Science behind Technology

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Desmet Ballestra - Mazzoni LB Leader in the design and supply of plants and machines for the production of soap and glycerine

Soap

Mazzoni LB

Since the beginning of its operation in 1946 Mazzoni LB focused on the design and supply of modern, efficient and easy-to-operate for soap, detergents and glycerine production.

Mazzoni LB is today the world leading company in the design and fabrication of complete plants and machinery to the soap and glycerine industry with over 2,500 plants installed in over 130 countries.

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Company Background Mazzoni LB core activities in soap and glycerine have been further expanded with the introduction of new sectors of activities:

• Household and personal care liquid detergents

• Bleach Water Plants: innovative technologies and process for Sodium Hypochlorite production

• Chemical Plants: special esters manufacturing plants for cosmetics and lubricants

• Packaging: flow-pack wrappers

• Confectionery: plants and machinery for chewing gums, bubble gums and licorice

With a market share superior 50%, Mazzoni LB is by far the market leader in soap and detergent activities on worldwide basis with a workforce of 110 people.

The recent investment in new technologies and the acquisition of new companies active in markets close to our core business make us believe that a substantial growth of our Company is expected in the next few years.

Our regional offices in Dubai and Nairobi, supported by a strong central sales and after-sales group of persons, are closer to our Customers needs. Local engineers are being trained to grant a more direct and fast troubleshooting.

Core Business Activities

SoapGlycerine

Bleach Water Rim blocks

Household & Personal Care

ChemicalsPlants

Flow-Pack Wrappers Confectionery

Soap

Fats & Oils Pretreatment• Continuous Bleaching• Batch Bleaching

Saponification• Continuous Saponification for neutral Fats & Oil• Continuous Semi-boiled Saponification• Batch Saponification

Neutralization• Continuous Fatty Acids Neutralization• Batch Fatty Acids Neutralization

Vacuum Drying• Laundry Soap Dryers• Toilet Soap Dryers

Finishing Lines• Laundry Soap• Toilet Soap• Syndet / combo/ translucent Soap

Glycerine Recovery• Spent Lyes Treatment• Spent Lyes Concentration• Glycerine Distillation / Refining

RIM Blocks• Rim Blocks Lines

Fats & Oils PretreatmentSGAContinuous bleaching plants for fats/oils to remove the colouring pigments by absorption with bleaching earth.Several solutions available according to the type of fat/oil bleached.Batch bleaching technologies are also available for small size plants.

Saponification & NeutralizationSCNTContinuous Saponification Plants for neutral fats/oils with glycerine extraction based on innovative technologies (Centrifugal Dosing Pumps with Mass Flow Meters, Tubular Reactor, Flash Cooler):a flexible solution allowing remarkable energy savings, flexibility, versatility, reduced maintenance.

SCT/SSCTContinuous Plants for Fatty Acids Neutralization and Neutral Fats/Oils Saponification SWING. Fatty Acids and Neutral Fats/oils blend can also be processed. Quick and easy feedstock changeovers from FA to Neutral Fats/Oils thanks to the reduced holding time and the simplified plant design.

Integrated Saponification & Drying PlantsSCT-C, SSCT-CThe Integrated Saponification & Drying Plants «SCT+C» and «SSCT+C» are the ideal solution for producing high quality soap noodles from Fatty Acids (SCT) and/or from Neutral Oils/Fats (SSCT) with a simplified and costs effective technology.The liquid soap is directly fed from the tubular reactor to the dryer, producing all types of laundry and toilet soap noodles at the required final TFM content with a remarkable energy saving.

Universal Saponification LoopThe newest Universal Saponification Loop allows producing liquid soap having TFM 55-71% with consequent negligible steam and electric power consumption.

Soap

Vacuum DryersCL-LBCLaundry Soap DryersCombined laundry soap dryers and finishing lines with electronic cutters and synchronized engraving rolls on two/four sides.

CToilet Soap EcodryersToilet soap Ecodryers allowing remarkable steam savings, higher performances, reduced fines formations through the innovative technical solutions of the Vapour Liquid Separator (VLS) and Indirect Condensation System (ICS).

VLSThe VLS pre evaporation system allows important energy saving: the steam liberated can be used to pre-heat raw materials, drive the booster of the vacuum plant, pre-heat the liquid soap before the heat exchanger of the dryer.

NO-Spray Vacuum ChambersInnovative ‘NO-SPAY’ Vacuum Chambers for laundry and toilet soap drying: thanks to the special tangential injection system of the liquid soap, the new vacuum chambers permit reduced fines formation (50% less than conventional atomizers), simplified operations (no nozzles, no seals for soap) and reduced maintenance.

Finishing LinesLTCToilet Soap Finishing LinesLTC conventional toilet soap finishing lines are available in several configurations to match any requirement of the most sophisticated soap maker.

Line’s capacities from 250 up to 5/6,000 kg/h are available, including:

• Dosing systems for chips and minor ingredients;• Mixers & Amalgamators• Refiners & Plodders,• Roll mills• Cutters• Stampers

LTC-MRPToilet Soap Finishing with Multi-Refining PloddersLTC-MRP innovative soap finishing lines including the Multi-Refining Plodder, a «one machine finishing line» for homogenizing, refining and extruding toilet soap (regular opaque, translucent, syndet and combo).

Integrated Packaging SolutionsThe new DTS «One Touch» Direct Transfer System can be mounted on medium and high-speed presses for the synchronized discharge of the stamped tablets into the pocketed belt of the packaging machines. The integration between the press and the packaging machine (wrapper, cartoner, flowpack) grants higher speeds and more efficient lines production.

Newest ULTRA-HIGH SPEED finishing lines with effective production of 700 bpm integrated with ACMA wrappers and cartoners via DTS Direct Transfer System.

Mazzoni can supply complete end of line solution including the packaging section machinery (wrappers, cartoners, flow-pack, case packers, bundlers, palletizes, etc)

Soap

Special ProductsInnovative solutions to match the sophisticated exigencies of a market in constant evolution are continuously developped by Mazzoni:

• Marbleized Soap• Translucent Soap• Syndet and Combo Bars

Marbleized SoapsA wide range of solutions to obtain marbleizing effects on soap bars are available:

• Liquid Solid• Solid Solid• Two Tones Bars

Translucent SoapsSpecial Multi-Purpose finishing lines (Multi-Refining Plodder) to produce translucent soap bars starting from additivated soap bases and from regular opaque soap bases.

Syndet & Combo BarsSpecial Finishing Lines to produce syndet and combo bars with cost effective solutions.

Laundry SoapsInnovative solutions to produce laundry bars with centered logo engravings on 2 and 4 faces.

RBL RIM BlocksCompact and versatile solutions for rim blocks manufacture. Rim blocks perform the following activities on toilet waters:

• Germs killing• Refreshing• Anti-limescale

Rim blocks process plants can be designed for in line neutralization of the active matter and automatic addition of the minor ingredients of for the simple mixing of the ready neutralized active matter with minor ingredients.

Several solutions are available depending on the type of the rim block and the capacity of the line:

• Twin-worm extruders for single colour rim blocks• Special twin-worm co-extruders for two colours rim blocks

Special dosing system for rim block gel injection/coating are available for sophisticated formulas and shapes.

Packaging

MLB-250 & MLB-500 FlowpackMLB-250 and MLB-500 Flowpack machines specially developed for toilet and laundry soaps packaging: the unique expertise in soap field has allowed adopting the best solutions for a smooth handling of the soap tablets at speed up to 500 bpm so achieving an increased efficiency of the soap lines and better quality of the soap packed.

MLB-500 and MLB-250 are available in two configurations:- Belts timing system when the Flowpack is supplied as stand-alone machine downstream of a

press or an embossing cutter. - DTS timing system when the Flowpack are integrated with the soap press through a Direct

Transfer System to pitch discharge the stamped tablets into the pocketed belt of the Flowpack, extended into the press frame.

Flowpack special systems are available for:- Multipack wrapping- String wrapping- Soap in a box wrapping

Integrated End of LineIntegrated end of line system including STUR-8, STUR-12, STUR-ULTRA 180 and STUR- ULTRA 140 Presses with «DTS» Direct Transfer System for the direct transfer of the stamped tablets into the pocketed belt of the packaging machines (flowpack, cartoners, wrappers).

Unprecedent speeds achievable with our DTS System: - 700 bpm paper wrapped tablets - 700 bpm carton box - 500 bpm flowpacked tablets

Waste Water Steam GenerationAutomation

Automation

Industry 4.0 approachPlants and lines are approached in full compliance with the Industry 4.0 model: data collection and storage, data driven algorithms allow maximum optimization of operation, maintenance, power consumption, total life-cycle cost.Advanced control and estimation techniques such as fuzzy logic and model-based automation are employed.Advanced user interfaces as Augmented Reality are also available.

Fully integrated automation systemA fully integrated automation architecture, based on a real-time Ethernet data highway, grants a high-speed, high-data-throughput connection between PLCs and sensor/actuators, between all machines in the line, and between the line and upper levels of automation and ICT systems.

Open environment All levels of automation higher than the machine control levels (line management stations, line supervisors, data acquisition and storage, etc.) are developed in open environments (Windows™; TCP/IP; LabView™,…), so that modifications and implementation of further functions are easy and modular, and connection to other systems is immediate and reliable.

Operator guidanceA rich set of operator guidance functions is implemented in the automation system: online machine manuals, maintenance/setup video tutorials, assisted/automatized configuration, etc.

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Research & Development

Research & Development

Our process technology responds to changes in the economic, technical and environmental needs of our customers.Our plants and machinery undergo continuous upgrading to incorporate the most recent innovation available so to allow smooth operations at competitive manufacturing costs

Customized R&D

Mazzoni LB Group invests more than 5% of its annual turnover in an impressive, strong R&D program to support its activities in soaps, detergents and surfactants, process plants and machinery.

R&D Programs

An ambitious cooperation program with the Engineering Departments of the Universities of Milan and Parma is in place to assist our internal R&D group.

Pilot Plants & Laboratory

Pilot plants and laboratory have been implemented in our premises to conduct laboratory and full scale trials. A dedicated team of chemists and process engineers work full time to support our engineering departments to develop new and more performing technologies. Our Pilot Plants and Laboratory are at Customers disposal to conduct tests on raw materials, intermediate and finished products.

Trial Plant Facility

A Trial Plant Facility is available to conduct FAT tests on complete finishing lines of any capacity. The location allows also joint trials with packaging machines such as flowpack, wrappers, cartoners and bundlers.

Full scale Mixer, Multi-refining Plodder and Cutter with capacities up to 5000 kg are available to test customers soap bases of any kind ‘soap, detergent, combo) as well as end of lines including soap presses and packaging machinery.

Complete ProjectsCustomer Service

Project Financing

Project financing schemes are implemented on the basis of specific Customer’s requirements.

Non-process/auxiliaries

Mazzoni can provide its engineering and commercial assistance for the supply non/auxiliary systems including:

• Water cooling systems• Steam boilers• Compressed air production• Electric power transformation and generation• Reception facilities• Raw material storage

Customer Service Online

Field Engineers• Assistance to erection• Assistance to start-up

Training Sessions

Process Optimisation

Preventive Maintenance

Processes UpgradesA special on-line service to assist our customers during the various phases of their project, providing continuous assistance by a qualified team of specialists.

Spare Parts Service Online

70 years archive with records of all supplied equipment

Technical know-how

Fast answers

Competitive supply of spare parts

Thorough knowledge of all projects

Quality of equipment and services

A special on-line service to assist our customers during the normal run of their plants providing quick and reliable answers to their day by day needs.

Recondioned Second Hand Equipment

The recent creation of the Second Hand Machinery Division allows to offer Mazzoni fully refurbished machinery to our customers permitting important capital outlay savings.

We can supply individual refurbished machines, complete refurbished finishing lines and combined finishing lines composed with second hand / new machinery so to cover all market requirements .

Machines are fully refurbished with original Mazzoni spare parts, 6 months guarantee apply on refurbished machinery.

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Hull

Busto Arsizio

Wailly

ParisMilanAtlanta

Mexico

Bogota

Lima

Sao Paulo

Buenos Aires

Moscow

MadridIstanbul

Kuala Lumpur

Shanghai

BangaloreSingapore

Surabaya

Brussels

Rome

The Desmet Ballestra Group

Worldwide close to you

Dubai

Nairobi

Science behind Technology

w w w . d e s m e t b a l l e s t r a . c o m

Soap