Binacchi in 1993 introduced the technology for detergent plants and now is an expert supplier with the most modern solutions for:

• powder detergent plants

• liquid detergent plants

• sulphonation plants 

Detergent powder processes

Spray drying technology (DSD plant)

Detergent powder manufacturing by Spray Drying Technology is the most used all over the world.

It consists of a slurry preparation and obtaining hollow beads by spraying the slurry in an adequate tower, in counter-current with a stream of hot air.
This plant is particularly suitable for low and medium density powders.

The Spray Drying technology is a widely used process, as it permits to obtain a voluminous powder (less product per unit of volume). The produced detergent is very soluble in water, therefore very indicated for hand washing of fabrics.

Granulation – agglomeration technology - no-tower process (DCG plant)

In Europe, United States and Japan the sales of detergents through supermarkets have focused the manufacturers to reduce transport costs. Moreover the phosphate ban and the utilization of zeolites, as well as the production of only machine washing powders has led the manufacturers to select the granulation-agglomeration process, a technology that has the advantage of being more compact, more economical but produces only high density products, therefore it is not advisable when the market needs big volumes of powder and when washing habits are not using automatic washing machines.

The biggest advantage of this technology is the lower fuel consumption for drying which reduces substantially manufacturing costs.

Also the building cost is very much lower.

Combo process

Various times the most reasonable way to manufacture medium density detergents is by combining (mixing) the low density detergent from a DSD plant together with a high density product from DGC granulation.

In this way a medium-high density detergent is manufactured at competitive costs, without limitations of formulations or selection of special density raw materials.

In addition using this combined technology there will be an ideal balance between anionic and non-ionic surfactants in the final product.

Of course this is the most expensive solution because foresees either the installation of a DSD plant as well as one DGC. 

Dry mix process

This process is extremely simple and consists of one special mixer, expressly designed for a gentle mixing of powders without breaking hollow beads of spray dried detergent or similar delicate materials. The granulation capacity of this mixer (i.e. the capacity of creating dust-free, free flowing agglomerates of powder raw materials using a liquid as binding agent) is limited. Therefore this solution is to be preferred when:

• a high density final product is acceptable (typical for Industrial & Institutional products) or
• spray dryed base is purchased with the aim of adding perfume and some additives (in such case final density can be low;
• intention is to install in the future a spray drying plant so this mixer can be used for “post-addition”.

Sulphonation plants

Having covered the area of powder and liquid detergent plants, Binacchi completes the portfolio of products including plants for te production of LABSA, SLES, fatty alcohols sulphates, etc. in order to cover at 360 degrees its service to customers.