Engineering Scale: A Case Study of Our 36-Ton Fully Automated Liquid Production Line in Algeria

1. The Vision: Building a "Super Factory"

In the competitive FMCG (Fast-Moving Consumer Goods) landscape of Algeria, manufacturers are no longer looking for standalone machines. They are looking for integrated systems that guarantee consistency, safety, and massive throughput.

Our latest project delivery is a testament to this shift. We have successfully designed, manufactured, and commissioned a colossal Liquid Detergent & Personal Care Production Line that redefines efficiency. This isn't just equipment; it is a fully automated ecosystem designed to handle over 40 tons of raw material per batch cycle.

3. Critical Technology: The "Brain" and The "Senses"

A tank is just stainless steel until you give it intelligence. This line features top-tier European technology integration.

The Brain: Siemens Smart Line Architecture

As seen in the control panel visuals, the entire facility is networked.

• Process Visualization: The Siemens HMIs display a real-time schematic of the entire piping network. Operators can track the flow instantly.
• Dual-Screen Control: We implemented a multi-station control logic. Full access to temperature, speed, and valves from any platform.
• Safety Interlocks: The PLC prevents "human error"—valves will not open if a destination tank is detected as full.

The Senses: Mettler Toledo Weighing Modules

Precision is the difference between a good product and a great one. We discarded traditional flow meters in favor of Gravimetric Dosing.

• Each 12T Blending Vessel sits on Mettler Toledo Load Cells (Swiss-engineered precision).
• Benefit: The system weighs the product in real-time. This ensures that every drop of ingredient added matches the formula strictly.

4. The Engineered Workflow (Process Flow)

The beauty of this line lies in its Interconnected Piping System:

1. Pre-Processing: Raw ingredients are heated and dispersed in the 2T Pre-mix Vessels.
2. Gravity Transfer: Once ready, the base mixture is transferred via sanitary piping—aided by gravity and transfer pumps—into the massive 12T Main Process Vessels.
3. High-Shear Homogenization: The main vessels utilize bottom-mounted homogenizers (0-3000 RPM) to create a stable, glossy emulsion.
4. Continuous Output: Finally, the finished product is pumped into the 6x 12T Holding Tanks. These buffer tanks allow the mixing team to start a new batch immediately.

5. Operational Safety & HSE Compliance

Safety is not an option; it’s a priority. Handling 12-ton vessels involves working at height, and we designed the system to protect your most valuable asset: your workforce.

• Fall Protection: Each 12T Blending Vessel is fitted with a reinforced Stainless Steel Safety Grid located securely under the manhole lid. This crucial feature prevents operators from accidentally falling into the tank during inspection or cleaning, strictly adhering to international HSE standards.
• Ergonomics: The integrated Hydraulic Freight Elevator ensures that workers never have to manually carry heavy raw materials up the stairs, significantly reducing the risk of back injuries and fatigue.