General
Shampoos are typically viscous liquids,
either clear or opaque (pearlised), containing 20–40%
solids, adjusted to approximately pH 5.5. Most,
but not all, have viscosities in the ratio of 500–1500
centipoise. A hair shampoo may be defined as a detergent
specifically formulated for the washing of hair,
and packaged in a user-convenient form. Typically,
a shampoo must clean well, rinse easily, impart
gloss to the hair, minimise tangle and not damage
the hair structure, or the scalp or the eyes.
MANUFACTURING PROCESS
Shampoos are manufactured by simple slow
blending in a stirred vessel. The vessel may be
jacketed for heating. Vessels are normally closed
type and subjected to vacuum to avoid excessive
foaming when foaming agent is added. For best
results contra type rotating stirrer is best used
for shampoo manufacturing.
Ingredients are weighed or metered incrementally
into the mixing vessel, with thorough mixing between
each addition. A moderate amount of heat is used
to reduce the viscosity and so facilitate ease
of mixing.
Some pearlising agents are waxy solids at ambient
temperature and require melting in a premixing
vessels before use. Demineralised water is most
commonly used in order to minimise contamination
of the product.
No further processing is required after blending,
& perfuming and the product may be packed
off directly from the mixing vessel. Or may be
transferred to storage vessels from where they
are transferred to the filling machines.
Many companies make the bases for the shampoos
where they do all the premxing of surfactants,
sles, other ingredients and sell the same to major
industries These industries are mainly called
the formulators and in this second level processing
will involve only the addition of water, colour
and fragrance. In case of ayurvedic or herbal
shampoos, they add their propriety formulae ingredients
themselves so that no one knows the exact nature
of ingredients and its details.
VESSELS REQUIRED FOR A SHAMPOO PLANT
MAIN SHAMPOO MANUFACTURING VESSEL
Manufacturing vessel is cylindrical vessels with
dished bottom vessels. 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 normally preferred by most of the
manufacturers for 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.
Vessel can also be provided with jacket which
can be used for both heating and cooling if required
by the client. Manufacturing vessel can be subjected
to full vacuum.
PREMIXING VESSEL
Premixing vessel is cylindrical vessels
with dished bottom vessels. Top of the vessel
is also dished end welded or can be provided with
loose lid too. Agitator assembly in the premix
vessel. Is high speed cowl/ saw cutter type agitator.
In some cases high speed homogenizer are 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.
Vessel is provided with jacket for heating. Jacket
can be steam heated or electrically heated as
per client’s requirement. Suitable insulation
and cladding is provided on the jacket. There
is no need for any vacuum in this vessel. Normally
the capacity
of this vessel is 60 % the capcity of the main
manufacturing vessel. Premix vessels can be 1
no or 2 nos as per the clients requirements and
formulae of the shampoo.
STORAGE VESSEL
Storage vessel is simple vessel used
to store shampoos. It is cylindrical type of vessel
with dished bottom, loose top lid. Bottom valve
is provided with din fittings to facilitate the
pipeline connection. Its capacity is the same
as the manufacturing vessel. Normally storage
tanks are more in number so that different types
of shampoos can be manufactured and stored. Filling
is then done as per the requirement & market
demands.
SLES/ SURFACTANTS STORAGE VESSEL
In manufacturing of shampoos the SLES/
surfactants form a major ingredients. Hence it
has to be stored in large quantities. Also if
drums of 200 kgs are bought it will turn expensive
for the manufacturers. Hence most of the manufacturers
but one entire tanker of surfactants and store
the same. Normally one weeks/ months usage of
surfactants are normally kept stored to ensure
continous production. Hence the capacity of this
storage tank will be taking into consideration
of the storage requirements of the client. This
tanks are vertical tanks with big heights with
flat bottom. Top is also closed with suitable
manhole and nozzles for effective loading into
the vessel through pumps. Similarly outlet is
also provided at the bottom where the surfactants
are tansfered from the storage vessel into the
manufacturing vessel or premix vessel through
pumps.
PUMPS
Transfer pumps are used to transfer material
from premix vessel to the manufacturing vessel
only if the mfg vessel is not under vacuum. If
it is under vacuum the premix is automatically
transferred into the main vessel through vacuum.
Transfer pumps are required for the following
o Transfering surfactants to premix / main vessel
o From main vessel to storage vessels
o From storage vessel to filling machine.
PIPELINE.
Interconnecting pipeline is provided for the plant
as per the layout of the clients room size. All
pipelines are electropolished from inside and
outside. All joints are DIN standards quick openable
types. Pipelines are used for transferring the
surfactants from storage tank to premix vessels,
from premix vessels to manufacturing vessels and
from mfg vessels to storage vessel and from storage
to filling line.
OTHERS
All vessels have CIP/ SIP nozzles & conical
filters are provided at the discharge of the vessels.
Entire plant is fully automatic and interconnected
by suitable pipeline & requires only one operator
for all the operations. Suitable working platform
is provided for cleaning and maintainence. An
integrated control panel fully automatic controlled
by a PLC is provided. (Optional)
CONTROL PANEL & AUTOMATION
Control panel is provided with all the starters,
overload relays, push buttons, lamps, ckt breakers
etc. all hardware required for automatic operation
of the shampoo mfg plant is provided in the control
panel.
Various automation is available as per clients
requirements to name a few
o PLC of any brand and configuration.
o Load cells under each vessel
o Pneumatically operated valves
o Any Other custom built automation
Capacities of shampoo manufacturing plants manufactured
200 Ltrs to 20000 ltrs / batch
OTHER TYPES OF SHAMPOO PLANTS AVAILABLE
Shampoo plants are also available in
economic range where open type with agitator vessels
are provided with various cheaper options to suit
every budget.
