Case studies: Reactors for hair dye preparation
Customer
The customer is a leading European cosmetics company specialising in the production of hair dyes and hair care products. With over 20 years in the sector, they are known globally for their innovation and quality.
Project
The customer needed to increase hair dye and shampoo production capacity without compromising product quality. Furthermore, they wanted a solution that would enable precise control over mixing processes and temperature, ensuring uniform consistency in every batch.
"INOXPA reactors increased production efficiency and end product quality."
"INOXPA reactors increased production efficiency and end product quality."
Why INOXPA?
INOXPA were chosen due to their reputation for manufacturing high quality skids and their ability to provide customised solutions. INOXPA's advanced technology and experience in the cosmetics industry proved decisive for the customer.
INOXPA solution
A 600L VISCOMIX reactor for hair dyes:
Six reactors for producing cosmetic hair dye creams, each with a capacity of 600 litres, installed on load cells, with direct steam heating and direct cooling using water from the grid.
Complete vacuum circuit with a vacuum pump and a hydraulic system for raising the top.
Split heating jacket for when operating with smaller volumes.
The product's static viscosity is 2,000 cP.
The system is prepared for operating in vacuum and to be sterilised using steam or superheated water.
The products are mixed using an agitator with elliptical anchor type propeller and a high shear bottom mixer with dual level external recirculation, and the mixer itself can feed the final mixture straight to the filling machine without using any transfer pump.
It comes with an operator touchscreen panel on the reactor, connected to a main panel and the customer's ERP, complying with Industry 4.0 standards. This enables virtually autonomous operation, safely managing recipes using barcodes to control solid ingredients and load cells to control liquid products.
3000L MCR reactor for shampoo:
3000L mixing plant for producing shampoo with up to 5,000 cP viscosity.
The 3000L reactor is equipped with a counter-rotating agitator incorporating helical blades with scrapers and central blades.
The raw materials are vacuum-loaded from the bottom inlet, with a 4-valve manifold used for loading. The system has a heating/cooling jacket using cold water and steam.
The system features 3 rotating spray balls at the top, plus removable spray balls that can be placed inside the tank for a deeper cleaning of the agitator's dead spots.
The mixing involves using a tank bottom mixer with external recirculation, which is ideal for higher viscosity products requiring higher particle shear, with 2 recirculation points located below the 1000L and 2000L volume levels.
Regarding the control elements, there is a panel with PLC S7-1500 for the system's automation. It comes with a 12" HMI Comfort touchscreen for semi-automatic process management on the main panel. The HMI panel can be used to save production records to an external USB drive.
Special features
- Production efficiency: Increased capacity and precise control over mixing processes and temperature.
- Versatility: Adaptable for operating with different volumes and viscosities.
- Quality and consistency: Ensures homogeneous dispersion and high quality of the end product.
- Advanced technology: Equipped with a Siemens touchscreen panel and automation systems for efficient and easy process management.
- Hygienic design: Complies with GMP and FDA standards, ensuring the best possible cleaning and sterilisation.
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Reactors for hair dye preparation
