Definition of Ointment
Ointments are those preparations that are miscible, immiscible, or emulsified with the skin secretions and intended to be applied to the skin a certain mucous membrane for emollient, protective therapeutic, or prophylactic purposes where a degree of occlusion is desired.
What is an ointment manufacturing plant?
The ointment manufacturing plant is built for the manufacture of ointments and various other cream-related products like gels, lotions, pastes, and other similar products. The ointment manufacturing plant consists of types of equipment and machinery for mixing the ingredients to form a homogenous mixture which is then filled into tubes or cans for storage employing a tube filling machine. The process of the ointment manufacturing plant starts from mixing ingredients and ends with filling the final product in the storage tubes for marketing.
Working Principle of Ointment Manufacturing Plant
The working principle of an ointment manufacturing plant is like first of all the hydrophilic ingredients (hydrophilic ingredients are those ingredients that are freely soluble in water) which are required for the manufacturing of a particular ointment. These ingredients
are filled into the water phase vessel. And water is added to it. The mechanical way of mixing is started, so the propeller stirrer is operated and the proper mixing is done. If there is a problem with further mixing, then further mixing is done by applying heat. This heat should not be provided directly; it should be provided in a jacketed way.
Now the second stage of mixing starts which is wax phase mixing, the wax phase mixing is done in the wax phase vessel. In the wax phase mixing first the wax type or oily type ingredients is mixed in a mechanical way. After mechanical way then it is heated so the wax or oil type ingredient is melted this way. Then for further mixing these ingredients are stirred well with a mechanical stirrer.
Now the liquid from both the vessels (Water Phase Vessel and Wax Phase Vessel) is filtered with a proper filter. And this filtered liquid phase is transferred to the manufacturing vessel by internal vacuum setup.
In the manufacturing vessel, both the liquids are thoroughly mixed. This mixing is done mechanically and we use a planetary mixer to mix these liquids until and unless a homogeneous mixture is obtained. The mixing method of planetary mixer is that it has high-speed beaters and agitators. A high-speed beater and agitator cause uniform distribution of particles so as a result a high level of homogenization and emulsification is obtained. After complete mixing in this section now this mixture is transferred to another vessel called a storage vessel.
The storage vessel is transportable and can move from one place to another by its wheel. Now this storage vessel is moved to a filling machine.
The operational method of filling the machine is that first the empty tubes (in which the ointment will be filled) are loaded in the filling machine and the process of filling is started. Now the quantity of ointment which is to fill in the tube is predetermined and is adjustable by tube filling machine. As the tubes are filled with ointment or cream. They are seal packed
to prevent leakage and remain tamper-proof in a series of sealing and packing machines.
Meanwhile, all the vessels which were used in the manufacturing, mixing, and filling process are washed thoroughly and is made ready for the next batch of ingredients. This is the overall working principle of an ointment manufacturing plant.
The ointment manufacturing plant has a working capacity of 200-500 kg/batch.
Parts of Ointment Manufacturing Plant
There are different parts of the Ointment Manufacturing Plant. Which play a key role in the manufacturing process of Ointment and creams.
Water phase vessel
Water phase vessel is a first step in the ointment manufacturing plant. In this phase, the water-soluble ingredients are dissolved in water. And the mixing is done mechanically by a stirrer. For further heating is applied to mix.
Wax heating vessel
Wax heating vessel is the second step in ointment manufacturing plant in this stage the oil and wax type of ingredient is dissolved and melted by heating and mechanical way of stirrer mixer.
Manufacturing vessel
This is the third step in the ointment manufacturing plant. Here the mixing of both the filtered solvents occurs. Water phase vessel solvent and oil phase solvent are collected in the manufacturing vessel and the mixing is started. This mixing is done with the help of a planetary mixer. The heating and cooling of ingredients are done in a jacketed way. And the jacket is supplied with hot water or steam for heating the ingredients. And for cooling of ingredients chilled cooled water is circulated in the jacketed system. Here is a glass window for observation of ingredients. Safety valves are present. The interlock system is present for safety purposes. Temperature regulators are present in this section of the ointment manufacturing plant. And pressure safety valves are present. Which controls the pressure which is present inside the ointment plant.
Planetary mixer
The planetary mixer is a mixer that is present in the manufacturing vessel of the ointment manufacturing plant. And the function of it is mixing by agitator way.
Colloid mill
Colloid mill is a special type of grinder which is present in an ointment manufacturing plant. And it breaks down large molecules, sometime lumps are formed inside the vessels. So these lumps are broken down.
Storage vessel
The storage vessel is a special type of tank in which ointment, cream, get, lotions, etc. are stored. It is freely attached and is removable from the ointment manufacturing plant. It is freely moveable from place to place by its wheels. It is a skid type in structure. And the lower portion is jacketed in which the ointment preparations can be heated.
Agitation assembly
This is a special type of assembly that is centrally located. This is giving final stirring to the product and it rotates with a speed of 960 revolutions per minute.
Homogenizer
Homogenizer is present in the main axis of the ointment manufacturing plant. Homogenizer helps in achieving high shear and homogeneity of the product.
Interconnecting pipeline
The function of interconnecting pipelines is the junction of the different vessels for wax, and water transfer of products. By these pipelines system, the recirculation of product in the manufacturing vessel occurs. The interconnected pipes assembly also contains the pipes responsible for creating a vacuum in the system.
Vacuum pump
The function of a vacuum pump is to create a vacuum environment in the vessels. The vacuum pump contains vacuum monitoring and vacuum suction valves.
Transfer pump
These are a special type of motors that causes the transfer of different phases of liquid from one vessel to other.
Integrated automatic control panel
In the ointment manufacturing plant there is a digital display that is operated with an electric supply. The control panel display has a touch screen. Speed of rotation and time adjustment of the product is controlled from these control panels. The temperature and coolness of the process are controlled by the digital control buttons from the control panel. The operation of the vacuum system is also controlled from the control panel. The recording of data of different batches is also recorded in the control panel. Control panel along with working platform are the key parts of the ointment manufacturing plant.
Ointment Manufacturing Plant layout and design
The ointment manufacturing plant consists of a water phase vessel that is filled with water and the ingredients that are soluble in water are mixed in the water phase vessel. The water phase vessel consists of a propeller stirrer for dissolving the ingredients. The propeller stirrer is driven by a motor. The water phase vessel has a jacket to support the heating or cooling of the vessel based on the requirements of the manufacturing process of each product.
The next vessel in the ointment manufacturing plant is the wax phase vessel which mixes the oils and wax components that are to be added to the mixture of the ointment. The wax phase vessel also consists of a propeller stirrer for mixing the wax or oils which is driven by a motor. The water phase vessel is jacketed to support the heating or cooling of the vessel based on the requirements of the manufacturing process of each product. The main large vessel is the manufacturing vessel which mixes the water solution from the water phase vessel and the mixed wax from the wax phase vessel. An intermediate vacuum system is used to transfer the water solution and wax to the manufacturing vessel. The manufacturing vessel used is mostly a planetary mixer
which is easier to make a homogenous mixture of ointment. The planetary mixer generally consists of a set of mixers and beaters to create a homogenous mixture. It also has a scraper to continuously and evenly mix the entire batch of ingredients. The manufacturing vessel system is also jacketed which helps to support the heating or cooling of the vessel based on the requirements of the manufacturing process of each product.
The storage vessel is present to collect the finished product of the homogenous mixture and the ointment mixture is further moved to the tube filling machine to be packed in tubes.
Properties of the ointment manufacturing plant
- The ointment manufacturing plant has jacketed vessels for the wax phase.
- The ointment manufacturing plant has jacketed vessel for water phase, and manufacturing vessels is also jacketed for heating/cooling of the ingredients inside them.
- The ointment manufacturing plant has an internal vacuum system for transporting mixtures from one vessel to another vessel.
- The ointment manufacturing plant has a planetary mixer, the function of which is to achieve a high level of emulsification and homogenization.
- The ointment manufacturing plant is specially designed with internal filters, the function of which is to filter liquids before transportation from one vessel to another.
- The ointment manufacturing plant has a Variable speed drive. Which is provided for propeller stirrer assembly to achieve different speeds.
- The ointment manufacturing plant has a Control panel system, the function of which is controlling, monitoring, and operating different processes.
- The ointment manufacturing plant has an Illuminated viewport to visually observe all the processes.
Advantages of ointment manufacturing plant
- It is a great advantage of ointment manufacturing plant that most of the work is done by the equipment as a result the Labor cost is reduced.
- It is a great advantage in the ointment manufacturing plant that it has monitoring devices to check the quality of each batch.
- In an ointment manufacturing plant, the level of reliability and consistency is high.
- The ointment manufacturing plant has a larger production rate as processes are carried out simultaneously without idling conditions.
- The ointment manufacturing plant is versatile as many different types of ointments, lotions, creams, gels, and pastes can be manufactured in the same equipment.
Application of ointment manufacturing plant in different industries
Pharmaceutical manufacturing Industry
By ointment manufacturing plant we can prepare different pharmaceutical products like antiseptic, anti-allergic, anti-fungal ointments.
Cream Manufacturing Plant
It is a great application of ointment manufacturing plant that different type of Cosmetics products like face creams, skin creams body lotions are manufactured by it.
Shampoo Manufacturing Plant
In an ointment manufacturing plant, we can manufacture basic cleaning and washing utilities like shampoo, etc.
Toothpaste Manufacturing Plant
In an ointment manufacturing plant we can prepare different types of tubes of toothpaste etc.
Gel Manufacturing Plant
In ointment manufacturing plants we can manufacture shaving creams, hair gels, wax, etc.
Lotion Manufacturing Plant
In an ointment manufacturing plant, we can prepare different types of lotions, like skin lotions, cool lotions, etc.
Shaving Cream Manufacturing Plant
In the manufacturing of different shaving creams, we take assistance from an ointment manufacturing plant.
Wax Manufacturing Plant
Various types of adhesives, glue, and resins are produced by an ointment manufacturing plant.
How much is the capacity of the Ointment Manufacturing Plant?
The ointment manufacturing capacity ranges from 200 kilograms per batch to 500 kilograms per batch.
Safety Feature
- It is a great achievement that the ointment manufacturing plant has Temperature monitor and control for jacketed vessels
- The ointment manufacturing plant is made up of High strength materials. So the chances of leakage or bursting are minimized.
- Ointment manufacturing plant internal pipelines all the vessels are Corrosion-resistant.
- The ointment manufacturing plant has Proper sealing through which the leakage of the material is controlled.
- The ointment manufacturing plant has Proper interlocking devices to secure the vessels while the process is carried out.