The customer
The client is a leading company in the professional and domestic cleaning sector, specializing in laundry and dry cleaning products. Located in the province of Turin, the production facility can produce over 50 tons of products per day, thanks to highly automated systems managed with the latest technologies.
The Project
The project’s goal was to increase the plant’s production capacity by creating a new chemical mixing plant for raw materials with a high degree of automation. Mixing raw materials, including bases and additives, is the main operation in detergent production. Granzotto’s intervention made the plant compatible with Industry 4.0 requirements, qualifying it for related tax incentives.
The Plant
The plant consists of:
- 3 external storage tanks for raw materials
- 1 buffer storage tank (S1)
- 1 warehouse for IBCs storing additives
- 5 mixing tanks
Raw materials are delivered to the external tanks by tankers, then transferred to the buffer tank S1 and subsequently to the mixing tanks, where they are mixed with additives as per the recipe. Additives are drawn directly from IBCs through a flexible tube and transferred to the mixers via the same line used for raw materials.
Alternatively, raw materials can be transferred directly to one of the 5 mixers without passing through tank S1. The mixed product is then transferred from the mixers to the filling lines (the product is sold in bottles of various sizes). The large capacity and buffer function of tank S1 increase the plant’s flexibility and production capacity. The mixed product can be transferred from the first mixer to tank S1, freeing the mixer for additional production. This allows for batches larger than the capacity of individual mixers. Tank S1 also has a recirculation system, managed by a volumetric pump, to keep the product moving without creating turbulence, thus preventing foam formation.
The Solutions
The Granzotto team implemented multiple solutions to address specific issues identified during discussions with the client and throughout the project. These issues are briefly listed and then detailed below:
- Water Shortage
- Contamination of products transferred through the same line
- High pressure losses when transferring more viscous products
- Foam formation during recirculation in the buffer tank
- Managing automation in a complex plant
Water Shortage
In liquid detergents, water is often the most significant component by volume. The client’s water supply network couldn’t support increased production capacity. Normal water dosing in the mixers would result in unacceptably long production times. Granzotto addressed this by creating a control system that uses a flow meter to manage water loading into the mixers at night, allowing daytime dosing and mixing without waiting for water to fill as per the recipe.
Contamination of Products Transferred Through the Same Line
The plant uses the same line to transfer surfactants and additives from the buffer tank S1 to various mixers. The client produces various products, including fabric softeners, which are chemically different from detergents and at risk of contamination. To prevent contamination, the transfer line is equipped with a PIG system (pigging system G-RECO) to recover residual product. The PIG is pushed with water, which is then recovered and reused. Using a PIG system also minimizes product waste, especially important given the lack of discharge points.
High Pressure Losses When Transferring More Viscous Products
Handling highly viscous substances is a common issue in the process industry. Some substances used in detergent formulations (e.g., glycerin) become too viscous for in-line transfer, especially during winter. Despite heated external storage tanks, the viscosity of some substances did not allow sufficient flow to the volumetric pump. Granzotto addressed this with a dual approach: oversizing the suction diameter from the tanks and equipping each external line with an electric tracing cable to maintain a consistent liquid temperature and prevent unwanted viscosity increases.
Foam Formation During Recirculation in the Buffer Tank
As mentioned, the buffer tank S1 has a recirculation system to keep the product moving. The recirculation system is designed to minimize turbulence and foam formation. In addition to using a low-foaming volumetric pump, the system reintroduces liquid along the tank’s inner sidewall, preventing air entrapment.
Managing Automation in a Complex Plant
Managing automation in a complex plant is challenging, especially with multiple equipment suppliers. Granzotto implemented sensors for automatic raw material dosing and interfaced with the centralized production management system, enabling remote recipe input and production reports. Granzotto also provided CE compliance certification for the plant according to the Machinery Directive (2006/42/EC). The interface with the production management system and compliance with the Machinery Directive allowed the client to benefit from Industry 4.0 tax incentives for advanced technological equipment.
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