What property do soaps, metal stearates, and lecithin oils all share? They are all surfactants used in our daily lives and all these materials have been made on plow mixers.  The surfactant industry touches all industries from colorants to personal care to petrochemical and many more.  Since surfactants manufacturers touch a wide variety of industries, manufacturers must have equipment that is versatile and can be adapted to a variety of applications.  Whether it be standard mixing, reacting, drying, or even extraction of material, Processall’s plow mixers can be customized to fit customers’ needs.

Processall Fluidized Bed Surfactants Blog Article

Our site has worked with many surfactant manufacturers in the past. Companies in the metal stearate industry have seen dramatic improvements with
overall site efficiencies because plow mixers can perform three of their operations in one piece of equipment.  Plow mixers can mix, react, and dry the materials for these operations all within one vessel. We have additionally worked with companies in the personal care arena to improve upon the processing and reaction time to make household detergents. Plow mixers are known to excel at extraction operations like the removal of lecithin oils.  They have even been used to help in the toothpaste and pharmaceutical industry with the manufacturing of surfactants like Cetylpyridinium chloride.

Processall’s employees have a long history of working with the surfactant industry aiding in everything from initial testing to installation of the unit to maintenance throughout the life cycle of the unit. Processall’s plow mixing technology gives manufacturers a leg up on the competition. Listed below are some of the benefits of moving toward plow mixing technologies for Surfactant plants.

  • Thermal jackets to allow for optimal temperature controls
  • Ability to remove water or organic solvents from material
  • High heat transfer rate because of the creation of a mechanically fluidized bed within the drying vessel
  • Vessel jacket allows different media (hot oil, steam, or tempered water) to be used depending upon the thermal sensitivity of the product
  • Ability to adjust between high pressure and low pressures depending on the steps in the process
  • Ability to serve as a reaction vessel and with the mixing action speeds up the rate of reaction
  • Vacuum lowers the vapor pressure of the liquid, facilitating quicker drying times
  • Allows for the collection of volatilized liquids
  • Mill breaks up clumps and can be used for defining particle size
  • High-speed mix which can handle materials as fine as dried oats without damaging the material
  • Easy to scale up and predict mix and drying times after lab testing
  • Vessels can be further outfitted to increase versatility:
    • Mechanical seals – will allow the vessel to be pressurized as well as reach low vacuum (28 Hg)
    • Liquid lances – allows media to be sprayed onto the substrate
  • Ability to perform the reaction and the mixing and drying within one unit resulting in:
    • Faster throughputs
    • Reduced energy consumption
    • Smaller footprint on the production floor

Areas plow mixers touch in the Surfactants industry:

  • Detergent manufacturing
  • Soap manufacturing
  • Toothpaste
  • Pharmaceuticals
  • Pigment dispersions
  • And many more

Processall maintains a fully equipped testing facility in Cincinnati, Ohio designed to provide customers with the data they need to develop their process, evaluate equipment, scale up, and identify the necessary equipment to maintain desired production volumes. We extend an open invitation to all potential customers to bring their product to our test center and get a “hands-on” experience with our technology and capabilities.

We also maintain a rental fleet that customers can utilize to do further testing at their facility or employ to minimize their startup costs for a new process.

Please feel free to contact us with all your material processing questions and our experienced industry professionals will help you find the right mixing solutions for your application.

Processall Blog