Guangdong Liyan Zhizao Biotechnology Co., Ltd
Cases Details
With the vigorous development of the facial mask industry, consumers have increasingly stringent requirements for product safety and efficacy. From raw material sterilization to finished product packaging, the cleanliness and process stability of each link directly determine the quality of facial mask. By introducing Kaida steam generator, a * * facial mask manufacturer successfully solved the problems of high energy consumption and unstable steam quality of traditional steam equipment, and achieved a leap forward development with production efficiency increased by 30% and product qualification rate exceeded 99%.
The 'Triple Dilemma' of Traditional Steam Equipment
The enterprise originally used two 2-ton gas boilers (one for backup and one for use) to supply steam, but faced three core issues:
Inadequate steam cleanliness: The steam generated has a high water content (up to 8% -10%), which is easy to cause the facial mask substrate to absorb water and deform, and the condensed water carrying impurities may pollute the material body.
Large temperature fluctuation: frequent startup and shutdown of the boiler causes the steam temperature to fluctuate by ± 5 ℃, affecting the stability of the active ingredients in the facial mask, resulting in incomplete local sterilization or material denaturation.
High energy consumption and cost: The thermal efficiency of the boiler is only 82%, and the annual consumption of natural gas exceeds 400000 cubic meters. In addition to the salary of the boiler worker and the annual inspection of the boiler, the annual operating cost of the equipment reaches 1.72 million yuan.
Kaida's four core technologies solve difficulties
In view of the strict demand for "cleanliness, stability and immediacy" of steam in the production of facial mask, Kaida has customized two 1-ton variable-frequency steam generators for it, and achieved breakthroughs through four innovative technologies:
1. Full DC technology: 5 seconds of steam output, ready to use immediately
Adopting a furnace without a boiler structure, the cold machine can produce high-temperature steam in just 5 seconds, shortening the preheating time by 30 minutes compared to traditional boilers. In the peak production period of facial mask, the equipment can be started and stopped on demand to avoid energy waste of "big horse pulling small car". For example, the enterprise needs to produce facial mask with different effects in four batches every day. Kaida equipment can supply steam accurately according to the production plan. The steam supply time of a single batch is reduced by 25%, and the daily average production capacity is increased by 12%.
2. Independent steam water separation system: steam moisture content ≤ 1%
Each device is equipped with 8 sets of patented steam water separation devices, which strictly control the steam moisture content within 1% through centrifugal separation and gravity settling technology. During the expansion of facial mask base material, the drying steam can evenly penetrate the fiber layer to avoid the shrinkage of the base material or the caking of the material body caused by the residual water. The measured data shows that the water absorption of facial mask base material is reduced from 3.2% to 0.8%, and the flatness of the product is increased by 40% after using Keyvia equipment.
3. Ultra low nitrogen combustion technology: NOx emission concentration<30mg/m ³
Adopting water-cooled low nitrogen combustion technology, the NOx emission concentration is stably controlled below 30mg/m ³. In the facial mask production workshop, low nitrogen steam effectively reduces the oxidative damage of nitrogen oxides to active ingredients, especially for sensitive ingredients such as vitamin C and hyaluronic acid. The third-party test report shows that the retention rate of active ingredients in facial mask has increased from 82% to 95% after the use of Capvision equipment.
4. Intelligent frequency conversion control: on-demand energy supply, comprehensive energy saving of 25%
The equipment is equipped with Siemens PLC intelligent control system, which can automatically adjust the power according to the steam demand of the production line (0.125-1.0 tons/hour). For example, in the mixing phase of facial mask material, the equipment operates at 30% load; When entering the high-temperature sterilization stage, it instantly increases to 100% load. Actual test data shows that the company saves about 290000 yuan in fuel costs annually from natural gas.