New mixing technology increases production capacity for body-care products

Urtekram International A/S is the largest Danish manufacturer of organic body-care products such as cream, shampoo and liquid deodorant. The company holds an Ecocert certification, and the products are free from chemical additives and parabens. None of Urtekram’s products have been tested on animals, and in recent years the company has experienced a soaring interest in organic and sustainable products. The company markets its products in Scandinavia and the EU as well as in selected markets in the Middle East and Asia.

Recently Urtekram International has achieved an increase in its production capacity for organic body-care products by installing new batch-mixing technology from GEA Liquid Processing, GEA Process Engineering’s technology centre for liquid mixing systems in Skanderborg, Denmark.

Steen Resen, Export Manager at Urtekram, said: “When we set up the success criteria for our investment, it was important to us that we would be able to increase production capacity by a factor of three. After putting the mixing plant into service, we have experienced an even larger increase of our production capacity. Suddenly we are faced with a payback time of less than two years, which is unique for us. The new investment has, among other things, contributed to a reduction of our total consumption of energy and power which is naturally completely in keeping with our ecological mindset.”

By investing in the new mixing system, Urtekram International has ensured the highest possible quality for its organic products. Steen Resen continued: “It is our experience that our customers are very quality conscious with regard to colour shades, viscosity and air in the product. Any obstacles we may have had in the past are now completely overcome thanks to the new mixing technology from GEA Liquid Processing. With the Batch Formula mixer, we now have a production plant that is at the forefront of technological development, and we have made sure that all products are 100% reproducible.”

In connection with Urtekram’s investment, several trials were performed at GEA Liquid Processing to ensure that the mixing system would be able to meet the requirements put forward by the customer. Kirsten Holt, Head of Planning at Urtekram, said: “When we started examining the market for mixing technology, we had very high demands for an optimal hygienic design, and the Batch Formula mixer was able to meet these demands completely. We became acquainted with GEA Liquid Processing at a FoodPharmaTech exhibition in Herning, Denmark. Subsequently, they contacted us, and the relationship was established. GEA Liquid Processing offered to run trials with different products at their pilot plant in Skanderborg. In the beginning, we were not very familiar with mixing technology, but during the trials we experienced the large potential of the mixer.”

“During our trials at GEA Liquid Processing, we experienced an amazing service mindedness which definitely helped us decide on which mixer type to invest in. Urtekram and GEA Liquid Processing have worked closely together on optimising the production plant so that it is prepared for future demands for new organic products,” Kirsten Holt concluded.

GEA Liquid Processing has supplied a complete energy-optimised solution that includes a GEA cooling unit contributing to a reduction of the cooling time and shortening of the batch time. Furthermore, the process water is heated in a plate heat exchanger from GEA PHE Systems, so that the process temperature is increased immediately.

Claus Patscheider, Product Manager at GEA Liquid Processing, said: “Working with Urtekram has been a rewarding experience for us. We have found a green and energy-optimised solution that goes hand in hand with Urtekram’s sustainable and ecological profile. One of the characteristic features of the Batch Formula mixer is the opportunity for ‘one-pot processing’ which - among other things - reduces resource consumption to a minimum.”