TECHNICAL SPECIFICATION 2861.98088.31 Vacuum Production Mixer for Shampoo, Lotions and low-viscous crèmes EKATO UNIMIX SRA 10 000 CONTENT 1 UNIMIX Production-Mixer Type SRA 10 000... 2 1.1 EKATO PARAVISC -Agitator... 4 1.2 Bowl... 5 1.3 UNIMIX homogenizer S-JET 2500... 6 1.4 Electrical control device... 8 2 Documentation... 9 3 Utilities to be provided on site... 10 4 Exclusions (Not included in scope of supply)... 10 5 Accessories... 11 5.1 Draw-in-execution #1 of Homogenizer... 11 5.2 Draw-in-execution #2 of Homogenizer... 11 5.3 Draw-in-execution #3 into vessel bottom... 11 5.4 CIP cleaning system of production vessel... 12 5.5 Vacuum producing aggregate... 13 5.6 Heating / Cooling unit for the production mixer... 13 5.7 DI water dosing via flow meter and tap-water connection... 14 5.8 Dosing tank 40 l... 14 5.9 Second operator panel (HMI)... 14 5.10 Recommended Spare Part Kit for UNIMIX SRA... 15 5.11 Pre-mix vessel for fat phase F2000... 16 5.12 Spare Part Kit for UNIMIX F... 19 6 Quality assurance (QA)... 20 6.1 Design-Qualification (DQ)... 20 6.2 Factory Acceptance Test (FAT) at EKATO-SYSTEMS... 20 6.3 Supervisor Installation... 20 6.4 Start up (on site)... 20 6.5 Site Acceptance Test (SAT)... 21 6.6 Training of operating personnel... 21 6.7 Process training:... 21 7 Packing, Transportation... 21 8 Appendix... 22 83818-Belcorp-Unimix-SRA10000-2861.98088.31-Tecspec Page 1 of 22
1 UNIMIX Production-Mixer Type SRA 10 000 Lid execution: Product viscosity max: (appearing viscosity at the agitator) Product density max: Working volume: Min. volume of operation: (depending on viscosity) Min. batch volume: SRA (flanged lid) 20.000 mpas 1.000 kg/m³ 10.000 litres 500 litres 2500 litres Geometry and performance of PARAVISC agitator, S-JET homogenizer, recirculation pipe, vessel etc. are according to BELCORP s existing UNIMIX machines. 100% scale-up and repeatability to existing formulas and processes is provided. Logotipo Belcorp Service voltage Three phase current 440 V 60 Hz, 3-phase A/C Execution Vessel In vertical execution, with welded- on double jacket with built-in guide gills for fluid and gaseous mediums. Against losses of heat the bowl is equipped with insulation made of rock wool and a tightly welded insulation jacket made of stainless steel. Admissible vessel pressure Product vessel: 0...3 bar abs., 133 C Double jacket: 0...5 bar abs., 151 C Design, calculation material selection and production conform to Pressure Equipment Directive PED, 97/23 EG category III, designed to contain fluids Group 2 (not combustible, not corrosive, not poisonous, not explosive). Notified body: German TÜV. The vessel is mounted on 3 legs standing on the floor. Dimension U-frame (approx.): 2984x2984 mm For operation, a platform is necessary (not included in the scope of supply). 83818-Belcorp-Unimix-SRA10000-2861.98088.31-Tecspec Page 2 of 22
Materials Product contacted parts: Stainless Steel 1.4404 (AISI 316 L) Cooling jacket: Stainless Steel 1.4301 (AISI 304) Insulation jacket: Stainless Steel 1.4301 (AISI 304) Product contacted seals: Viton Piping and fittings Product contacted parts: Corresponding to DIN 11850/R2 (tube connections DIN 11851/11864/32676) Heating and cooling unit: Corresponding to DIN EN ISO 1127 (tube connections DIN 2501) Surface treatment of the vessel Machine inside: Product contacted machine parts of vessel ground Ra 0,8 µm Lid, baffle and agitator ground/polished Ra 0,4 µm Machine outside: Cylindrical part of the vessel ground Ra 0,8 µm Bottom and lid ground Ra 0,8 µm Welding seams ground, pickled and passivated Agitator and homogenizer drive blasted and provided with a prime and body coat. Colour according to RAL 9002. 83818-Belcorp-Unimix-SRA10000-2861.98088.31-Tecspec Page 3 of 22
1.1 EKATO PARAVISC -Agitator Consisting of agitating tool, shaft, bevel gear reducer and motor. Design: EKATO patented Z-type PARAVISC Design without screws in the product wetted area (according to cgmp, pharmaceutical standard). Due to the PARAVISC design the production mixer is suited for a wide range of viscosities. It guarantees an extremely good vertical mixing. By means of the continuous movement of the product along the wall, short cooling times are achieved. Due to reduced surface area remain consequently less product residues. The PARAVISC has no additional mixing blades, the product room is free of obstacles. This allows for best and quick de-aeration of the product. All UNIMIX units at BELCORP are equipped with the PARAVISC agitator. This allows for achieving very homogeneous product in the complete batch volume and to scale-up heating-cooling and mixing times as well as energy input. Logotipo Belcorp Machine model: SRA 10 000 Power of PARAVISC agitator (up to 20.000 mpas): 30 kw rpm of mixing tool (cw, ccw, reverse mode): 4 22 min -1 Rpm of mixing tool step-less controlled by a frequency converter incl. reverse operation mode. Shaft sealing Sealing of the agitator shaft by a 4-fold set of sealing rings. Scraping system Material of construction for product bowl scrapers is PTFE. Design is the EKATO UNIMIX bi-directional pivot-type. For the installation and de-installation of these scrapers no stainless steel safety ring and no screw is needed. The scraper is fixed by a single bolt. Axial forces are absorbed by the scraper support. 83818-Belcorp-Unimix-SRA10000-2861.98088.31-Tecspec Page 4 of 22
1.2 Bowl Lid Domed construction, provided with the following ports and connections: 1x PARAVISC agitator 450x50 1x Baffle with temperature sensor 1x Hand- / manhole DN 500 1x Sight glass with double wiper DN 150 DIN 28120 1x Sight glass lamp with timer DN 100 DIN 11851 4x Stud for CIP DN 50 DIN 11864 1x Stud (e.g. for dosing funnel) DN 32 DIN 11864 1x Stud (spare) DN50 DIN 11865 1x Pressure indicator -1... 2 bar g with transmitter (4... 20 ma) DN 50 DIN 11864 1x Vacuum (with el.-pn. operated valve and limit switch) DN 65 DIN 11864 1x Venting (with el.-pn. operated valve and limit switch, filter not DN 40 DIN 11864 included) 1x Compressed air / nitrogen (with el.-pn. operated valve and DN 25 DIN 11864 limit switch, filter not included) 1x Safety valve and over pressure protection DN 40 DIN 11865 Vessel wall Cylindrical, with guide gills and insulation, provided with the following ports and connections: 1x Recirculation pipe (above insulation) DN 150 DIN 11864 1x Recirculation pipe (through insulation) DN 150 DIN 11864 1x Pressure release of double jacket (for each zone) G 3/8" ISO 228 1x Cable conduit through insulation 1x Vacuum pipe through insulation Bottom Domed construction, provided with the following ports and connections: 1x S-JET homogenizer 475x51 1x Bottom draw-in DN 65 SUEDMO 1x Heating / cooling fluid inlet DN 80 DIN 2633 1x Heating / cooling fluid outlet DN 80 DIN 2633 1x Temperatur measuring (see below) Temperature measuring (2x) Product temperature measuring device Pt 100. Range: 0... +150 C Position 1): Position 2): in baffle in bottom (to ensure proper measurement of small filling volumes, located in homogeniser inlet, enabling complete scraping of the bottom) 1) 2) 83818-Belcorp-Unimix-SRA10000-2861.98088.31-Tecspec Page 5 of 22
1.3 UNIMIX homogenizer S-JET 2500 cgmp conform high performance homogenizer, designed for applications in pharmaceutical production. According to the rotor / stator principle, located centrically at the bottom of the vessel. Homogenizer model: S-JET 2500 Power (up to 20.000 mpas): 55 kw Speed of homogenizer: 500... 1800 min -1 infinitely variable speed (within the specified range) controlled by frequency inverter. Controlled BTO numbers (Batch Turn Over), assuring repeatability of product quality and production times, avoiding overheating or breaking of the emulsion. The BTO concept allows for safe scale-up of the homogenizing time between all UNIMIX units at BELCORP, with the same results in droplet size, droplet size distribution, viscosity, texture, distribution of colour, pigments etc. Logotipo Belcorp The homogenizer is adjustable and can work in 2 positions: 100% internal or 100% external: 1) INTERNAL: The product will be homogenized inside the vessel, reentry below the product level, radial in parallel to the vessel bottom 2) EXTERNAL: The product is homogenized and pumped via external circulation pipe into the upper part of the vessel, re-entry above the product level By operating the respective valves in the circulating pipe the vessel contents can be discharged. In both operation modes liquids and solids can be drawn in directly into the rotor-stator system. 83818-Belcorp-Unimix-SRA10000-2861.98088.31-Tecspec Page 6 of 22
Pressure execution of homogenizer The homogenizer develops a discharge pressure (up to 3 bar) which can be used to discharge high viscous finished product. When this feature is used with a CIP system the result is shorter cleaning cycles and enhanced cleaning efficiency. Shaft sealing Shaft sealing of the homogenizer is accomplished with a double acting mechanical seal. Mechanical seal faces: Product contacted: SiC / SiC / Viton Atmospheric contacted: SiC / SiC / Viton The seal rings are cooled and lubricated by a mixture of glycerine / water, white oil, etc. The mechanical seal assembly is designed to promote circulation of the cooling and lubricating fluid through a compensation tank. The compensation tank is equipped with: pressure gauge with two limit contacts (low and high) two level contacts (low actuating alarm and low/ low stopping homogenizer) pressure relief safety valve cooling coil built into compensation tank, including valve to open/close the cooling water valve during homogeniser operation (water saving) Circulation pipe Circulation pipe with electro-pneumatically operated butterfly valves suitable for either external circulating or discharging of the product. Incl. 1x manual sample valve, mounted in the vertical part of the circulation pipe. The sample valve can be flushed with water (even during production). Not included in CIP-circuit. UNIMIX Production-Mixer Type SRA 10 000 Number of re-entries (above maximum filling level): 1 Number of re-entries (above 50% filling level): 1 83818-Belcorp-Unimix-SRA10000-2861.98088.31-Tecspec Page 7 of 22
1.4 Electrical control device consisting of Master Control Cabinet (MCC) electrically wired and equipped with all terminal strips, relays, safety devices, PLC etc., with: Main power disconnect (lockout) Power supply: 3 phase AC 440 V 60 Hz Control voltage 24 V DC Frequency inverter for PARAVISC agitator Frequency inverter for S-JET homogenizer Frequency inverter for vacuum pump PLC is SIEMENS S7 Material: epoxy coated carbon steel Incl. cooling of the control cabinet Operator Panel (HMI) x2 Made from Stainless Steel, IP69K (inclined top side), including two (2x) separate 15 touch-panels (IP65) incl. visualization acc. to the existing UNIMIX machines at BELCORP. Position: Between both manholes and close to draw-in valves (see layout). The automation allows for a comfortable and safe operation of the equipment. The following process parameters and machine functions are selected from the operator panel: SRA production mixer: Homogenizer on / off / speed / operating time Homogenizer internal / external (S-JET -Homogenizer) Draw-in function Agitator on / off / speed / direction (left-right) / operating time Discharge Vessel light CIP Heating and cooling (3 zones) Pressure/Vacuum/Venting F premix vessel: See F premix vessel. Single process parameters can be protected with a password. Separate controls incorporated in the Operator Panel Control power on / off Emergency stop (mushroom style push button) All alarms will be displayed on the operator interface terminal. Material: Stainless steel. Cables between master control cabinet and operator panel (included) approx.: 30 m ATEX-Conformity / Explosion-proof execution Not considered. Remark: The machine will be installed at approx. 2.600 m above sea level. 83818-Belcorp-Unimix-SRA10000-2861.98088.31-Tecspec Page 8 of 22
Remote control TS-adapter (with included modem) for remote automation maintenance by EKATO SYSTEMS. Direct analogue telephone connection to be provided by the customer. To be connected temporarily to provide fast and direct technical assistance, service and program modification. 2 Documentation Scope according to previously supplied machines to BELCORP with additional translations: 1 set in paper form, 1x on CD in English/Spanish, including: 1 operator manual (Spanish) 1 functional description (Spanish) 1 list of components (Spanish) 1 drawings / spare parts list of EKATO SYSTEMS (English) 1 maintenance check list (Spanish) 1 lubricants and coolants (English) 1 electrical wiring diagram (English) 1 sub-supplier documentation (English; in Spanish if available from sub-supplier) 1 certificates for product contacting parts and seals acc. to EN 10204-2.1 (English) 1 protocols DQ (English) / FAT / SAT ( Spanish) 1 calibration protocols (English) 1 surface protocols (English) 1 passivation protocols ( Spanish) 1 IQ / OQ (scope acc. to EKATO standard, Spanish) 1 TÜV-documents of vessel, lid and safety valve (English) Additionally for the production vessel: 1x welder certificates 1x certificates of non-destructive testing of selected welding seams (double jacket and homogenizer flange) Logotipo Belcorp 83818-Belcorp-Unimix-SRA10000-2861.98088.31-Tecspec Page 9 of 22
3 Utilities to be provided on site Electrical power supply (440 V, 60 Hz, 3-phase A/C) Compressed air (min. 7 bar abs, dry, oil free), with service valve Process water, with service valve Cooling water: max. admissible pressure 4 bar abs, with service valve Steam or heating water, max. admissible pressure 5 bar abs, with service valve 4 Exclusions (Not included in scope of supply) Connection of cooling water and steam to heating / cooling unit Connection of cooling water and condensate from heating / cooling unit Piping between heating / cooling unit and vessel Connection of water-feed to vacuum pump Connection of exhaust from vacuum pump Piping between vacuum pump and vessel Connection of compressed air to compressed air supply Power supply to main control cabinet Cable trays Wall-, floor- and ceiling passages Insulation of the complete piping system Crane and/or forklift incl. staff to transport equipment from truck to final location Welding materials/gases Disposal of packing materials Workshop room Operator platform Dosing function for raw materials, DI-water etc. or signal exchange with customers utilities supply line or filling machine (if not specifically mentioned) Air or product filter (if not specifically mentioned) Any not mentioned item 83818-Belcorp-Unimix-SRA10000-2861.98088.31-Tecspec Page 10 of 22
5 Accessories 5.1 Draw-in-execution #1 of Homogenizer A port with a gap free butterfly intake valve (with variable opening angle, oscillating between 2 programmable positions during suction), will be provided directly to the aspirating mouth of the homogenizer. For easy introduction of powdery materials (emulsifiers, thickeners) directly into the inlet of the rotor/stator section of the homogenizer. Lump formation and agglomeration are avoided due to immediate dispersion with the product in the vessel after induction. 5.2 Draw-in-execution #2 of Homogenizer A second draw-in valve, identically to the previous position will be supplied for suction in of liquids, transfer of fat phase etc. This feature provides the possibility to run HOT/COLD-processes. Homogenizer model and size: S-JET 2500 Diameter of draw-in valve #1: DN 65 Diameter of draw-in valve #2: DN 65 5.3 Draw-in-execution #3 into vessel bottom A draw-in valve located in the vessel bottom. For solid raw materials like crushed apricot kernels, almond shells etc. for exfoliation products, abrasive skin cleanser etc., or liquids for shampoos or lotions. UNIMIX Production-Mixer Type SRA 10 000 Diameter of draw-in valve #3: DN 65 Accessories 5.1, 5.2, 5.3: The control includes an alarm contact set to -200 mbar, assuring that the valves close automatically, when pressure inside vessel should increase about this point. It is excluded that the product can flow backwards into the suction hose. Operation of the intake valves via a radio controlled foot switch. Includes 2 x suction lance with false air supply. The workplace for the 3 draw-in functions is at floor level. 83818-Belcorp-Unimix-SRA10000-2861.98088.31-Tecspec Page 11 of 22
5.4 CIP cleaning system of production vessel Consisting of a set of jets incl. connection ports, suitable to work via homogenizer. Execution of jets: Spray ball type. Incl. one electro-pneumatically operated butterfly valve in the circulating line. No necessity to dismount parts for cleaning, no necessity for an additional CIP-pump. CIP-sequences are programmed in the PLC. Times can be modified. CIP Manifold Pipe manifold, that allows the automatic cleaning of the raw material inlet ports and valves on the homogenizer (#1 and #2) and in the bottom (#3). After the discharge of the finished product, the operator connects the CIP manifold manually. 83818-Belcorp-Unimix-SRA10000-2861.98088.31-Tecspec Page 12 of 22
5.5 Vacuum producing aggregate Consisting of a water-ring vacuum pump system with motor and electrical control. The suction capacity is designed for safe, quick and comfortable process and operation when solids are drawn-in, cold phases are added or the product is de-aerated. Max. set value acc. to height of 2.600m (approx. -740 mbar). UNIMIX Production-Mixer Type SRA 10 000 Suction capacity at suction pressure of 100 mbar: 400 m³/h Motor vacuum pump (with VFD): 15 kw Included are: Vacuum pump Separator for air / cooling water Cavitation protection pipe Suction site check valve Valve for cooling water inlet Needle valve for adjusting of cooling water volume Check valve to prevent back flow of cooling water Incl. integration into the control system Piping between pump and UNIMIX production mixer not included (to be executed with flexible pipes, when weigh cells are used). Connection to premix vessel: not included. 5.6 Heating / Cooling unit for the production mixer Pneumatically actuated. Mounted on separate skid, for the heating with steam, cooling with water and automatic water discharge, blow-out before both heating and cooling. Consisting of: 1 digital temperature controller (included in PLC) 1 valve with el.-pn. actuator for steam DN 80 1 valve with el.-pn. actuator for condensate DN 40 1 steam trap 1 valve with el.-pn. actuator for cooling water inlet. DN 80 1 valve with el.-pn. actuator for cooling water outlet DN 80 1 valve for air DN 25 1 valve with el.-pn. actuator for water discharge DN 80 1 safety valve Incl.: Three (x3)-zone heating Three-zone heating-cooling of 25%, 50% or 100% of the bowl of the manufacturing vessel. Incl.: 6 el.-pn. operated valves for selection of 1 / 2 / 3 zones Piping between the rack and the UNIMIX production mixer not included (to be executed with flexible pipes, when weigh cells are used) Counter-flanges to be delivered by EKATO. 83818-Belcorp-Unimix-SRA10000-2861.98088.31-Tecspec Page 13 of 22
5.7 DI water dosing via flow meter and tap-water connection DI-water dosing into the production mixer SRA and F premix vessel. Coriolis mass flow meter type Siemens Sitrans, nominal diameter DN 40. Butterfly-valve with variable opening angle in order to reduce recoil in customers loop when closing the valve 2 diaphragm valves behind the butterfly-valve (diameter to be defined) 2 diaphragm valves on each upper CIP-pipe (SRA and F) 1 butterfly-valve in each upper CIP-pipe to avoid backflow Shut-off valve to DI-water loop: Not included, but controlled from OP. Including programming of dosing function into SRA and F vessel and integration into controls. Position of the stud: to be defined (lid, upper CIP-pipe and sprayballs, homogenizer suction valve for liquids or elsewhere). For tap water:1 butterfly valve on each upper CIP-pipe (SRA and F) The tap-water filling is not an automated dosing function. Open/close is controlled via the operator panel (can be time limited to be defined) 5.8 Dosing tank 40 l Executed with cone-shaped bottom, cylindrical vertical part and flat lid, hinged. With hand operated diaphragm valve. 5.9 Second operator panel (HMI) Made from Stainless Steel, IP69K (inclined top side), including one (1x) separate 15 Touch Panel (IP65) for a more ergonomic use of the unit. The second Touch Panel with identical functions and visualization as the first panel (Position to be defined). For operation at ground floor, beam welded on the vessel jacket. During production the panels can be locked between each other. Separate controls incorporated in the second Operator Panel: Emergency stop (mushroom style push button) Alarms will be displayed on the operator interface terminal. Material: Stainless steel. 83818-Belcorp-Unimix-SRA10000-2861.98088.31-Tecspec Page 14 of 22
5.10 Recommended Spare Part Kit for UNIMIX SRA One kit for the above specified UNIMIX SRA production mixer, consisting of 1x Mechanical seal (for homogenizer) 1x Stator (for S-JET homogenizer) 1x Rotor (for S-JET homogenizer) 3 Sets of O-rings 3 Set of o-rings for fittings 3 Set of middle seals for valves 1x Shaft sealing (4 lip seals) for PARAVISC agitator 1x set of scrapers 5x Limit switches 1x proportional valve at homogenizer with actuator Rotor and seal for vacuum pump. Inner mode changing ring (homogenizer) Outer mode changing ring with magnets (homogenizer) 83818-Belcorp-Unimix-SRA10000-2861.98088.31-Tecspec Page 15 of 22
5.11 Pre-mix vessel for fat phase F2000 Execution: Full vacuum rated with CIP Vertical arrangement with EKATO UNIMIX heating jacket, insulation and welded stainless steel outer jacket. With welded lid. The vessel is hanging in the platform on 3 support brackets. Flanges located at the bottom allow for mounting the vessel on 3 legs. Maximum Filling Volume: Minimum Filling Volume: Product viscosity max: (appearing viscosity at the agitator) Product density max: 2000 liters ~ 400 liters up to 6.000 mpas up to 1.000 kg/m³ Design pressure & temperature Product vessel: 0...3 bar abs., 133 C Heating/cooling space: 0...5 bar abs., 151 C Materials of the premix vessel Same as for SRA. Surface treatment of the premix vessel Same as for SRA. Functions of the Premix vessel: The following process parameters and machine functions are selected from the operator panel: Agitator on / off / speed / operating time Draw-in function Discharge and transfer into the S-JET homogenizer of the UNIMIX production mixer Vessel light CIP Heating (2 zones) Pressure/Vacuum/Venting 83818-Belcorp-Unimix-SRA10000-2861.98088.31-Tecspec Page 16 of 22
Connections Lid Domed construction, provided with the following ports and connections: 1x Flange for agitator DIN 1092-1 DN 200 1x Manhole -/- DN 500 1x Sight glass with double wiper DIN 28120 DN 150 1x Sight glass lamp with timer DIN 11851 DN 100 2x Stud for CIP DIN 11864 DN 25 1x Stud (spare) DIN 11865 DN 50 Removable multi-port manifold with incorporating washing head, for: 1x Pressure indicator -1... 2 bar g with transmitter (4... 20 ma) DIN 11864 DN 50 1x Vacuum (with el.-pn. operated valve and limit switch) DIN 11864 DN 50 1x Venting (with el.-pn. operated valve and limit switch, filter not DIN 11864 DN 25 included) 1x Compressed air / nitrogen (with el.-pn. operated valve and DIN 11864 DN 25 limit switch, filter not included) 1x Safety valve and over pressure protection DIN 11865 DN 40 Vessel wall Cylindrical, with guide gills and insulation, provided with the following ports and connections: 1x Cable conduit through insulation 1x Vacuum pipe through insulation 1x Pressure release of double jacket (for each zone) ISO 228 Bottom Domed construction, provided with the following ports and connections: 1x El.-pn. valve for discharge and transfer to SRA and CIP DIN 11864 DN 65 1x Bottom draw-in SUEDMO DN 40 1x Heating fluid inlet DIN 2633 DN 50 1x Heating fluid outlet DIN 2633 DN 50 1x Flange/connection for temperature measuring (see below) Temperature measuring Measurement Range: 0 to +150ºC Location: One (1) temperature indicator (dual Pt 100 element) will be built into the bottom of the vessel 83818-Belcorp-Unimix-SRA10000-2861.98088.31-Tecspec Page 17 of 22
Mizer Agitator Consisting of agitating tool and motor. Execution: Axial dissolver type "EKATO Mizer Position : top-mounted, ex-centrically UNIMIX Premix Vessel Type F 2000 Power (variable speed via VFD): 5,5 kw In the same shaft, an EKATO pitched blade impeller agitator is arranged above the mizer agitator in order to assure a better vertical flow. Product contacted materials Agitator shaft: Stainless Steel 1.4462 Mounting flange, impeller: Stainless Steel 1.4301/1.4571 Surface treatment ground/polished Ra 0,4 µm Shaft sealing Sealing of the agitator shaft by a 4-fold set of sealing rings. CIP cleaning system of fat-premix vessel Consisting of a set of jets incl. connection ports, suitable to work with a separate CIP booster pump (included). Execution of jets: Spray ball type. Incl. 2 el.-pn. operated butterfly valves. Heating of the pre- phase vessel (Remark: 2 zones) Mounted on the vessel. Heating with steam. Consisting of the following: 1 digital temperature controller (included in PLC) 1 valve with electro-pneumatic actuator for steam DN 50 1 steam trap 1 safety valve 3 el.-pn. operated valves for selection of 1 / 2 zones 83818-Belcorp-Unimix-SRA10000-2861.98088.31-Tecspec Page 18 of 22
Transfer Piping from premix vessel to production tank Transfer from the bottom of the premix vessel directly into the draw-in valve for liquids of the homogenizer of the production vessel, enabling HOT/COLD-processes, assuring short pipe lengths and therefore minimizing product losses. The transfer is a automatic function, with el.-pn. operated valves with limit switches. Vacuum aided transfer (allowing for positive pressure on premix vessel as well). One fat phase filter (mesh 200 µm) to be delivered. Neither isolation nor electrical heating of the transfer pipe are included. CIP of the transfer pipe via CIP-pump. The F premix-vessel and the SRA production vessel can be CIPed independently from each other. Vacuum pump connection to the premix vessel The premix vessel is provided with a el.-pn. valve for the connection to the vacuum pump (piping included inside the skid borders), allowing for the draw-in of raw materials, de-aeration and quick drying of the equipment. Bottom mounted draw-in valve Suitable for the sub-surface introduction of solids and liquids. Controls and Operation like Homogenizer valves. Included: CIP-manifold. Suction lance not included. 5.12 Spare Part Kit for UNIMIX F One kit for the above specified UNIMIX F premix vessel, consisting of: 4x lip seals (for agitator) 3 Sets of O-rings 3 Set of o-rings for fittings 3 Set of middle seals for valves 3x Limit switches 83818-Belcorp-Unimix-SRA10000-2861.98088.31-Tecspec Page 19 of 22
6 Quality assurance (QA) Included times for QA according to Order Confirmation. 6.1 Design-Qualification (DQ) The following documents will be checked internally and confirmed/signed by the customer P&ID and Technical Specification Unit layout and alignment 6.2 Factory Acceptance Test (FAT) at EKATO-SYSTEMS The equipment will be checked by the customer/user during FIQ and FOQ before shipment. Included time: See OC. Factory Installation Qualification (FIQ) The following tests will be carried out and recorded Coincidence of installation and P&ID Identification of the components Completeness of scope of supply Coincidence of installation and specification Coincidence of instrumentation installation and design of the measuring and control instruments Coincidence of electrical installation and electrical hardware Factory Operation Qualification (FOQ) The following test will be carried out and recorded: Function of all components (vacuum, agitator, homogeniser etc.) with calibrated measuring instruments Check unit tightness and discharge ability Check of signals of all components Check interaction of controls and function of the unit (demonstration with water) no product test Protocol of FOQ 6.3 Supervisor Installation Installation of the equipment in production area Crane and/or forklift incl. staff to unload and transport equipment from truck to final location and erection is provided by others, the supervision (mechanical and electrical) of complete installation is done by EKATO. Included time: See OC. 6.4 Start up (on site) Consists of: Functional test with water Setting of response times and observation intervals Optimisation of parameter settings Optimisation of parameter limits Optimisation of process conditions Included time: See OC. 83818-Belcorp-Unimix-SRA10000-2861.98088.31-Tecspec Page 20 of 22
6.5 Site Acceptance Test (SAT) The approval of the unit and their performance will be given by the customer/user after successful tests according to FIQ and FOQ test procedure. Included time: See OC. 6.6 Training of operating personnel Done by EKATO SYSTEMS Based on final documentation Performance will be recorded in writing Signed by customer/user Will be performed during Start-Up and SAT. Electrical training and on operation as well as training on mechanical maintenance will be realized by the respective EKATO personnel. Additional quoted time for mechanical training and maintenance: Additional quoted time for electrical training and operation: See OC. See OC. 6.7 Process training: Summarized training on theory and practice for SRA3000, SRA5000 and SRA10000. 7 Packing, Transportation See Commercial Conditions. Travel expenses such as airfare, travel time, rental car, accommodation, meals, etc. are not included in our estimates and will be billed according to the prevailing "Service Rates Schedule". Included times are best-estimates, based on 8 daily working hours. Additional time for FAT, Supervision, Start-Up, SAT and Training due to delay not caused by EKATO SYSTEMS or requested by the customer will be charged according to our service rates. 83818-Belcorp-Unimix-SRA10000-2861.98088.31-Tecspec Page 21 of 22
8 Appendix Suppliers EKATO UNIMIX standard accessories will be supplied by: Gearboxes for Agitators: Nord, SEW, SIEMENS Motors: Leroy Somer, SEW, Nord, VEM, SIEMENS Vacuum Pumps: Speck, Busch Pressure/Vacuum gauges: AB, Labom PLC: Siemens Simatic S7 Butterfly Valves: AWH Diaphragm Valves: Gemü, SED Instrumentation air fittings and tubing: Festo Angle seat globe valve: End, Gemü, Burkert Steam traps: Gestra, Spirax Sarco Mechanical seals: ESD, Burgmann, Flowserve Level sensors: Endress + Hauser, KSR- Kübler Mass-Flow sensors: Siemens (Belcorp request) Conductive-Flow sensors: Endress + Hauser, Krohne Temperature controls/devices: Endress + Hauser, Jumo Agitators, Dispersers: EKATO Fluid, EKATO RMT Steam and compressed air filter: Ultrafilter, Millipore Product filter: Nocado, Pall, Millipore Recording device: Jumo, Yokogawa Limit switches: Pepperl + Fuchs Frequency converter: Siemens (Belcorp request) or similar (the selection of the supplier is to Ekato s discretion) Photos and drawings in this Technical Specification are examples and not contractually binding. 83818-Belcorp-Unimix-SRA10000-2861.98088.31-Tecspec Page 22 of 22