Client: A leading FMCG manufacturer, Indonesia
Application: Lauric Acid (C12), Myristic Acid (C14), Palmitic Acid (C16), Stearic Acid (C18)
Capacity: 5 TPH
Location: Medan, Indonesia
Project Scope: Design, Engineering, Supply, and Commissioning of a Spray Cooling–Beading Plant
The Real Challenge
The client approached Shachi Engineering with a clear but complex requirement
One beading plant that could handle four different fatty acids efficiently.
Each acid has its own flow behavior, melting point, iodine value (IV), and cooling characteristics.
The risk? A one-size-fits-all setup could compromise product quality, stability, or performance. The core concern was switching between products without losing efficiency or consistency.
Shachi’s Approach
Instead of treating this as just another beading system, Shachi considered it a materials problem with an engineering answer. The goal was to build a plant that adapts not struggles across all four applications.
Here’s how it was done:
1. Open & Closed Loop Flexibility
Based on the product’s cooling behaviour and environmental factors, the plant was designed to run in both open and closed loop modes.
2. Iodine Value Range Handling
The system was made compatible with an IV range of 1 to 20, so that low as well as high IV products can be operated in a single plant.
3. Removal of Heat of Crystallization
An External Vibratory Fluidized Bed (VFB) Cooler was integrated to efficiently remove the heat of crystallization after the bead formation so that lump formation of the beads can be avoided.
4. Fine Separation & Clean Discharge
A high-efficiency cyclone separator captured fines, and clean air was exhausted to the atmosphere or recycled back to the system during closed-loop operation.
5. Uniform Air Flow Distribution
Uniform air flow was engineered throughout the spray chamber with specially designed air distribution to avoid irregular bead formation, which is especially critical when switching between multiple products of different melting point.
6. Automation with PLC-SCADA
A fully automated control system gave the plant operators visibility, control, and repeatability minimizing manual errors and ensuring smooth changeovers.
The Outcome
The 5TPH plant is now commissioned and operational, running smoothly across all four fatty acid applications.
- Changeovers are efficient
- Product quality is consistent
- Energy use is optimized
- Operational control is seamless
What started as one challenge became an opportunity to build a solution that was adaptable, efficient, and easy to run everything the client needed.
Looking for a beading plant that runs for multiple fatty acids applications?
Let’s build one that works for your plant, materials, and teams.
Reach out to us at www.shachiengineering.co