Cosmetic Cream / Lotion / Gel 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 Plant is 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.
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 jacketed 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 containerized manner and allows efficient production of large batches of cream.
Complete Cosmetic Cream Plant consists of following equipments,
- Wax Phase Vessel
- Water Phase Vessel
- Manufacturing Vessel
- Batch Storage Vessel
- Twin Lobe type product transfer Pump
- Positive displacement type Transfer Pump
- Vacuum Pump
- Interconnecting pipe line
- Integrated Control Panel
- Working Platform
Technical specifications: –
A. Wax Phase Vessel
| Sr. no. | Description | Specifications |
| TAG | Wax Phase Vessel | |
| 01 | GENERAL SPECIFICATIONS | |
| A | Function | To prepare wax phase require for Cosmetic Cream manufacturing |
| B | Code | Built as per Good Engineering Practice and to comply cGMP standard |
| C | MOC | SS 316 contact parts and SS 304 non contact parts. Heavy parts and structures shall be cladded with SS 304 materials. |
| D | Type | Cylindrical Vertical with bottom dish end and loose top lid. |
| E | Mounting | Vertical on Legs |
| 02 | PROCESS DETAILS & OPERATIONAL DATA | |
| A | Operation Type | Batch |
| B | Fluid Handled in vessel | Pharmaceutical Cosmetic Cream |
| C | Specific Gravity | 0.8 gms/cc |
| D | Fluid Handled in Jacket | Hot Water / Raw water |
| E | Service | Phase preparation for Cosmetic Cream preparation |
| F | Operating Temperature | 20-80 deg. C |
| G | Operating Pressure | ATM |
| H | Operating pressure in Jacket | 1.5 Kgs/cm2 |
| I | Minimum Steerable Volume | 25 % of Working Volume |
| J | Min. Temperature sensing Volume | 20% of working Volume |
| 03 | MATERIAL OF CONSTRUCTION | |
| A | Shell / Bottom / Top dish | SA 240 Gr. 316 |
| B | Jacket | SA 240 Gr. 304 |
| C | Stirrer Mounting Pad | SA 240 Gr. 316 |
| D | Stirrer Shaft | SS 316 |
| E | Gasket | Food grade Silicon |
| F | Nozzles | SS 316 |
| G | Mechanical Seal Type | N/A |
| H | Baffles | SS 316 |
| I | Monkey Ladder | SS 316 |
| J | Legs Pipe | SS 304 |
| K | Base plate | SS 304 |
| L | Hardware – Internal | SS 316 |
| M | Hardware – external | SS 304 |
| N | Product outlet Valve type / MOC | Sanitary Design with 1 side flange an 1 side TC connection / SS 316 |
| 05 | INSULATION AND CLADDING | |
| A | Type of insulation | Mineral wool |
| B | Insulation Thickness | 50 mm |
| C | Insulation cladding | SS 304, full welded |
| 06 | DRIVE AND AGITATOR DATA | |
| A | Type of agitator | SILVERSON type / Propeller type as per requirement |
| B | Agitator Entry | Top Entry. |
| C | No. of Impeller | 01 |
| D | Impeller Dia | As per design |
| E | Shaft Dia. | As per design |
| G | Shaft Type | Solid |
| H | RPM | 1440 RPM |
| I | No. of Baffles | 01 No. |
| J | Motor Type | TEFC/Non FLP / 3Ph/415V/AC |
| L | Transmission | Direct Mounting |
| 07 | SURFACE FINISH | |
| A | Product Contact Parts | 220 grit mirror finish |
| B | Product non contact parts | 180 Grit Matt finish |
| C | Mild Steel Surfaces | Coat of Zinc phosphate epoxy primer Final Coat of light gray acrylic polyurethane enamel paint – IF APPLICABLE. |
B. Water Phase Vessel
| Sr. no. | Description | Specifications |
| TAG | Wax Phase Vessel | |
| 01 | GENERAL SPECIFICATIONS | |
| A | Function | To prepare wax phase require for Cosmetic Cream manufacturing |
| B | Code | Built as per Good Engineering Practice and to comply cGMP standard |
| C | MOC | SS 316 contact parts and SS 304 non contact parts. Heavy parts and structures shall be cladded with SS 304 materials. |
| D | Type | Cylindrical Vertical with bottom dish end and loose top lid. |
| E | Mounting | Vertical on Legs |
| 02 | PROCESS DETAILS & OPERATIONAL DATA | |
| A | Operation Type | Batch |
| B | Fluid Handled in vessel | Pharmaceutical Cosmetic Cream |
| C | Specific Gravity | 0.8 gms/cc |
| D | Fluid Handled in Jacket | Hot Water / Raw water |
| E | Service | Phase preparation for Cosmetic Cream preparation |
| F | Operating Temperature | 20-80 deg. C |
| G | Operating Pressure | ATM |
| H | Operating pressure in Jacket | 1.5 Kgs/cm2 |
| I | Minimum Steerable Volume | 25 % of Working Volume |
| J | Min. Temperature sensing Volume | 20% of working Volume |
| 03 | MATERIAL OF CONSTRUCTION | |
| A | Shell / Bottom / Top dish | SA 240 Gr. 316 |
| B | Jacket | SA 240 Gr. 304 |
| C | Stirrer Mounting Pad | SA 240 Gr. 316 |
| D | Stirrer Shaft | SS 316 |
| E | Gasket | Food grade Silicon |
| F | Nozzles | SS 316 |
| G | Mechanical Seal Type | N/A |
| H | Baffles | SS 316 |
| I | Monkey Ladder | SS 316 |
| J | Legs Pipe | SS 304 |
| K | Base plate | SS 304 |
| L | Hardware – Internal | SS 316 |
| M | Hardware – external | SS 304 |
| N | Product outlet Valve type / MOC | Sanitary Design with 1 side flange an 1 side TC connection / SS 316 |
| 05 | INSULATION AND CLADDING | |
| A | Type of insulation | Mineral wool |
| B | Insulation Thickness | 50 mm |
| C | Insulation cladding | SS 304, full welded |
| 06 | DRIVE AND AGITATOR DATA | |
| A | Type of agitator | SILVERSON type / Propeller type as per requirement |
| B | Agitator Entry | Top Entry. |
| C | No. of Impeller | 01 |
| D | Impeller Dia | As per design |
| E | Shaft Dia. | As per design |
| G | Shaft Type | Solid |
| H | RPM | 1440 RPM |
| I | No. of Baffles | 01 No. |
| J | Motor Type | TEFC/Non FLP / 3Ph/415V/AC |
| L | Transmission | Direct Mounting |
| 07 | SURFACE FINISH | |
| A | Product Contact Parts | 220 grit mirror finish |
| B | Product non contact parts | 180 Grit Matt finish |
| C | Mild Steel Surfaces | Coat of Zinc phosphate epoxy primer Final Coat of light gray acrylic polyurethane enamel paint – IF APPLICABLE |
C. Manufacturing Vessel
| Sr. no. | Description | Specifications | |
| TAG | Cosmetic Cream Manufacturing Vessel | ||
| 01 | GENERAL SPECIFICATIONS | ||
| A | Function | To prepare Cosmetic Cream | |
| B | Code | Built as per Good Engineering Practice and to comply cGMP standard | |
| C | MOC | SS 316 contact parts and SS 304 non contact parts. Heavy parts and structures shall be cladded with SS 304 materials. | |
| D | Type | Cylindrical Vertical with bottom dish end welded and top dish end with body flange | |
| E | Mounting | Vertical on stand. | |
| 02 | PROCESS DETAILS & OPERATIONAL DATA | ||
| A | Operation Type | Batch | |
| B | Fluid Handled in vessel | Pharmaceutical Cosmetic Cream | |
| C | Specific Gravity | 0.8 gms/cc | |
| D | Fluid Handled in Jacket | Hot Water / Raw water | |
| E | Service | Preparation of Cosmetic Cream | |
| F | Operating Temperature | 4 to 80 Deg. C | |
| G | Operating Pressure | FV to ATM Kgs/cm2 | |
| H | Operating pressure in Jacket | 1.5 Kgs/cm2 | |
| I | Minimum Steerable Volume | 25 % of Working Volume | |
| J | Min. Temperature sensing Volume | 20% of working Volume | |
| 03 | MATERIAL OF CONSTRUCTION | ||
| A | Shell / Bottom / Top dish | SA 240 Gr. 316 | |
| B | Jacket | SA 240 Gr. 304 | |
| C | Stirrer Mounting Pad | SA 240 Gr. 316 | |
| D | Stirrer Shaft | SS 316 | |
| E | Gasket | Food grade Silicon | |
| F | Nozzles | SS 316 | |
| G | Mechanical Seal Type | N/A | |
| H | Baffles | SS 316 | |
| I | Hardware – Internal | SS 316 | |
| J | Hardware – external | SS 304 | |
| K | Product outlet Valve type / MOC | Sanitary Design with 1 side flange an 1 side TC connection / SS 316 | |
| 05 | INSULATION AND CLADDING | ||
| A | Type of insulation | Mineral wool | |
| B | Insulation Thickness | 50 mm | |
| C | Insulation cladding | SS 304, full welded | |
| 06 | DRIVE AND AGITATOR DATA | ||
| A | Type of agitator | Semi Contra Type with top entry homogenizer | |
| B | Agitator Entry | Top Entry for Semi Contra & Homogenizer | |
| C | No. of Agitator | 01 | |
| D | Agitator Design | As per design | |
| E | Shaft Dia. | As per design | |
| G | Shaft Type | Solid | |
| H | RPM | 20- 70 for Semi Contra Agitator ( Varable through VFD) & 1440 for Homogenizer | |
| I | No. of Fix Baffles | As per design | |
| J | Motor Type | TEFC/Non FLP / 3Ph/415V/AC | |
| K | Transmission | Rigid Coupling for shaft joint inside the vessel and Flexible coupling for gear box – agitator shaft. Motor to Gear Box – direct couple | |
| L | Shaft Sealing | Single Dry seal for top agitator ( Leak proof / Hi Fab Make) & Double cartridge water cooled type for homogenizer – SIGMA / Techno-Seal Make | |
| Water Flow detection sensor for double cartridge seal shall be provided which will trip the motor, if the water flow to the sensor is stopped. | |||
| M | Gear Box for Main Drive | Worm reduction type | |
| N | Bearing Housing | SS 304 Bearing housing with heavy duty Taper roller bearings – 02 nos. | |
| O | Drive Stool assembly | SS 304 stool with 20 thick SS 304 Flanges | |
| P | Agitator PAD Plate | Solid SS 316 – 25 mm thick * 250 Dia. | |
| Q | Scrapper Blades | 02 Nos. Floating type PTFE scrapper blades shall be provided to cover total wall surfaces of the mixing vessel. | |
| R | TOP Dish Lifting | By means of 02 nos. hydraulic cylinders and power pack unit. | |
| S | Host Burst check valve | Will Be provided which will not allow the lifted load to come down in case the hydraulic hose pipe burst or any leakages from hose pipe / joint. | |
| 07 | SURFACE FINISH | ||
| A | Product Contact Parts | 220 grit mirror finish | |
| B | Product non contact parts | 180 Grit Matt finish | |
| C | Mild Steel Surfaces | Coat of Zinc phosphate epoxy primer Final Coat of light gray acrylic polyurethane enamel paint | If applicable |
D. INTER CONENCTING PIPE LINES
Inter connecting pipe line provided as under;
- From wax phase vessel to manufacturing vessel through inline type conical filter
- From water phase vessel to manufacturing vessel through inline type conical filter
All interconnecting pipe lines are internally electro polished and with TC joints for easy in cleaning
E. WATER RING TYPE VACUUM PUMP
- PUMP TYPE : Water Ring type
- Model : Standard
- MOC : C. I.
F. INTEGRATED CONTROL PANEL
SS 304 power panel, which shall be mounted on service floor consisting of require switch gears and fuses. SS 304 Operating panel mounted near the equipment inside the production area, consisting of following controls
- Main Drive motor ON OFF for wax phase vessel with motor ON indication.
- DTIC for wax phase vessel
- Main Drive motor ON OFF for water phase vessel with motor ON indication.
- DTIC for water phase vessel.
- Main Drive motor ON-OFF for manufacturing vessel with motor ON indication.
- POT for RPM variation for semi contra agitator.
- Main drive ON-OFF for homogenizer motor with motor ON indication.
- Timer for homogenizer motor.
- Vacuum pump ON OFF.
- Steam ON-OFF selector switch for all jacketed vessels.
- Total process timer.
SAFETY FEATURES
- Water flow sensor for mechanical seal of bottom entry homogenizer.
- Single phase preventer.
- Over Load relay for motor overloading protection.
- Heat Extraction fan and ventilation filter in power panel.
- Emergency OFF in operating panel.
Note: Cable between power panel to control panel and from power panel to respective motors are not in our scope of supply.
| 01 | GENERAL POINTS | ||
| A | All product contact parts shall be of SS 316 & non contact parts shall be of SS 304, unless otherwise specified | ||
| B | All electrical shall be of non FLP construction. | ||
| C | All electrical switch gears shall be of C&S / L&T / Siemens make | ||
| 02 | DOCUMENTS | ||
| A | FDS | Provided immediate up on receipt of order | |
| B | DQ | Provided immediate up on receipt of order | |
| C | Drawing for approval | Provided immediate up on receipt of order | |
| D | Final As built Drawing | Provided along with machine dispatch | |
| E | IQ / OQ / PQ | Provided along with machine dispatch | |
| F | O&M Manual | Provided along with machine dispatch | |
| G | MTR | Provided along with machine dispatch | |
| H | RM test certificates | Provided along with machine dispatch | |
| I | Bought out items test certificates | Provided along with machine dispatch | |
| J | Electrical Diagram | Provided along with machine dispatch | |
| K | Internal Trial report | Provided along with machine dispatch | |
| L | Warrantee Certificate | Provided along with machine dispatch | In our format |
| M | FAT file / report | Provided before FAT | |
| N | SAT file / report | Provided along with machine dispatch | |
Batch Size
Available model 50 KG to 10,000KG working Capacity.