WALDNER Brief - Nr. 172.pdf - Waldner Firmengruppe

Toothpaste for the world
by alexander.wenk@waldner.de and alexander.lukas@ekato.com
Bisher liegt die maximale Anlagengröße einer Zahnpastaproduktion
zwischen 4.000 und 5.000 Litern Nutzvolumen, wobei
der Ausstoß zwischen ca. 2.000 bis 3.000 Litern Zahnpasta
pro Stunde liegt. Die zwei realisierten Produktionsanlagen mit
jeweils 10.000 Liter Nutzvolumen können je nach Produktdichte
12.000 bis 16.000 kg Zahnpasta pro Ansatz herstellen. Dabei
liegt der Produktausstoß zwischen 6000/8000 und 8000/11.000
kg pro Stunde. Dies entspricht einer Steigerung der Produktionsrate
um mehr als 100% auf das Doppelte.
Wir sind der festen Überzeugung, dass unser Partner – die
Firma EKATO SYSTEMS GmbH – mit diesem Meilenstein neue
Anlagenverkäufe bei bestehenden und neuen Kunden generieren
kann und freuen uns, unsere jahrelange Partnerschaft
durch Folgeaufträge hierdurch weiter auszubauen und unsere
Leistungsfähigkeit sowie Termintreue in dieser auch für uns
neuen Dimension erneut unter Beweis stellen zu können.
I n f o - B o x
Für wie viel Menschen reicht die Zahnpasta?
Aus einer Tube Zahncreme mit 125 g
Inhalt kann man 338 cm Zahncreme
herauspressen. Eine durchschnittliche
Zahnbürste für Erwachsene hat einen
3 cm langen Kopf, der einer Kinderzahnbürste
ist 2 cm lang. Putzt man
sich 2 mal am Tag die Zähne, so
reichen 125 g Zahnpasta für einen
Erwachsenen für etwa 63 Tage. Ein
Kind kommt circa 94 Tage damit aus.
Voraussetzung dafür ist jedoch, dass
der Zahnbürstenkopf vollständig mit
dem Strang aus Paste behaftet wird.
Ein sparsamerer Gebrauch schont das
You can squeeze 338 cm of toothpaste
out of a 125 g tube of toothpaste. An
average adult toothbrush has a 3 cm
long head, while the head of a child's
toothbrush is 2 cm. If you clean your
teeth twice a day, then a 125 g tube
of toothpaste will last an adult around
63 days and will last a child around 94
days. The precondition here is, however,
that the toothbrush head is fully
covered with the stripe of toothpaste.
More economical use of toothpaste
Fertig zur Fahrt nach
Schopfheim: Die Behälter
sind fertig verladen und
warten auf das Begleitfahrzeug
der Polizei.
Ready for the journey to
Schopfheim: The vessels
have been fully loaded and
are waiting for the police
escort vehicle
Portmonee, jedoch nicht die Zähne.
Der durchschnittliche Anlagenoutput
liegt wie oben gelesen bei 8000 kg/
Stunde. Dividiert man einmal die Stundenleistung
durch den Tubeninhalt,
0,125 kg, so ergibt sich der Wert von
64.000 Tuben pro Stunde. Da 125g
Zahnpasta 63 Tage ausreichen, benötigt
man 2,77g pro Person pro Tag.
Somit kann mit dem Stundenoutput von
8.000 kg der Tagesbedarf von ca. 2,88
Mio. Menschen bedient werden.
For how many people is th e re e nough toothpaste?
saves money but doesn't save your
teeth! The average output of the plant is
8,000 kg/hour, as stated above. If you
divide the hourly output by the content
of a tube (0.125 kg), then you arrive at
a figure of 64,000 tubes per hour. As
125 g of toothpaste lasts for 63 days,
you need 2.77 g per person per day.
The hourly output of 8,000 kg would
therefore meet the daily requirement of
around 2.88 million people.
The Process Systems division has produced the largest
global toothpaste production plant together with Schopfheim-based
EKATO SYSTEMS GmbH. The plant has an hourly
output of 64,000 tubes, a figure that corresponds to the daily
consumption of toothpaste of almost 3 million people. The
two companies achieved a milestone by using reliable scaledup
technology to produce a plant designed for large-volume
batch processes. Waldner produced the main component of
the plant, namely the two agitator vessels.
The completion of the project was a huge challenge and it
was only with massive effort on all sides that the challenges
could be overcome. The benchmark data on the two vessels
manufactured by Waldner alone demonstrates the huge scale
of the project: a weight of almost 15 tonnes per vessel, walls
of up to 20 mm thick, an overall height of just under 6 metres
and dimensions of 4 x 4 metres. The efforts of global companies
to concentrate their production capacities on a small
number of locations worldwide has also reached the personal
care sector and modern production plants have to be able to
manufacture large volumes with maximum flexibility.
Complex production process
A production plant for the manufacture of toothpaste essentially
consists of a vessel with an agitator that can be evacuated,
a homogeniser to homogenise the product to the required
fineness of grind and different dosing systems to feed in raw
materials. The liquid raw materials used are either preweighed
and introduced into the vessel by vacuum suction or
are dosed in by means of gravimetric methods. Powdery substances
or thickeners to increase the viscosity of the mixture
can be dosed in, for instance, using the integrated homogeniser,
or fed into the vessel by suction through a valve in the
base. The above results in the following system requirements
in relation to the manufacturing process: precise dosing of
large volumes of liquid ingredients, fast homogenisation of
thickeners without the formation of agglomerates and inhomogeneities,
rapid integration and wetting of large volumes of
powders, homogeneity of product throughout the entire content
of the vessel, addition of soaps without the formation of foam,
rapid de-gassing of the toothpaste, homogeneous mixing of
active agents, temperature control and high product yield.
To date, the maximum plant size for a toothpaste manufacturing
plant has been between 4,000 and 5,000 litres of
effective volume, with the output lying between about 2,000 to
3,000 litres of toothpaste per hour. The two production plants
completed, each with an effective volume of 10,000 litres,
can produce between 12,000 and 16,000 kg of toothpaste per
charge, depending on the density of the product, equating to
a product output of between 6,000/8,000 and 8,000/11,000 kg
per hour. This corresponds to a 100% increase in the production
rate, effectively a doubling of the output.
Projects
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