Transcript Selling an Idea or a Product

Littleford Day Inc.
Where Processing Ideas become Reality.
Processing Detergents
with Littleford Equipment
Littleford Day Inc.
Where Processing Ideas Become Reality.
Littleford Equipment for the Detergent Industry
Presentation Index
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Contents
Our Engineering for Detergents: Neutralizing, Mixing, Drying, Densifying.
Preparation of Dry Powder Detergents using Dry Neutralization.
Wet and Dry Neutralization. -Comparative TableThe ”Fluidized-Bed Operation” for Detergent manufacturing.
Chopper action on Acids dispersion.
Manufacturing options for the FM/FKM Equipment.
How do we build them.
Our Regular Sizes.
Densification of Dry Powder Detergents in our CB Units.
The Littleford CB High Speed Processor.
Advanced drying process in the Littleford equipment.
Advantages of the Choppers operation in drying.
Granulation in the Littleford equipment.
Rental Program.
Service and Spare Parts.
Technical Center: Our Lab. Facilities. Testing/Optimizing your products.
Cutting Edge Engineering for:
Dry Neutralization.
Mixing of additional components.
Drying.
Densification.
The specially designed tools in the Littleford FM/FKM
equipment create a mechanically fluidized bed of material
providing exceptionally fast and accurate contacting of
the acid and powder. Supplementary high speed impact
choppers supply localized high shear fields required for
the thorough dispersion of the acid. The choppers also
aid in deagglomeration and densification of the product.
After an excellent neutralization has been accomplished,
blending of the dry neutralized surfactant with the remaining components of the detergent is done in the same
vessel. This can be done in a batch or continuous basis.
Extremely accurate drying so as densification is also done,
if required, in our FM/FKM machines.
Our CB High-Speed Processors, in combination with the
KM mixers provide continuous densification of detergents,
to fully suit demanding market requirements.
Preparation of Dry Powder Detergents
using Dry Neutralization.
Dry Powder Detergent Formulations are usually composed of a combination of Ionic and/or Non-Ionic
surfactants, builders (such as carbonates, phosphates, silicates, brightening agents, etc.) and inerts.
These components are processed to form a dry powder product possessing desirable flow properties
and appearance.
There are two generally accepted methods by which to arrive at the final product.
One is a “Wet” Process and the other is a “Dry” Process.
In the wet formulation, the product of the sulfonation (a heavy liquid acid) is added to a caustic solution. The resulting surfactant is in slurry form. This slurry is homogenized with the other components
of the mix in a vertical stirred tank. The resulting material is a heavy past, which is pumped to a spray
drying tower where the moisture is removed. The dry, low density, hollow granules are collected at the
bottom and may be packaged as it is or may be processed further.
Since the trend in today´s market
is towards densified detergent, this low density product is often densified in additional equipment.
In the Dry Process the surfactant is prepared by spraying the liquid acid onto Sodium Carbonate. This
is known as Dry Neutralization. The resulting surfactant is a dry granular powder. The dry surfactant
may then be blended with the other components of the mix.
Since the resulting mix is dry, the costly
spray drying operation is eliminated. A Non-Ionic surfactant is sometimes sprayed onto the product
to enhance flowability and reduce dusting.
The manner in which the liquid acid is added to the sodium carbonate is critical.
The acid must be
added at a controlled rate and dispersed uniformly to avoid overwetting, which would produce large
we t agglomerates containing unreacted material not suitable for use in the final blending operation.
When processed properly, the product of the dry neutralization will be homogenous in composition
and particle size.
The specially designed mixing tools in the Littleford FM/FKM Series Mixer,
create a mechanically fluidized bed of material, providing exceptionally fast and accurate contacting
of the acid and powder.
High speed impact choppers supply localized high shear fields required for
the thorough dispersion of the acid, and aid in deagglomeration and densification of the product.
Blending of the dry neutralized surfactant with the remaining components of the detergent formulation
is then done.
Using the same vessel for both the dry neutralization and final blending is yet another
advantage of using Littleford Day Technology.
Wet and Dry Neutralization
A Comparison between two Processes:
The Wet-Type Process.
In the wet formulation, the product of the
sulfonation (a heavy liquid acid) is added
to a caustic solution. The resulting surfactant is in a slurry form. This slurry is then
homogenized with the other components
of the mix in a vertical stirred tank. The
resulting material is a heavy paste, which
is pumped to a spray drying tower where
the moisture is removed. The dry, low density, hollow granules are formed. Since the
trend in today´s market is towards densified detergents, this low density product
is often densified in additional equipment.
The
Advantages:
The Dry-Type Process.
The surfactant is prepared by spraying
the liquid acid onto sodium carbonate.
This is known as Dry Neutralization.
The resulting surfactant is a dry granular powder. The dry surfactant may then
be blended with the other dry components of the mix. Since the resulting
mix is dry, the costly spray drying operation is eliminated. A Non-Ionic surfactant is sometimes sprayed onto the
product to enhance flowability and
reduce dusting.
No need for costly spray drying.
Simpler, less expensive system.
Single Vessel for Neutralization and
Mixing of final detergent components.
The “Fluidized Bed” Operation for Mixing & Drying:
Liquid dispersion is done by spraying The unique action created by the movement of the
liquids against fluidized powder, by mixing elements produce intense but gentle interTop and / or Bottom Mounted Nozzles. mingling of the materials of the mix in a mechanically fluidized bed.
The unique mixing action
of the FKM series mixers
is accomplished by a horizontal shaft which revolves at a high rate of speed
rapidly projecting and hurling the mix materials away
from the vessel wall into
free space, filling the
entire vessel. The mixing
action causes the materials
to crisscross in the direction of the vessel walls and
inversely back again, providing a high volume rate
of material transfer. The
mechanically fluidized bed
of particles is the basis of
it´s mixing efficiency and
accuracy, including combinations with diverse specific gravities as well as other
problems such as liquid
incorporation and heat transfer.
Mixing elements are
designed to force the
product into appropiate components of
axial & radial motion.
High-Speed Blending Choppers enhance mixing
action by controlling particle size and trace
ingredient dispersion, usually without the need
for additional process steps.
Chopper Action, sending fluidized particles upward, against
sprayed liquids flowing in the opposite direction.
Superb Liquids Dispersion into Powders, through high speed Choppers
(Showing Top Injection Type. Bottom Liquids Injection also available)
Manufacturing Options:
Material: C.Steel, 304 S.S., 316 SS., Special.
Interior: Std. #120 Grit or higher.
Vacuum System:
Stack (s)
Pulse Back Filter (s)
Condenser, Receivers.
Vacuum Pumps.
Liquid Injection: Tower, Manifold.
Top and / or Bottom Mountings.
Vessel Construction:
Atmospheric Std.,
Vacuum Rated,
Pressure Rated,
Sanitary Construction.
FDA Ratings.
Seals: Std. Packing,
Positive Pressure
Mechanical.
Electric's: H.P., TEFC,Expl.Proof.
Feeding Ports
Drive Type.
Sanitary or Welded Design
RPM´s: 1 or 2 Speeds,
Variable Speed.
Hydraulic Coupling.
Plows: Std.,Heat Transfer, Becker
Jacket. Std. 75 PSI
Other PSI Ratings
Heating & Cooling
Discharge Valve :
Manual,Pneumatic.
Ball type, Butterfly,
Sphericals & Slide
Options.
Special Bases, Load Cells.
Choppers: H.P., TEFC, Expl.Proof
Blade Types
Control Panels: Manual, Automatic. RPM Control
Batch Times, Amp,Power,Reports
How do we build them:
Standard or Sanitary Construction.
TEFC or Explosion Proof Electric's.
Full Vacuum or rated for several
Internal Pressure Ratings.
Single or Variable Speeds.
Vacuum Systems
Shell in Carbon Steel
304 SS or 316 SS
#120 Grit finish.
Pulse Back
Filters.
Liquid Dispersion Systems.
Access ports with safety
limit switches.
Reinforced
Shafts and
Drives.
Std.Packing,
Air type &
Mechanical
Seals
Jacket designed
for high rates of
thermal
transference.
75 PSIG
Littleford
Mixing Plows designed to create
a fluidized bed and excellent
thermal transfer.
Contour discharge Valve,
for No-Dead Spots
High Speed Choppers, for
granulation control, lump
breaking & dispersion
Our regular FM/ FKM sizes:
Working capacity depends on the process, and is
normally between 50% and 70% of total capacity.
Model
TOTAL CAPACITY
Liters Gallons
Cu.Ft.
FKM-300-D
FKM-600-D
FKM-1200-D
FKM-1200-E
FKM-2000-D
FKM-2000-E
FKM-3000-D
FKM-4200-D
FKM-6000-D
FKM-8000-D
FKM-10000-D
FKM-13500-D
FKM-15000-D
FKM-20000-D
FKM-25000-D
300
600
1200
1200
2000
2000
3000
4200
6000
8000
10000
13500
15000
20000
25000
79
159
317
317
530
530
792
1109
1584
2113
2642
3555
3960
5284
6605
11
22
42
42
71
71
106
148
212
283
353
495
530
706
883
DIMENSIONS *
A
B
C
39”
49”
98”
67”
117”
79”
117”
136”
117”
157”
198”
198”
198”
198”
234”
28”
34”
34”
42”
42”
50”
50”
54”
68”
68”
68”
79”
85”
95”
99”
35”
43”
43”
50”
51”
60”
60”
68”
80”
80”
80”
92”
96”
107”
110”
C
B
A
Littleford Day Inc.
Densification of Dry Powdered Detergents:
Until recently, the manufacture of most dry detergent products relied on the Spray Drying Process to
produce a light density powder product (18-22 Lb/Ft3, Aprox).
The Spray dried powder consisted of
homogeneous, hollow, spherical particles.
Reducing the overall cost of producing dry detergents
provided the driving force behind the development of more densified products.
Densification of the
detergent results in reduced packaging costs and waste, reducing shipping costs and smaller shelf
space requirements at the point sale.
When leaders in the detergent industry began searching for a
process to densify detergents, they quickly arrived at the concept of using a high speed continuous
mixer to achieve their goals. A mixer densifies the product by adding work energy to the product via
mechanical shear.
The continuous mixer/mixing systems best satisfying industry´s needs are the Littleford CB Series
High Speed Processor (as a stand-alone unit), and the CB used in combination with a l arger KM
Series Littleford Continuous Ploghshare Mixer. The desired level of densification determines which
equipment configuration is used. The CB Processor features a jacketed, horizontal, clam shell-type
mixing chamber, with a horizontal shaft with a significant quantity of specially designed feeding and
mixing tools arranged in a spiral-like pattern, to supply high shear mixing rates and material transport.
Liquid may be added via a manifold system located at the lower half of the shell.
The typical retention time of detergent product in the CB Processor is 15 to 20 Seconds. During that
time the product is subjected to intense mechanical shear causing the fragile spray dried granules to
break up and densify. Increases in product density of up to 50% are common (or an increase to 25 to
30 Lb/Ft3). If further densification is required, product is then transferred to a Littleford KM Mixer,
which provides additional mechanical shear via the rolling/agglomerating action of the curve-sided
mixing tools. Liquids can also be added in this unit, and high speed impact choppers are used to aid
in both liquid dispersion and lumps breaking. Common retention times in the KM Mixers are 5-10 Min.
Final product densities of 45 Lb/Ft3, or greater are achieved, increasing original density up to 100%.
Littleford CB High Speed Processor:
Densification of Detergents through
addition of high shear input rates.
Model No.
CB-30
Ideal for the densification of detergent powders. Typical
retention time of detergent productis 15 to 20 seconds. During that
CB-50
time the product is subjected to intense mechanical shear, causing
CB-60
the fragile spray dried granules to break up and densify. Increases
CB-75
in product density of up to 50%
CB-100
If further densification is required,
High Shear
Mixing &
product is then transferred to a KM
Densification Predensification
series continuous mixer, delivering
Zone
Zone
up to 100% density increase.
Heating/Cooling
Jacket (Top
& Bottom Shell)
Dinamically
Balanced
High Speed
Shaft.
Pneumatic Control of
Discharge Gate
Littleford Day Inc.
Throughput (Lbs/Hr)
Minimum
Maximum
900
5,400
9,900
19,000
30,000
4,500
27,000
49,000
95,000
150,000
Charge
Chute
Charging
Zone
Double
Row
Spherical
Bearings
Tangential Liquid Lances
on Bottom- Top, Optional
To an optional KM Continuous Mixer, for up to 100% Densification
Advanced Drying Technology
1.-High efficiency drying of Suspensions, pastes, and bulk materials.
2.-Fast drying cycles and discharge.
3.-Allows efficient drying of sensitive materials at low Temperatures.
4.-Complete dispersion of agglomerates, lumps and fiber bundles.
5.-Homogeneous mixing of dissimilar ingredients.
6.-Drying operations from liquid state to free-flowing powder in one vessel.
7.-Allows liquid addition during processing.
8.-Adapts itself to effective recovery of costly solvents.
9.-Eliminates need for additional processing equipment.
The Key to this State-of-the Art drying
technology is the unique, mechanically
fluidized ploughshare action which agitates and individualize the solid particles to be dried. The ploughshare action
forces the product into a 3-dimensions
motion that individualizes each particle,
continuosly exposing tremendous surface
area for drying.
The particles constantly
contact one another, and the heated interior walls of the jacketed vessel furthering
the drying process.
Our dryers are also
equipped with independently operated,
high shear choppers, to reduce the particle
size of the lumps or agglomerates, to expose undried materials and ensure thoroughly
dried particle interior. Deagglomeration
further shortens drying time.
Heated Pulse Back
Filter with Stack.
Wet Product
Condenser
Littleford
Dryer.
Dry Product
Recovery
Tank.
Vacuum
Pump.
Advance Drying:
Advanced Drying:
The Chopper Advantages.
PASTE
GRANULE
POWDER
M
O
I
S
T
U
R
E
Internal Drying
without Choppers
External Drying
with Choppers
DRYING TIME
The action of the turbulent plows and the high shear choppers reduce the forming lumps
to smaller granules, thus exposing large amounts of new surface area for drying.
Granulation
Granulation Validation
Cycle Time vs Power (Watts)
Stop Liquid
Addition
P
o
w
Littleford mixers/granulators, equipped
with plow-like mixing tools, develop an
intermediate intensity mix action, which
is gentle, yet thorough.
This action is
supplemented by high shear choppers,
which quickly disperse minor liquid, or
powder ingredients.
In a typical run, the excipient and the
powdered active ingredient are charged
to the static granulator and mixed, with
choppers, for several minutes, until the
power curve levels off, indicating that
dispersion is complete. Then the agglomerating liquids are sprayed into the
active chopper field, where t hey are
quickly dispersed into the batch.
The degree of granulation, and thus the
amount of power utilized, is dependent
upon the amount of liquid added to the
batch, so as of the wet mix batch time.
The action of the plows causes “snowballing”; the choppers generates small,
granules.
e
r
Large Granules
Start
Dry Mix
Medium Granules
Small Granules
D
e
m
a
n
d
Cycle Time
Start
Liquid Addition
For a Given:
Liquid Level: More Wet-Mix Time = Material more wet out,
Higher Power used &
More uniform particles.
Wet-Mix Time: Higher Liquid Level = Material more wet out,
Higher Power used &
larger granule size.
Rental Programs
In addition to our Process Development & Testing Programs, our
Rental Program offers a unique opportunity to test our processing
equipment in your own Plant.
Batch Mixing / Processing
Ploughshare Units, both
for atmospheric / vacuum
and Pressure Ops. : From
Table-Top 5 & 20 Lts units
to Pilot 130 Lts. Machines
Larger sizes are available.
Daymax # 10 Dispersers,
for high quality dispersions
of solids into liquids, such
as plastisol, varnish, paint,
and other applications.
W-10 High - Intensity
vertical mixer, for PVC
Compounding and /or
other applications requiring High-Shear Op.
Ten Liters Capacity.
FA-3.5 Mixer, Nauta-Type,
for special mixing / drying
requirements. 24.6 Gallons
Working Capacity.
A portion of the rental cost, under this program, will be applied
to the purchase of any related Littleford Day Equipment.
Service & Spare Parts



Exclusive Dept. for
customer assistance.
Laboratory for
formulations &
optimization.
Specialized Field
Service Engineers.



Stock of common
required parts.
Top American Mfrd.
Parts: SKF, Falk,
Chesterton, etc.,etc.
Assistance in
Spanish, if required.
Process Development & Testing
Main Office: Florence, Ky. Ph.- (606) 525-7600. Fax: 525-1446
Latin America: Mexico Cy.Ph.- (52-5)550-9459. Fax: 550-9459
Cosmetics
Detergents & Soaps
Foundry Additives
Pharmaceutical
Ceramics
Fertilizers/Seeds
Rubber
Greater
Mortar Mixes
Cincinnati
Brake Linings
Airport
Powdered Metals
Herbicides
Flame Retardant Chemicals
Pigments & Color Flushing
BMC & SMC Plastics.
Color Concentrates
PVC Compounding
Coatings
Plastisols
Adhesives & Caulks
Inks & Varnish
ChemicalReactions & Drying
Cellulose Reactions
Spices
Chocolate processing
Gelatin & Powdered drinks
Bakery Mixes
Instantanization
Minutes away from Greater Cincinnati Airport, Our Lab. Center
is fully equipped with all the required machinery for product
development: Mixers, Dryers, Reactors, Granulators, Intensive
Mixers-Coolers and support equipment such as filtering and
vacuum drying systems.
To Cincinnati
I-275
Technical Center Main Equipment:
I-75
Donaldson Rd.
Turfway Rd.
U.S. 42
Exit 180
Florence
Union
Industrial
Road (1 Mi)
(1/2 Mi)
7451 Empire Drive
Florence, KY. 41042-2985
To Lexington
Bring Us Your Toughest
Mixing, Drying & Reacting
Problems.
FM-130 Mixer/Processor Ploughshare
DVT-130 Polyphase Reactor
KM-150 Continuous Mixer/Processor
M-5 Lab. Mixer & Dryer
W-180/K-300 PVC Compounder
W-10 High Intensity Mixer
Daymax 10 Pastes Disperser
Daymax 100 Pastes Disperser
Mixtruder Sigma Double-Arm Mixer
Mogul Tangential Sigma Mixer
Cincinnatus Overlapping Sigma Mixer
FA-10 Nauta Processor