Tested Products

Carbopol 980

Carbopol Ultrez 10 & 20

Problem

The existing system is less effective, which takes 90-100 minutes to complete Full Mixing & Transfer

Performance Measurement & Criteria

• Allowable mixing and transferring within 30 minutes time with the toughest powder: CARBOPOL 980 & ULTREZ 10.
• To make sure no Fisheyes and lumps.
• To make sure no Clogging at funnel inlet.
• Proper mixing and sampling by Senior Process Design Engineer once complete.
• Provide training and handling skills to specific operators and engineers as back up. (Easy Handling).

Solution  

With Alfa Laval Hybrid Powder Mixer

The Installation of HPM

Result

• Reducing installation costs:
  Combining pumping and powder mixing functions into a single unit. (ROTARY LOBE PUMP + HIGH SHEAR MIXER)

• Reducing operating costs:
  future combination with Isomix, only one electrical motor (15 K.W) for the complete system instead of high shear mixer at 18.5K.W at full speed + RLP (5.5 K.W). 37% lesser in Energy Saving~37%.

• Fast and Homogenous Powder Dissolving:
  The 4 different shear steps (Injector, Rotor-Stator, Impeller, Circulation) are able to dissolve the powder effectively and to homogenize. Production time reduced from 100 minutes to only 30 minutes. Saved 70% of the time in overall production.

• High pressure:
  It can create up to 4 bar pressure without an extra pump, for transferring at the same time after 5 minutes of circulation.

• Additional Equipment:
  Enable to install additional equipment after the HPM, such as instrumentation, heat exchanger and ISO-MIX. Currently cleaned manually after mixing.

• Discharge- and/or CIP-Pump:
  Used as a transfer pump after mixing and/or as a CIP pump together with Isomix. (comparing with using high pressure jet, more energy saved)

• Easy Maintenance:
  It is easy to do maintenance, as the funnel is not welded on the frame. (buying spares ball valve & funnel for easy dismantling and replacement for emergency of mishandling).