GEA collaborated with a manufacturer to implement a fully automated, multi-purpose liquid processing plant for the production of home and personal care (HPC) products. Previously dominated by imports, the new plant allows the company to enter the local HPC market with high standards of hygiene, flexibility, operator safety, meeting customer demands while creating new growth opportunities. The plant has a theoretical capacity of 15,000 tons per year when operating on day shifts only.
Established as an importer and distributor of well-known European brands, the company gradually expanded into manufacturing. Over time, it invested in production equipment for tissue products and has since broadened its portfolio to include a variety of HPC products such as baby care items, cosmetic wipes, hygiene products, and household paper goods.
To further align with regional market trends, the company decided to invest in its own advanced production technology and develop private-label HPC products.
The installed plant has been designed and built to the same hygiene standards applied in food-grade industries such as dairy and brewing. Operating as a closed system, it enables the production of relatively small batches and supports rapid product changeovers.
Compared with traditional solutions that require dedicated lines for each product, this system offers significantly greater flexibility and improved operator safety.
The equipment supplied by GEA includes raw material handling and storage systems, dosing and mixing technology—including the GEA BATCH FORMULA® system—final product storage, and a Clean-in-Place (CIP) solution. Operating in accordance with international hygiene and production standards, the plant produces high-quality products while also meeting strict sustainability requirements.
Although based on proven technologies, the project presented certain challenges.
Many of the products involved are highly viscous, requiring transport through heat-traced pipelines and storage in temperature-controlled tanks. Additionally, some substances are highly active and may cause skin irritation, making enhanced safety measures essential to protect the workforce. To further optimize efficiency, pigging systems are used to recover residual product during changeovers and reduce the need for cleaning chemicals. The system design also minimizes dead ends in pipework, enabling more effective and efficient cleaning.
The collaboration throughout the project was highly professional, with strong technical support and responsiveness. Since becoming fully operational, the plant has enabled the manufacturer to expand production capacity and prepare for future growth, including potential 24/7 operation or additional processing units to meet increasing demand.
Hygiene Standards
