Softsoap Finishing Skid OpTech 3 Training

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Softsoap Finishing Skid OpTech 3 Training

• Skid Design
• Level 1

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Softsoap Finishing Skids

• Summary
• Finishing skids provide for the continuous and
  instantaneous blending of raw ingredients to make
  finished product.
• Advantages
• Automated
• Flexibility
• Accuracy
• Takes up little space compared to batch process
• Minimal waste generated

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Softsoap Finishing Skid Main Ingredients

• Bulk Ingredients
• Vanilla Base
• Fruits Body Wash
• Beaded Body Wash
• Structured
• AB Lite
• ABEX
• Harmonize
• ESP
• Brine
• Citric Acid
• Oil Phase (Pure Cashmere)
• Tote/Drum Ingredients
• Color Phase
• Fragrance Phase
• Beads Slurry (Structured Formulas)

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Softsoap Liquid Hand Soap Finishing Skids 11, 12,
14, 15 Layout
pH probe
In-Line Viscometer
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Softsoap Line 12 Finishing Skid
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Softsoap Body Wash Finishing Skid 13 Layout
pH probe
In-Line Viscometer
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Why is Line 13 Different?

• Static Mixers on Line 13 skid are staggered
  throughout skid to allow for proper mixing of
  Body Wash products
• More mixing elements used due to the greater
  viscosity of the product

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Softsoap Line 13 Finishing Skid
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Viscosity and Viscometer Fundamentals
What is Viscosity? - A measure of the
thickness of a liquid - A liquids resistance
to movement or deformation - True Viscosity
cannot be measured it must be calculated -
True Viscosity Shear Stress/Shear Rate -
Shear rate is applied - Shear stress is
measured - True Viscosity is calculated -
Relative Viscosity can be determined on a
calibrated system
Ways to Determine (Measure) Viscosity -
Flowing through a pipe (Flow rate, Differential
pressure) - Rotational motion (Lab rheometers
- Brookfield viscometers)
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Further Explanation of Viscosity

• Viscosity is shear stress divided by the shear
  strain rate. These units of measurement provide
  at least a limited estimate of fundamental
  material properties.
• The easiest way to picture shear is to visualize
  a deck of cards which have a vertical line marked
  on the side. As pressure is applied to the top
  of the deck, the cards slide over one another and
  the marked dots on the individual cards start to
  separate. The shear rate is the rate at which
  these dots separate.

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Inline Viscosity Measurement System

• Stand Alone System Components
• Pump
• Flow meter
• Differential Pressure Transmitter
• Pressure Sensor
• PC
• PLC Cabinet
• Software

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Continuous Liquids In-Line Viscometer
Post-Add Ingredients
Process Control Computer
Citric Acid
Perfume
Color
Brine
Head Tank
LHS or BW
Common Base
To Filler
Viscometer Computer
Mass Flow Meter
Pump
w/Temperature Sensor
dP Cell
Residence Time Loop (Four minutes)
Viscosity Measurement Tube
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Morristown Plant In-Line Viscometers

• How do the Viscometers work?
• The Viscometer pump turns on when the skid goes
  into processing.
• It pumps the product through a side stream after
  post-addition and after it has passed through the
  static mixers
• In the side stream, the product goes first
  through a 3-minute residence time loop where the
  viscosity is allowed to build.
• The product then goes through a 30 straight
  section of open pipe where the pressure drop is
  measured by a dP cell.
• The flow rate is held constant via a flow meter
  and a PID control function on the pump speed.
• The Viscosity is calculated from the temperature
  and the difference in pressure using a set of
  equations.

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Morristown Plant In-Line Viscometers

• How the Viscometers are used
• The Viscometer works in conjunction with the
  Plant Process Control PLC to automatically adjust
  the post-add brine percentage to keep the
  Viscosity on target.
• Whenever the skid is processing, the Viscometer
  determines a new value for the Viscosity every
  second.
• The Viscosity value is sent to the Plant PLC and
  updates on the Main Process screen every second.
• A timed controller compares the current Viscosity
  value to the Viscosity target and makes an
  adjustment every four minutes to the brine
  percent set point based on the difference between
  the Viscosity reading and the target.
• The brine adjustment controller waits another
  four minutes delay before making another change
  to the brine percent.

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What Are We Going To Do Today?

• Skid Design Theory
• Demonstrate understanding of skid design and
  equipment layout.
• Describe skid process from vanilla injection to
  the time it reaches filler, providing as much
  detail as possible.
• Describe major difference in design of Line 13
  skid versus all other skids in SS.
• Name each of the viscometer components and their
  corresponding functions.
• Wonderware GUI familiarity
• Demonstrate familiarity with the Wonderware
  Interface screens
• Locate the change over screen
• Locate the vanilla tanks PID screen
• Change the speed on the vanilla pump
• Change the percentage of a control valve
• Log into/out of Wonderware

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Questions?