2 T/h Fully Automatic Heated Liquid Detergent Turnkey EPC Plant in Congo

Location: Congo | Capacity: 2 t/h | Process: Heated | Control: Fully Automatic
Cost-Down Focus: Fuel cost • Labor • Rework rate

A detergent manufacturer in Congo required a 2 t/h liquid detergent production line with heating, delivered on a turnkey EPC basis. The key target was lower total operating cost (OPEX) while maintaining stable product quality, with measurable improvements in fuel consumption, labor efficiency, and rework rate.

• Heating-driven OPEX: fuel cost is a major expense in heated processes
• Batch consistency: viscosity/homogeneity fluctuations lead to rework and raw material loss
• Labor reliance: semi-manual operation increases labor cost and deviation risk
• Typical market solutions often over-size heating/mixing, increasing long-term OPEX

Water treatment → hot/soft water preparation → raw material storage → solid material pre-dissolving → buffering/holding → main proportioning & mixing (heated) → cooling/settling (defoaming) → filtration → finished product storage → filling & packing.

1) Heating System Optimization (Fuel Cost Reduction)

• Right-sized heating based on actual batch demand and target temperature
• Tank and pipeline insulation to reduce heat loss
• Temperature control strategy to avoid overheating and repeated heating cycles
• Reduced heating time through optimized sequence and heat transfer design
• Result: lower fuel OPEX vs typical baseline heated configurations (optional: X–Y%)

2) Quality Stability Design (Less Rework)

• Dedicated pre-dissolving for solids to reduce undissolved particles
• Optimized dosing order and mixing control for stable viscosity and homogeneity
• Settling/defoaming + filtration to reduce bubbles and defects

Result: lower rework rate and fewer out-of-spec batches (optional: X–Y%)

3) Fully Automatic Control (Lower Labor, Higher Repeatability)

• Full automatic PLC control with recipe management for dosing, heating, mixing, transfer, filtration, and filling coordination
• Automatic sequencing reduces manual errors and operator dependency
• Interlocks/alarms protect quality and equipment, preventing deviation and reprocessing

Result: reduced labor input per shift and more consistent quality vs semi-manual supplier solutions

4) EPC Delivery & Lifecycle Support (Lower Total Cost of Ownership)
Consulting, engineering design, manufacturing, installation, commissioning and training-plus long-term spare parts and maintenance support.

Lower fuel cost from optimized heating and reduced heat loss

Lower labor cost enabled by fully automatic operation

Lower rework rate due to consistent batching, controlled heating, defoaming and filtration

Faster ramp-up through turnkey EPC delivery and on-site commissioning support

"The line runs stably with consistent quality across shifts. Compared with the options we evaluated, the long-term operating cost is more favorable, and commissioning/training was efficient."

Planning a fully automatic heated liquid detergent line (2 t/h or customized)?

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