Engineering Project Synopsis
IMD Process delivered a fully integrated turnkey manufacturing facility for a major cosmetic manufacturer, designed specifically for the high-volume production of shaving gel products. The project encompassed the complete design, build, installation, and commissioning of a hygienic process plant and manufacturing environment, ensuring compliance with cosmetic manufacturing standards and providing a highly efficient, automated production system.
Facility Design & Construction
A new purpose-built manufacturing room was developed to support hygienic processing and long-term operational efficiency.
Key infrastructure elements included:
- Hygienic resin flooring system designed for chemical resistance, durability, and washdown cleaning.
- Purpose-designed drainage system integrated into the floor to manage washdown and process cleaning.
- Hygienic white wall plant room construction to support high sanitation standards and easy maintenance.
- Optimised layout allowing safe access to vessels, pumps, pipework, and service equipment.
The room was engineered to accommodate both process equipment and operator access, ensuring efficient workflow during production and maintenance activities.
Process Equipment Installation
At the core of the manufacturing system are two high-capacity mixing vessels designed for the controlled production of shaving gel formulations.
The installed system includes:
- 2 × 10,000 litre stainless steel mixing vessels
- Stainless steel access platforms and operator walkways
- Fully hygienic sanitary pipework and valve manifolds
- Automated valve technology for controlled product routing
- Hygienic process pumps for product transfer
- Integrated heating and cooling system for temperature-controlled processing
The vessels allow precise control of mixing, temperature regulation, and ingredient incorporation, ensuring consistent batch quality.
Automation & Control
A fully integrated automation platform was installed to allow operators to manage the entire manufacturing process efficiently.
The system includes:
- Central HMI operator control panel
- Control panels with variable speed drives
- Automation of mixing, pumping, valve sequencing, and temperature control
- Process monitoring and control for all major equipment
- Simplified operator interface for recipe control and batch management
This automation architecture enables repeatable production, reduced operator intervention, and improved product consistency.
Product Transfer & Downstream Integration
IMD Process designed and installed sanitary transfer lines that deliver finished product directly from the mixing vessels to the filling machines.
The hygienic pipework system ensures:
- Minimal product hold-up
- Clean product transfer
- Reduced contamination risk
- Seamless integration with downstream packaging operations
Clean-In-Place (CIP) System
To support hygienic production and reduce downtime between batches, a fully integrated CIP system was installed.
The CIP system provides automated cleaning of:
- Mixing vessels
- Process pipework
- Pumps
- Valves
- Transfer lines
This allows rapid and reliable cleaning cycles while maintaining strict cosmetic manufacturing hygiene standards.
Environmental Control
To maintain stable production conditions, the facility includes a dedicated HVAC climate control system for the manufacturing room.
The HVAC system provides:
- Controlled temperature and humidity
- Stable production environment
- Improved operator comfort
- Compliance with cosmetic manufacturing requirements
Project Outcome
The completed facility provides the client with a modern, hygienic, and fully automated manufacturing systemcapable of producing large volumes of shaving gel with consistent quality.
By delivering a complete turnkey solution — from room construction through to process automation and commissioning — IMD Process enabled the client to bring a new production capability online efficiently and reliably.
