Powder Detergent Plant
Our Production system that can produce powder detergent equivalent to Tower System (Spray Dryer) quality with low investment cost.
Quality detergent must be fluid, white, standard in a certain particle size and easily soluble in water at any temperature. Today, powder detergent can be produced by two known methods: Spray-Drying Tower and Dry-Mix method. The Spray-Drying Tower method is preferred as it can produce
higher quality products than the Dry-Mix method.
1- Spray-Drying Tower Powder Detergent Production System:
In this method: In order to produce powder detergent, a mixture of basic chemical raw materials in the form of sludge is first made. (Labsa, Liquid Caustic, S.Silicate, STPP, S.Sulphate, H.Soda etc. raw materials are mixed with water to provide physical and chemical mixture of raw materials with each other.) This mixture is sprayed in slurry form from the top of the Spray-Dryer Tower with a High Pressure Pump. The water in the mud is removed by being hit with hot air from the bottom of the tower. Raw materials (Non-ionic, Enzymes, S.Percarbonate, Perfume, Colored particles, etc.) that will degrade in hot and aqueous environments are mixed later as additives.
Advantages of Spray-Drying Tower Method:
A low density and partially homogeneous powder is obtained.
Disadvantages of Spray-Drying Tower Method:
High equipment, building, infrastructure investment and maintenance costs are required. Due to the stop-start cost of the production, it has to work for a long time without stopping and in a fixed formula. Pipe, pump and filter lines must be washed at the beginning and end of production. Although some of the washing water is included in the system, some of it causes environmental pollution as waste. Due to high-capacity air fans, fine dust particles are retained by dust cyclones and cloth filters, but dust collector systems cannot be 100% efficient. For every 3 tons of product, at least 1 ton of water is consumed by evaporation. This amount of water increases even more in formulas with high activity and STPP. In addition, since these products cause loss of capacity, operating and energy costs increase.
2- Dry-Mix Powder Detergent Production System:
It is a system that requires the use of a minimum amount of liquid raw materials and does not require water in any way and therefore does not require a drying process.
Advantages of Dry-Mix Method:
Requires very low equipment, building and infrastructure investment and maintenance costs. Production starts and ends are free of charge. Not working for a long time in a continuous and fixed formula does not create an additional cost. There is no need for water consumption.
Disadvantages of Dry-Mix Method:
There are so many disadvantages that it is prevented from being preferred in general. An inhomogeneous powder with a density of min.750 g/L is obtained. Powder raw materials are evenly distributed together, preserving their own structure and roperties. Liquid Active Substance and Essence are sprayed onto powder surfaces. Coarse particles are included in the mixture as coarse, fine powder particles as fine powder. For this reason, the particle structure of the detergent cannot be homogeneous at the desired level. At the same time, it does not have a high production capacity.
The fact that powder detergent manufacturers are limited to only these two methods and the first of these methods has very high investment and operating costs, the second one cannot reach the
desired quality, moreover, it restricts the transition to different product processes; IT MAKES OUR PRODUCT UNIQUE.
The innovation of our Powder Detergent Production System;
Unlike the Spray-Dryer Tower, it allows thermosensitive (heat sensitive) raw materials (such as non-ionic) to take place in a homogeneous structure without using a temperature source other than the exothermic reaction heat in the environment.
Unlike the Spray-Dryer Tower, the process of removing water from the mixture;
With the recipe created, it will be provided with a reaction that takes advantage of the drying/hydration capabilities of the raw materials. The fact that this process is an exothermic reaction and does not require any other heat other than the reaction heat ensures that thermosensitive raw materials are also included in the reaction and form a homogeneous structure. Thanks to the hydration capabilities of the raw materials, the water desired to be removed from the material will be converted into hydrate, and the material will be dried and thus the desired particles will be obtained.
Our system allows the use of ecological-organic raw materials, raw materials that deteriorate in heat (which cannot be used in the Spray-Dryer Tower system) and up to 30% active substances. Unlike the Spray-Dryer Tower system, it allows the use of raw materials with high water carrying capacity, such as STTP (Sodium Carbonate) in very high quantities.
It allows the direct use of Hydrogen Peroxide (H2O2) as bleach. In terms of density, less density is obtained than the average density of each raw material. 550-750 gr/L: It is an ideal density especially in matic detergents in today's conditions.
We can summarize the disadvantages of the Spray-Dryer Tower System against our system, together with the numbers in the table below, with a few examples;
• High operating costs occur in case of interruption in the operation of the system. The energy spent in stopping and taking off is an element that increases the cost. Therefore, it is not suitable to provide flexibility to low production quantities when needed.
• Transition between formulas: There is approximately 500 kg of product in the transfer line, pumps, filters, pipes, etc. While making a formula change in production, the production line must be purified from the product with the previous formula. A product with an intermediate formula of about 1000 kg is formed by mixing with the product remaining in the line, 500 kg of the product with the new formula coming in succession. This intermediate formula is not a precise and homogeneous mixture and is wasted. In addition, a residual product layer between 3 and 15 cm is formed on the walls of the tower, which has a surface area.
