One of the major problem we were trying to overcome was to lower the cost of the machine. This is very critical as the commercialization is very depended on return on investment (ROI). Phase1 statement of cost of machine was 7.000.- EUR which were not so acceptable for many investors.
Due to this obstacle we were trying to overcome, we were in constant search for better ways to develop the machine. We were inspired from a laboratory-mixing device that we have seen at Hannover Messe Industrial Automation at Hannover, Germany. After deeper technical feasibility reviews of this concept we have decided to change the mixing and filling method. We are totally relieved to be able to come over this major cost structure problem and now we have a new target cost of 3.000.- EUR per machine that will allow ROI to be around 1 year.
We may shortly explain this method as; mixing all ingredients in the pack rather than mixing first and then filling it into the pack. This method doesn’t need inline cleaning system, which was a major and solving costly problem. At the same time we don't need hot-seal pack closing mechanism, as the filling of ingredients will be done thru the lid of the pack by suitable nozzles. This will also lower the cost of the machines and the electricity consumption, which is also a great progress.
We would like to explain in detail what we have accomplished in super-high concentrated detergent extracts formulation at Phase1 period. We have conducted deeper literature researches and web searches, attended to chemical exhibitions and symposiums in order to track closely the developments in chemical industry. We have gathered laundry detergent samples from different markets and brands to expand our sample products archive. Those samples have been examined in our laboratory. Laboratory examinations involve; organoleptic analyzes, pH value measurement, viscosity measurement, density measurement, total dissolved material measurement and active ingredients measurements. Those conducted works help us to keep a close eye on market conditions and competitor products portfolios. We have contacted numerous raw material suppliers, attended to international and local fairs and kept a close eye on ultimate innovations on chemical industry. We are happy to see that all major companies’ research & development activities, especially global giants, are focused on liquid laundry detergents rather than powder laundry detergents, which is a major advantage for our concept.
We have gone far beyond the point we aimed through Phase 1 on detergent chemical formulation framework. The improved formulation we are developing is much more promising. One of the newest raw materials we use in our development is called Methyl Ester Sulfonate (MES). This is a new alternative to Sodium Lauryl Ether Sulfate (SLES), which is one of the main ingredients in laundry detergents.
One of our major aim was to lower the cost of the machine. This is very critical as the commercialization is very depended on return on investment (ROI) especially for retail channel. Phase1 statement of cost of the machine was 7.000.- EUR, which were a critical level.
Therefore, we were in constant search in better and easier ways to develop the working mechanism of the machine. We were inspired from a laboratory-mixing device that we have seen at Hannover Messe Industrial Automation fair at Hannover, Germany.
After deeper technical feasibility reviews of this concept, we have decided to change the whole mixing and filling method. We are totally relieved to be able to come over this critical cost structure problem and now we have a new cost structure target of 3.000.- EUR per machine that will decline the ROI into 3-year in worst case study for an average retailer sales volume.
We may shortly explain this method as; mixing all ingredients in the product pack rather than mixing first and then filling it into the pack. This method doesn’t need inline cleaning system, which was a costly problem. At the same time we don't need hot-seal pack closing mechanism, as the filling of ingredients will be done thru the lid of the pack by suitable nozzles. This will also lower the cost of the machines and the electricity consumption, which is also a great progress.
Another major gain we reached thru changing the whole mixing system is to have more space within the machine, which gave us courage to add extra product offerings than only laundry detergent. We redesigned the machine that will allow us to offer laundry softener, which is a complimentary product for laundry care. This expansion can also lead to having more offerings like carpet cleaner and/or extra strong stain removal additives for extra tough stain problems. In version1, the mixing system is “Closed loop mixing system” by inline mixer pump. Pipe washing and drying process between each product preparations is needed, which increases process time and creates wastewater. Mixing high viscosity materials increases process time. Cleaning and drying process and packaging closure components increase the energy consumption and the cost. In ver.2 the mixing system is Planetary Centrifugal Mixing System. In this system raw materials are dosed directly into packaging and mixing process is conducted inside packaging. Therefore there is no need for cleaning and drying processes between each product preparation. Together with this achievement product preparation process time has decreased by 50% down to 45 seconds. Wastewater problem is eliminated caused by cleaning process. There is no need for drying process and packaging edge closure process because of new direct package dosing and mixing process.
