Automated Batch Processing System for a New Detergent Product

Despite the challenges posed by compressed timelines and space constraints, EPIC successfully delivered a comprehensive modular skid solution within two months, from the first purchase order to commissioning. The seamless integration of the new systems into the manufacturing facility enabled the customer to be the first to market with a competitive new product.

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Hygienic Process System Design

Project

Overview

  • Industry: Consumer Products
  • Company Size: Over $10BB in Revenue
  • Location: USA
  • Customer Use Case: Batch Mixing and Blending

Customer’s

Challenge

A multinational consumer products company faced the challenge of introducing a new product to market quickly to gain a competitive edge. However, they encountered constraints in terms of time, budget, and space.

Epic

Solution

EPIC Systems was awarded the project due to its ability to meet the condensed timeline and its efficient engineering and fabrication techniques. To ensure confidentiality and maintain high construction standards, EPIC built and assembled all modular skids in its advanced fabrication shop. The project engineers and manufacturing crew worked tirelessly, including overtime, to meet the tight schedule. Collaborative efforts between EPIC and the customer during fabrication ensured adjustments were made promptly, and progress was continuously monitored. 

Each skid was meticulously designed to fit the small factory footprints and navigate through narrow doorways during installation. Piping organization on the blending skid was simplified for easy maintenance and change-out of raw material connection points. Both skids were delivered pre-wired and ready for utilities hook-up, streamlining the installation process. 

The main batch manufacturing process skid was designed to handle raw materials from multiple sources, incorporating valves, pumps, and mixers programmed to follow a precise batch sequence. Additionally, a raw materials pre-mix skid was engineered to provide fragrances and dye to the blending skid, enhancing efficiency in the production process. 

EPIC’s scope also included comprehensive calculations for heat tracing, loading, and electrical requirements, ensuring seamless integration of the new systems with existing infrastructure. Integration with packaging equipment was executed to enhance communication and data acquisition, contributing to overall equipment effectiveness (OEE). 

A sophisticated batching control system was programmed to meter ingredients accurately based on customer-defined recipes, incorporating fail-safe measures to ensure precise mixing. Furthermore, EPIC installed two flow meters with different measuring technologies to meet the customer’s stringent accuracy requirements. 

 

  • Automated Batch Processing System Installed

    Automated Batch Processing System Installed

  • Raw Materials for Automated Batch Processing System

    Raw Materials for Batch Processing System

  • Automated Batch Mixing System Assembly

    Batch Mixing System Assembly

Project

Impact

  • Market Leadership Position: EPIC’s ability to meet the condensed deadline enabled the customer to quickly introduce a new, competitive product to the market. By being first to market with this innovative offering, the customer gained a significant advantage, positioning themselves as an industry leader and capturing valuable market share ahead of competitors.
  • Operational Efficiency: By strategically separating the existing liquid process from detergent production, EPIC created an independent manufacturing environment tailored to the customer’s needs. This segmentation not only optimized operational efficiency but also facilitated streamlined production processes, enhancing overall productivity and quality control. 
  • Cost Optimization: Through meticulous engineering and design, EPIC ensured the seamless integration of new systems into existing space without the need for costly expansions. By maximizing space utilization and minimizing additional infrastructure investments, EPIC enabled the customer to achieve their objectives within budgetary constraints, driving cost savings and operational agility. 
  • Precision and Consistency: The implementation of an automated blending skid guaranteed product accuracy and consistency, mitigating the risk of errors and variability in production. By leveraging advanced automation technologies, EPIC enhanced quality control measures, ensuring that each product met the highest standards of excellence, thus bolstering customer satisfaction and brand reputation. 

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