Batch at the limit?!
Current situation of the process





capacity usage at the maximum
optimized processes
standardized formulations
limited capacities
concentration of production sites
Current economic situation
 potential of increasing the
productivity is limited
 cost pressure
 strong competition
 limited capacities
 and how can we assist?
Customer benefits
continuous vs. batch





throughput increased by 25 %
cleaning time optimised
identical footprint
maintenance efforts minimised
time for maintenance reduced by 15%
 substantial cost savings
Cost benefit – example
percentage material costs
percentage direct labour costs
percentage indirect production costs
batch machine
80,0%
10,0%
10,0%
working hours per year
output in liter per hour
total output in liter per year
material costs per liter in Euro
batch machine
7.500
4.000
30.000.000
1,00
new plant
7.500
5.000
37.500.000
1,00
batch machine
30.000.000
3.750.000
3.750.000
37.500.000
1,250
conti plant
37.500.000
3.750.000
3.750.000
45.000.000
1,200
1.500.000
cost annual output in Euro
material
direct labour*
indirect production*
finished product unpacked
cost per liter
savings per year
investment in plant
payback period
* amount remains the same at batch or conti
conti plant
2.800.000
< 2 years
25,00%
20,00%
-4,00%
Our solution:
continuous production
of toothpaste
The process
 Ingredients
 without pre-mixing
 directly from stock to
plant
 Dosing
 fully automated
 exact control
 perfect, constant
quality
The process
 Wetting
 revolutionary
powder-wetting
 less agglomeration
 De-aeration  perfect density
 Dispersing
 perfect particle size
The process
 Additives
 in every phase of
production possible
 highest flexibility
 Control
 full automation
 completely
reproducible
The process
 Quality con-  in-line measuring of
trol
viscosity, particle size,
density, flow rate,
pH-value, pressure and
temperature
 On-line quality control
The process
 Storage and
 less storage before
filling:
filling necessary
Continuous production meets your
requirements
 leading in technology
 higher output at lower costs
Our intention
 together with you we want to combine
 products
 processes
 technology and
 automation

to be one step ahead!
The concept
Legend:
1
density
2
viscosity
3
flow rate
4
temperature
5
particle size
6
pressure
VE
de-aerator
PWM powder-wetting-machine
M/DIL inline homogenizer
FL
filling line
The concept
The concept
Solid storage
and filling
Continuous
production
Liquid storage and
filling
The concept
The concept
The first trials: The complete plant
Liquid and dry
phase
Powder wetting machine
The first trials
product outlet after
powder wetting
Product outlet after de-aeration
product outlet after
de-aeration
Dosing: exact control, perfect and
constant quality
The vision
 You have the knowledge of the product
 We have knowledge of machinery and
process technology
 Together we can find a new way of
processing toothpaste
Let‘s set a new milestone!