+91 99608 88136 kyra@kyrainternational.co.in

CREAM/GEL/LOTION MANUFACTURING PLANT

Contact Us How we work

CREAM/GEL/LOTION MANUFACTURING PLANT

Contact Us How we work

CREAM/GEL/LOTION MANUFACTURING PLANT

Contact Us How we work
CREAM/GEL/LOTION MANUFACTURING PLANT

Creams are those preparations that are miscible, immiscible, or emulsified with the skin secretions and intended to be applied to the skin at a specific mucous membrane for emollient, protective therapeutic, or prophylactic purposes where a degree of occlusion is desired.

The Cream Manufacturing Plantis built for the manufacture of creams and various other cream-related products like gels, lotions, Pastes, and other similar products. It consists of types of equipment and machinery for mixing the ingredients to form a tube-filling machine. The process of the cream manufacturing plant starts with mixing ingredients and ends with filling the final product in the storage tubes for marketing

CAPACITY - 5 - 10000 Ltrs
WORKING PROCESS

The working principle of a Cream Manufacturing Plant is as follows: first, the hydrophilic ingredients (hydrophilic ingredients are freely soluble in water) that are required for producing a specific cream. The water phase vessel is filled with these ingredients. Furthermore, water is added to it. The mechanical mixing method is initiated, and the propeller stirrer is activated to ensure proper mixing. If there is a problem with further mixing, it is done by applying heat. This heat should not be provided directly, but rather in ajacketed manner.

The working of a cream manufacturing plant is quite simple. It takes the ingredients in powder form, and then these are mixed with the wax and water in the respective phase vessel. The operator can control the mixing process, along with the temperature and pressure during this stage. Then the mixed products are moved to the manufacturing vessel in a vacuum environment. The entire process is completed in a contamination free manner and allows efficient production of large batches of cream.

KEY SPECIFICATIONS
  • Weighing Facility (Load Cell)
  • VFD for all Anchors and homogenizers.
  • Contra Anchor for High Viscous Products like Toothpaste and Wax.
  • PLC based, with touch screen HMI and SCADA packages.
  • 21 CFR Part 11- Provision & Compliance.
  • Top Dish for Pre-Mix Vessels.
  • Thermowell & Thermosiphon.
  • Vent Filters
  • FLP Panel
  • Utility Pipeline
  • Branded/reputed make accessories ( VFD, Load Cell, Valves, Pressure Gauge, Diaphragm Valve, Spray Ball, Steam Trap, Sight Glass, wiper, Sensor, Electrical Components, etc.)
  • Qualification Documents -IQ, DQ, OQ and FAT Protocol
FEATURES & BENEFITS
  • Top covers with hydro lift
  • High-speed Inline or In-built Homogenizer
  • Internal or External Recirculation System.
  • Automation system ofthe highest standard
  • Low sheared force & smooth processing
  • Effective standard designing & manufacturing with sanitary conditions
  • Agitator supported in Teflon scrapping mechanism
  • Contact parts made of Stainless Steel 316L
  • Non-contact parts made of Stainless Steel 304
  • Step-less speed controlled double speed contra-mixing slow agitator
  • Dedicated Sanitization system & skidded CIP
KEY APPLICATIONS
  • Skincare cosmetics
  • Hair cosmetic products
  • Lotions
  • Emulsions
  • Toothpaste
  • Wax
  • Cream
  • Lipstick
  • Gel
  • Calamine
COMPONENTS

The Cream Manufacturing Plant consists of the following equipment. Which plays a key role in the manufacturing process of Cream/Gel/Lotion, and Ointments.

WATER PHASE VESSEL

The water phase vessel is the first step in the Cream Manufacturing. In this phase, the water-soluble ingredients are dissolved inwater.In addition, a stirrer does the mixing mechanically. For further heating is applied to the mix.

  • Jacket for heating & cooling.
  • Heating Jacket Pressure (4 bar).
  • Heating by steam or hot water circulation.
  • Propeller stirring with top mounting.
  • Temperature controller & safety pressure Valve.
  • Bottom discharge with valve.

WAX HEATING VESSEL

Wax heating vessel is the second step in the Cream Manufacturing, In this stage the oil and wax type of ingredient is dissolved and melted by heating and mechanical way of stirrer mixer.

  • Jacket for heating & cooling.
  • Heating Jacket Pressure (4 bar).
  • Heating by steam or hot water circulation.
  • Propeller stirring with top mounting.
  • Temperature controller & safety pressure Valve.
  • Bottom discharge with valve.

MANUFACTURING VESSEL

This is the third step in the Cream Manufacturing. Here the mixing of both the filtered solvents occurs.Water phase vessel solvent and oil phase solvent are collected in the manufacturing vessel and the mixing is started. This mi xing is done with the help of a planetary mixer.

The heating and cooling of ingredients are done in a jacketed way. And the jacket is supplied with hot water or steam for heating the ingredients. In addition, for cooling of ingredients chilled cooled water is circulated in the jacketed system. Here is a glass window for observation of ingredients. Safety valves are present. The interlock system is present for safety purposes. Temperature regulators are present in this section of the Cream Manufacturing Plant. Which controls the pressure that is present inside the Cream Processing plant.

  • Vacuumed process
  • Vessel Inside Pressure (-1 /+2 Bar)
  • Heating Jacket Pressure (-1 /+6 bar)
  • Heating by steam or hot water circulation.
  • Agitator mixer with self-pressure Teflon scrapper.
  • Scrapper cleanly working on both sides.
  • High-speed Homogenizer with toothed Rotor -stator type.
  • RPM sleeplessly with variable speed drive for agitator & Homogenizer.
  • High shear & pressurization of the homogenizer.
  • Thus, homogenization of high viscosities up to 400.000 mPas.
  • Homogenizer mounted on the lower position in the center ofthe vessel.
  • Top lid with motorized top lid for lifting & lowering.
  • Safety Interlock process with limit switch.
  • Connection for Vacuum, Charging, Eyeglass window, Light glass, CIP, SIP, Pressure gauge & safety valve
VACUUM PUMP

The function of a vacuum pump is to create a vacuum environment in the vessels. The vacuum pump contains vacuum monitoring and vacuum suction valves.

  • Water Ring Vacuum Pump.
  • Vacuum gauge & Vacuum relief valve.
INTERCONNECTING PIPELINE

The function of interconnecting pipelines is the junction of the different vessels for wax, and water transfer of products. Through these pipelines system, the recirculation of products in the manufacturing vessel occurs. The interconnected pipes assembly also co ntains the pipes responsible for creating a vacuum in the system.

  • Interconnecting Pipeline of all vessels for transfer of Water, Wax & products.
  • Recirculation in manufacturing vessels.
  • Vacuum connecting pipe.
STORAGE VESSEL

It is a special type of tank in which cream, gel, lotions, ointment, etc. are stored. It is freely attached and is removable from the Cream Manufacturing Plant. It is freely moveable from place to place by its wheels. It is a skid type in structure. Moreover, the lower portion is jacketed in which the Cream preparations can be heated.

  • Skid type storage vessel. .
  • Bottom cone is Jacket for heating.
CONTROLS & VISUALIZATION

In Cream Manufacturing Plant there is a digital display that is operated with an electric supply. The control panel display has a touch screen. The speed of rotation and time adjustment of the product is controlled by these control panels. The temperature and the digital control buttons from the control panel control coolness of the process. The operation of the vacuum system is also controlled by the control panel. The recording data from different batches is also recorded in the control panel. Control panels alongwith the working platform are the key parts of the cream manufacturing plant.

  • Electric Controls with digital display.
  • Optional PLC Controls with HMI Touch screen.
  • RPM and Process time entries.
  • Temperature controls- Heat/cool.
  • Vacuum Start- Stop.
  • Integrated Data recording for batch.
WORKING PLATFORM
  • Rigid structure with anti-slipping embossed plate.
  • Made from AISI 304.
SAFETY FEATURES
  • Emergency stop button
  • Safety vacuum relief valve & Indicator Gauge.
  • Safety Pressure Valve.
  • Limit switch at the top lid
KEY ADVANTAGES:
  • Saving valuable batch process time.
  • Lower maintenance cost, as no moving components are used.
  • Re-circulation after mixing provided. Mixing and dispersing quality.
  • Adjustable, specially designed inline filters provided.
  • To prevent contamination from hand contact.
  • Larger production rate

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Gala no. 229 Pride Indl.Estate, Sativali Road, Waliv Phata, Vasai East, Maharashtra - 401208

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Phone: +91 99608 88136
+91 8087588854

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