contamination between recipes Heating up of powder during liquid dosing, losing intensity Static charge of powder Cleaning time 21

20 How your process challenges are adressed by this technology Process challenges Dust/fines generation Lumps Long process cycles Moisture build up Cross contamination between recipees Cleaning time Static charge of powder Heating up of powder during liquid dosing, losing intensity Process characteristics No breakage High homogeneity Short cycle times Liquid dosing capability due to ever moving product bed Quick and easy to clean Self-emptying (typ.>99,9%) No frictional heat generation Cooling capability with air and jacket 22

21 All nice promises. Test first! 23

22 Our Machines: Special features and sizes 24

23 Our smallest has only a 1-10 liters batch Lindor L10 lab mixer 25

24 The small, medium and large size models vary in geometry and design L70 & L200 > Manually operated pilot mixer L100 > PLC controlled R&D mixer L500 L1000 > Production mixer, 1.5 m, separate in-/outlet, 3 scoops L1500 L2300 > 2 rows of 3 scoops = 6 scoops L3000 L5000 > 2.2 m, 1 (L3000) or 2 rows of scoops L6000 L25000 > m, 2 rows of scoops, 2 motors 26

25 Lindor mixer combining heating (double jacket), liquid injection, CIP cleaning 27

26 Our largest machine has a max batch of liters 15 Tons 28

27 Cleaning is important, is getting even more important and will continue to gain importance! 29

28 Key points to take away Powder integrity is key! Each application deserves it s own best mixer selection and configuration Test before you buy, optimise after you install Use gravity it is equal for each particle and it is free! Stay with low shear as much as possible as long as possible Tune your operation for future needs Flexible Clean Pure processing - NO side effects 30

29 Being focussed and small company when we build a large machine, we celebrate! 31

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32 Heating, cooling, drying are possible with a steam/water or thermal oil jacket 8 Barg steam to 170 C Hot water to 120 C Cooling with water/glycol Air heating/cooling/drying to ~150 C or to ~350 C Batch size 1000 liter KONTI mixing possible Patented 34

33 Blending and flavouring tea Reason for Lindor Mixer Homogeneous blend No breakage of leaves Quick mixing (2 3 minutes) Even distribution of liquids Sizes installed (batch size) 25 kg 5000 kg 35

34 Mixing breakfast cereals Reason for Lindor Mixer Homogeneous product No breakage of ingredients No segregation Short cycle times Sizes installed 30 kg 1000 kg 36

35 Mixing instant products Reason for Lindor Mixer Powder quality Low maintenance Production capacity, short cycle times Sizes installed 30 kg 1000 kg 37

36 Mixing infant formula & infant cereals Reason for Lindor Mixer Homogeneity Powder quality particle integrity Easy cleaning (with QSR) Sizes installed 300 kg 2000 kg 38

37 Mixing snacks Reason for Lindor Mixer Homogeneous product No breakage of ingredients No segregation Sizes installed From L500 L