In-Line Blending Skid Expands Product Portfolio at Minimal Cost

With limited budget and floor space, EPIC designed an efficient solution for doubling the variety of fragrances mixed in the customer’s facility. The automated controls and efficient washout system improved operational efficiency, while the re-blend process minimized material waste, maximizing cost savings and overall system performance. 

Hygienic Process System Design

Project

Overview

  • Industry: Consumer Goods
  • Company Size: Fortune 500
  • Location: USA
  • Customer Use Case: In-line Blending

Customer’s

Challenge

A client in the fragrance industry faced the challenge of expanding their production capacity without increasing the footprint of their existing manufacturing line. They required a solution that could efficiently mix two different products and over 20 different fragrances on a single process line. Traditional methods involving multiple storage tanks were not only space-intensive but also incurred higher capital costs. 

Epic

Solution

EPIC Systems designed and delivered an innovative in-line blending skid solution to meet the client’s requirements. The system was integrated into the client’s existing fragrance mixing line, seamlessly expanding its capacity without extending its physical footprint. 

The in-line blending skid incorporated several key features to optimize efficiency and flexibility. It began with an outside pre-mix module in a designated hazardous area, fabricating a base formula containing ethanol. This base formula was then fed into the building through pipes connecting to the in-line blending system. 

Using ingredient trees, the system combined various raw materials from the storage area into the product formula, eliminating the need for multiple storage tanks. Fragrances were integrated via a perfume in-line blending system, allowing for just-in-time mixing and minimizing downtime. Static mixers ensured homogeneous blends, while a resurge tank with a recirculation pump regulated flow and maintained proper mixing before filling. 

The skid’s automated controls matched blend and fill rates, coupling the blending and filling systems while regulating pressure to accommodate fluctuations. Additionally, a product-to-product washout system facilitated efficient cleaning between batches, with scrap material re-blended into appropriate product batches to minimize waste. 

Project

Impact

  • Cost Efficiency: EPIC’s in-line blending skid solution significantly reduced capital costs by eliminating the need for multiple storage tanks and streamlined the production process, ensuring optimal resource utilization. 
  • Space Optimization: Compact in-line blending skid design minimized the physical footprint required for production expansion, maximizing space utilization within the existing facility and reducing the need for costly facility expansion or reconfiguration. 
  • Waste Reduction: Through efficient washout processes and re-blending of scrap material, EPIC’s solution minimized material waste, maximizing resource efficiency and reducing environmental impact while enhancing overall cost-effectiveness. 
  • Operational Efficiency: With automated controls and integrated systems, the customer was able to optimize operational efficiency, matching blend and fill rates, and regulating pressure to maintain consistent performance, ultimately increasing throughput and reducing downtime. 

More Client

Success Stories

Multi-Skid Process System for a New Time-Release Fragrance Technology

Multi-Skid Process System for a New Time-Release Fragrance Technology

EPIC’s innovative solutions and meticulous project management enabled the successful design, fabrication, and delivery of multi-skid systems, addressing many challenges faced by the consumer fragrance company and ensuring seamless production of their new product.

Our Solutions

EPIC Systems is a multidisciplinary engineering integrator specialized in industrial automation for process manufacturers. We deliver solutions in the following areas:

Process Systems

Machine Vision

Robotics

Industrial Automation