Gel Detergent Production via Segmented Batch and Filling Lines
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Solution Overview
Problem
Existing processes for producing gel-like detergents are inflexible, expose sensitive ingredients to high temperatures leading to loss, and struggle with bubble formation and volatile ingredient loss during production.
Innovation Solution
A method involving a batch production line where a premix of water, glycerin, and surfactants is created, then supplemented with fragrances and dyes on a filling line at lower temperatures, minimizing exposure and bubble formation, and allowing for flexible production variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If all ingredients are mixed in several stages in a batch production line at high temperatures, then the premix can be produced efficiently with good mixing, but sensitive ingredients like fragrances and dyes are exposed to very high temperatures for extended periods leading to partial loss
Solution Approach 1:
The production process is divided into two separate lines: a batch production line for mixing the premix without fragrances and dyes, and a filling line where these sensitive ingredients are added at the end. This segmentation allows the premix to be produced efficiently at high temperatures while the sensitive ingredients are protected from thermal degradation by being added only after the hot mixing phase is complete.
Solution Approach 2:
The premix is prepared in advance on the batch production line at high temperatures to ensure good mixing and low viscosity, but the sensitive ingredients are reserved and added only at the final stage on the filling line. This preliminary action of preparing the base mixture separately allows subsequent addition of temperature-sensitive components without exposing them to damaging conditions.
2Stability of the object's composition
If vacuum is used to eliminate bubbles during mixing, then bubble formation is reduced, but volatile ingredients especially fragrances are lost
Solution Approach 1:
The process separates bubble elimination into two stages: first, the premix is deaerated in the batch production line before fragrances are added, and second, the filling line operates at lower temperatures to minimize bubble formation during final product assembly. This segmentation ensures that vacuum treatment occurs before volatile ingredients are introduced, preventing their loss.
Solution Approach 2:
The premix undergoes vacuum treatment and bubble elimination before the volatile fragrances and dyes are added on the filling line. This preliminary deaeration action removes bubbles from the base mixture without exposing volatile ingredients to vacuum conditions that would cause their loss.
3Productivity
If the premix is produced in advance on a batch production line, then continuous production is achieved, but the process becomes inflexible and cleaning effort increases
Solution Approach 1:
The production system is segmented into a continuous batch production line for the premix and a flexible filling line for final product assembly. The batch production line can continuously produce the same premix formulation, while the filling line can be quickly reconfigured to add different fragrances and dyes for various end products, providing both efficiency and flexibility.
Solution Approach 2:
The batch production line produces a universal premix that can serve multiple product formulations, while the filling line performs the multi-functional role of adding different supplements for various end products. This universality allows the same premix to be used for different final products, maintaining flexibility without sacrificing continuous production capability.
4Ease of manufacture
If high temperatures are used on the batch production line, then the premix has low viscosity and mixes well, but temperature-sensitive substances are destroyed
Solution Approach 1:
The process segments temperature application: high temperatures are applied only to the premix on the batch production line where mixing ease is required, while the filling line operates at lower temperatures to protect temperature-sensitive substances. This segmentation allows each stage to operate at the optimal temperature for its specific function.
Solution Approach 2:
Different parts of the production process operate at different temperatures: the batch production line uses high temperatures locally where good mixing is needed, while the filling line uses lower temperatures locally where temperature-sensitive ingredients are handled. This local quality approach optimizes each stage's conditions without compromising the other.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables continuous, cost-effective, and flexible production with reduced cleaning effort and waste, while preserving temperature-sensitive ingredients by adding fragrances and dyes just before bottling, thus maintaining product quality and variability.
Implementation Method 1
The two starting mixtures are mixed in a mixer of the batch production line. This can, in particular, be a static mixer.
Implementation Method 2
the premix is provided on the batch production line at a temperature of at least 60°C, in particular at least 75°C. Such high temperatures on the batch production line have the advantage that the premix has a relatively low viscosity
Implementation Method 3
the supplements are added on the filling line at temperatures of no more than 40°C. In particular, the supplements can be added on the filling line at room temperature.
Data Source
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AI summary
The invention relates to a method for producing gel-like substances, comprising the provision of a premixture on a batch production line (2), the premixture containing at least water, glycerin and surfactants, and the addition of supplements (10, 13) to the premixture on a filling line (3) which is subsequent to the batch production line (2), the supplements (10, 13) comprising at least fragrances.