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ALPLA, a factory in Silvassa, Dadra & Nagar Haveli, supplies Hindustan Unilever Ltd. (HUL) with soaps, shower gels, and toothpaste. The company ran into a big problem with its toothpaste production line.

Introduction

Efficiency is the backbone of any manufacturing industry, and toothpaste production is no exception. Downtime, product wastage, and cleaning inefficiencies can lead to major operational challenges, affecting both productivity and profitability. At IUS Equipment Pvt. Ltd., we specialize in providing advanced pigging systems that help manufacturers overcome these issues effectively.

This case study highlights how our pigging system transformed the production process for a leading toothpaste manufacturer, solving critical problems related to product waste, pipeline blockages, and cleaning time.

The Challenge: Frequent Production Disruptions

Toothpaste manufacturing involves handling high-viscosity materials that require precise filling mechanisms. However, ALPHA faced severe difficulties in their production line due to the nature of their product.

Key Problems Faced:

ALPLA makes toothpaste. The thickness of the toothpaste caused major issues when filling tube containers. The automatic filling machine often stopped because of toothpaste built up in the pipes. When the product touches air, it gets hard and blocks the pipes.

1. Frequent Pipeline Clogging
   • Toothpaste is thick and sticky, leading to frequent accumulation inside the pipes.
   • This resulted in repeated clogging, affecting the automatic filling machines.
2. Production Stoppages
   • Every time a blockage occurred, the production line had to be stopped for cleaning and maintenance.
   • These stoppages significantly reduced overall output and efficiency.
3. Product Waste
   • Due to product build-up in the pipelines, a substantial amount of toothpaste was lost during each batch.
   • On an average, 20 tubes per batch were wasted due to unutilized residue inside the pipes.
4. Extended Cleaning Time
   • The cleaning process took around 4-5 hours per batch, leading to prolonged downtime between productions.
   • This increased operational costs and decreased overall productivity.

The company needed a smart and efficient solution to address these challenges without compromising product quality.

The Solution: Implementing an Advanced Pigging System

To tackle these issues, our team at IUS Equipment Pvt. Ltd. set up a special pigging system for ALPLA. This system helped the company in recovering the leftover toothpaste from the pipeline before Clean-In-Place (CIP) in a good way.

Our experts at IUS Equipment Pvt. Ltd. introduced a state-of-the-art pigging system customized for toothpaste manufacturing. Pigging technology involves using a specialized projectile, known as a pig, that moves through the pipeline, pushing out residual product before the cleaning process begins.

How the Pigging System Works:

1. Product Recovery:
   • The pig effectively recovers up to 95% of toothpaste left in the pipelines, reducing product loss to nearly zero.
2. Minimized Downtime:
   • By preventing blockages and reducing the need for frequent deep cleaning, production stoppages were significantly cut down.
3. Reduced Cleaning Time (CIP Optimization):
   • Since the pig removes most of the residual toothpaste, CIP cycles become shorter and more efficient.
4. Lower Operational Costs:
   • With less downtime, reduced wastage, and improved efficiency, the manufacturing plant saw a noticeable cost reduction in daily operations.

The Impact: Significant Improvements in Production

The implementation of the pigging system resulted in tangible benefits for the toothpaste manufacturer:

• 95% Product Recovery: Less raw material wasted, leading to higher profitability.
• Reduced Downtime: More production time available, resulting in higher output per day.
• Optimized CIP Process: Cleaning time was cut in half, allowing faster batch transitions.
• Cost Savings: Lower waste and downtime translated into substantial cost reductions over time.

Why Choose Pigging for Your Toothpaste Manufacturing?

If you are in the toothpaste manufacturing industry, a pigging system can be a game-changer for your operations. Here’s why:

• Improved Efficiency: Less downtime means smoother, uninterrupted production.
• Eco-Friendly Production: Reduced waste leads to sustainable manufacturing practices.
• Better ROI: Recovering more product ensures maximum yield from raw materials.
• Faster Cleaning Cycles: Shorter CIP processes save time and reduce labor costs.

Conclusion

At IUS Equipment Pvt. Ltd., we pride ourselves on offering cutting-edge pigging solutions tailored to the needs of toothpaste manufacturers. Our expertise in handling complex production challenges ensures that manufacturers achieve higher efficiency, reduced costs, and improved sustainability.

If you’re looking to boost productivity and minimize waste in your toothpaste manufacturing process, get in touch with us today. Let us help you transform your production line with our advanced pigging systems!