Lotion, Shampoo Manufacturing Plant

Lotion / Shampoo / Toothpaste / Ointment / Cream Manufacturing Plant

Lotion Manufacturing Plant, Shampoo Manufacturing Plant, Ointment Manufacturing Plant, Cream Manufacturing Plant

Shampoo /Lotion Manufacturing Plants are available in both Fully Automatic Closed type (Under vacuum) , Fully Automatic open type (Non vacuum) & Single vessel Type. Shampoo / Lotions Mfg Plants consists of a Premix vessel, Shampoo & Lotiona mfg. vessel, Storage Vessel, Transfer Pump, Vacuum Pump Control panel, Working Platform.

Main Shampoo Manufacturing Vessel

 Manufacturing vessel is cylindrical vessels with dished bottom vessels. The top of the vessel is also dished end welded. Agitator assembly in the manufacturing vessel., slow speed Anchor agitator is provided in the manufacturing vessel. However, for best results, contra-rotating or semi contra-rotating agitators are generally preferred by most of the manufacturers for the excellent quality of the shampoo produced. CIP turbo disk is provided at the top of the vessel for cleaning. Suitable nozzles, manholes, valves, etc., are provided on the vessel. The vessel can also be provided with a jacket, which can be used for both heating and cooling if required by the client. The manufacturing vessel can be subjected to a full vacuum.

Shampoo, lotion, cream manufacturing plant

Premixing Vessel

 A premixing vessel is a cylindrical vessel with dished bottom vessels. The vessel’s top is also dished end welded or can be provided with a loose lid. Agitator assembly in the premix vessel. It is a high-speed cowl/ saw cutter type agitator. In some cases, a high-speed homogenizer is also provided. CIP turbo disk is provided at the top of the vessel for cleaning. Suitable nozzles, manholes, valves, etc., are provided on the vessel. The vessel is provided with a jacket for heating. The jacket can be steam heated or electrically heated as per the client’s requirement. 

Suitable insulation and cladding are provided on the jacket. There is no need for any vacuum in this vessel. Usually, the capacity of this vessel is 60 % of the capacity of the main manufacturing vessel. Premix vessels can be 1 no or 2 nos as per the client’s requirements and formulae of the shampoo.

Storage Vessel

 A storage vessel is a simple vessel used to store shampoos. It is a cylindrical type of vessel with dished bottom, loose top lid. The bottom valve is provided with din fittings to facilitate the pipeline connection. Its capacity is the same as the manufacturing vessel. Usually, storage tanks are more in number so that different types of shampoos can be manufactured and stored. The filling is then done as per the requirement & market demands.

Control Panel & Automation

 Control panel is provided with all the starters, overload relays, pushbuttons, lamps, circuit breakers, etc. all hardware required for the shampoo manufacturing g plant’s automatic operation is provided in the control panel. Various Automation is available as per client’s requirements, to name a few:

•  PLC based Automation

•  Load cells under each vessel

•  Pneumatically operated valves

•  Any Other custom-built automation

•  Capacities of shampoo manufacturing plants manufactured

• 200 Ltrs to 20000 ltrs / batch

Usage/Application: Ointment / Lotion / Cream / Shampoo / Facewash / Gel

Applepack’s Shampoo Manufacturing Plant is a state-of-the-art facility designed to meet the diverse needs of modern shampoo production, whether for baby shampoos, protein-enriched formulas, herbal shampoos, or more. The plant is engineered to produce high-quality shampoos with superior efficiency, safety, and ease of operation. Below is an overview of its features, functionality, and benefits:

Overview of the Shampoo Manufacturing Process:

Shampoos are typically viscous liquids that contain 20–40% solids and are adjusted to a pH of around 5.5 for optimal hair care. They typically have a viscosity range between 500–1500 centipoises, depending on the formulation. The manufacturing process involves combining surfactants, conditioning agents, thickeners, and other active ingredients to achieve a product that cleans, lathers, and conditions the hair without causing damage.

Key Components of the Shampoo Manufacturing Plant:

1. Jacketed Manufacturing Vessel:
   • Used to mix the ingredients, the jacket ensures the vessel is maintained at the optimal temperature, whether heating or cooling is required. It provides uniform dispersion of ingredients to avoid clumping and ensures a consistent product.
2. Water Phase Vessel:
   • This vessel is where the aqueous ingredients (water, surfactants, etc.) are mixed. The vessel is heated using a steam or electrical heating system to ensure that all ingredients dissolve properly.
3. Oil Phase Vessel (if applicable):
   • For shampoos that require oil or conditioning agents, this vessel ensures that the oil phase ingredients (such as oils, proteins, or botanical extracts) are mixed thoroughly and incorporated at the correct temperature.
4. Homogenizer/Emulsifier:
   • A high-shear homogenizer is often used to emulsify oil and water phases into a uniform solution. This ensures a consistent particle size (often below 5 microns) to prevent separation and enhance the shampoo’s texture.
5. Vacuum Pump:
   • A vacuum system is used during manufacturing to reduce air bubbles and prevent contamination, ensuring a clean, smooth product with minimal air entrainment.
6. Mixing and Agitation Systems:
   • The system includes anchor-type agitators or high-speed mixers that provide thorough mixing of ingredients, ensuring even distribution of solids like thickeners, active ingredients, and conditioning agents.
7. Storage and Buffer Tanks:
   • The final product is stored in these tanks before being transferred to the filling station. The buffer tanks ensure the stability of the mixture and smooth transition for packaging.
8. Filling and Packaging Systems:
   • The plant includes fully automated filling stations that ensure accurate and hygienic filling of shampoo into bottles, pouches, or other packaging formats.
9. CIP (Cleaning-In-Place) and SIP (Sterilization-In-Place) Modules:
   • These modules allow for easy cleaning and sterilization of the system without disassembly, ensuring that different formulations can be produced in the same plant without cross-contamination.
10. Control Panel and Automation:
    • PLC (Programmable Logic Controller) systems, SCADA architecture, and touchscreen control panels make operation intuitive and efficient. Automated systems control the mixing, temperature, and flow of ingredients, reducing the need for manual intervention.
11. Load Cells:
    • Load cells are used for precise weighing and dosing of ingredients, ensuring accurate formulations for every batch.
12. Interconnecting Pipelines and Valves:
    • The pipes are designed to ensure efficient and safe transfer of ingredients between vessels. Tri-clamp connections and pneumatically operated valves ensure hygiene and tight sealing.

Key Features of the Shampoo Manufacturing Plant:

• High Efficiency and Output:
  • The plant is designed to optimize production speed and output while maintaining product quality. Automated controls allow one operator to manage the entire production line, minimizing labor costs and human error.
• Customizable Production:
  • Whether you’re producing baby shampoo, protein shampoo, herbal shampoo, or any other variation, the system can be customized to handle different formulations with minimal adjustments.
• Hygienic and Safe Production:
  • With the inclusion of CIP and SIP modules, the system ensures that all equipment is cleaned and sterilized without manual disassembly, reducing downtime and ensuring product safety.
• Consistent Product Quality:
  • The homogenizer, precise temperature control, and controlled mixing processes ensure that each batch has consistent viscosity, appearance, and performance.
• Compliance with Industry Standards:
  • The plant meets major international standards, including WHO-GMP, cGMP, and other local manufacturing guidelines, ensuring high-quality products and regulatory compliance.
• Energy Efficient:
  • The energy-efficient heating and cooling systems ensure that the plant operates with minimal energy consumption, which reduces operational costs.
• Scalable and Flexible:
  • The plant can be scaled for small, medium, or large-scale production. It also supports the development of a wide variety of shampoo products, from high-volume commercial formulas to niche or premium brands.

Benefits of Applepack’s Shampoo Manufacturing Plant:

1. Reduced Production Time:
   • The automation and precise control over mixing and temperature ensure faster processing times and reduced batch changeover.
2. Minimized Workforce Requirement:
   • With an automated system, only one operator and a helper are typically needed to run the entire plant, reducing labor costs and human error.
3. Lower Maintenance:
   • The plant’s modular design and use of stainless steel (SS316L) ensure long-term durability and low-maintenance operation, reducing operational downtime.
4. Safe and Non-Contaminating Manufacturing:
   • The vacuum system, CIP/SIP capabilities, and automated material transfer minimize the chance of contamination, ensuring high product purity.
5. High-Quality, Consistent Shampoo:
   • With advanced homogenization, precise ingredient mixing, and controlled temperature regulation, every batch has the same high quality and performance characteristics.
6. Cost Efficiency:
   • The efficiency of the plant means lower energy costs, reduced labor requirements, and minimal waste generation, all contributing to lower overall production costs.

Conclusion:

Applepack’s Shampoo Manufacturing Plant is a reliable, high-tech solution for producing shampoos at scale with efficiency, safety, and consistent product quality. It is ideal for manufacturers aiming to stay competitive in the growing personal care market by offering a versatile, automated, and easy-to-operate system that can produce a wide variety of shampoo products—whether for mass-market or premium lines.