Littleford Day Inc. Where Processing Ideas become Reality.

1. Littleford Day Inc. Where Processing Ideas become Reality.

2. Processing Detergents with Littleford Equipment Littleford Day Inc. Where Processing Ideas Become Reality.

3. Littleford Equipment for the Detergent Industry Presentation Index Page Contents 4 Our Engineering for Detergents:Neutralizing, Mixing, Drying, Densifying. 5 Preparation of Dry Powder Detergents using Dry Neutralization. 6 Wet and Dry Neutralization. -Comparative Table- 7 The ”Fluidized-Bed Operation” for Detergent manufacturing. 8 Chopper action on Acids dispersion. 9 Manufacturing options for the FM/FKM Equipment. 10 How do we build them. 11 Our Regular Sizes. 12 Densification of Dry Powder Detergents in our CB Units. 13 The Littleford CB High Speed Processor. 14 Advanced drying process in the Littleford equipment. 15 Advantages of the Choppers operation in drying. 16 Granulation in the Littleford equipment. 17 Rental Program. 18 Service and Spare Parts. 19 Technical Center: Our Lab. Facilities. Testing/Optimizing your products.

4. Cutting Edge Engineering for: Dry Neutralization. Mixing of additional components. Drying. Densification. The specially designed tools in the Littleford FM/FKM equipment create a mechanically fluidized bed of material providing exceptionally fast and accurate contacting of the acid and powder. Supplementary high speed impact choppers supply localized high shear fields required for the thorough dispersion of the acid. The choppers also aid in deagglomeration and densification of the product. After an excellent neutralization has been accomplished, blending of the dry neutralized surfactant with the remai- ning components of the detergent is done in the same vessel. This can be done in a batch or continuous basis. Extremely accurate drying so as densification is also done, if required, in our FM/FKM machines. Our CB High-Speed Processors, in combination with the KM mixers provide continuous densification of detergents, to fully suit demanding market requirements.

5. Preparation of Dry Powder Detergents using Dry Neutralization. Dry Powder Detergent Formulations are usually composed of a combination of Ionic and/or Non-Ionic surfactants, builders (such as carbonates, phosphates, silicates, brightening agents, etc.) and inerts. These components are processed to form a dry powder product possessing desirable flow properties and appearance. There are two generally accepted methods by which to arrive at the final product. One is a “Wet” Process and the other is a “Dry” Process. In the wet formulation, the product of the sulfonation (a heavy liquid acid) is added to a caustic solu- tion. The resulting surfactant is in slurry form. This slurry is homogenized with the other components of the mix in a vertical stirred tank. The resulting material is a heavy past, which is pumped to a spray drying tower where the moisture is removed. The dry, low density, hollow granules are collected at the bottom and may be packaged as it is or may be processed further. Since the trend in today´s market is towards densified detergent, this low density product is often densified in additional equipment. In the Dry Process the surfactant is prepared by spraying the liquid acid onto Sodium Carbonate. This is known as Dry Neutralization. The resulting surfactant is a dry granular powder. The dry surfactant may then be blended with the other components of the mix. Since the resulting mix is dry, the costly spray drying operation is eliminated. A Non-Ionic surfactant is sometimes sprayed onto the product to enhance flowability and reduce dusting. The manner in which the liquid acid is added to the sodium carbonate is critical. The acid must be added at a controlled rate and dispersed uniformly to avoid overwetting, which would produce large we t agglomerates containing unreacted material not suitable for use in the final blending operation. When processed properly, the product of the dry neutralization will be homogenous in composition and particle size. The specially designed mixing tools in the Littleford FM/FKM Series Mixer, create a mechanically fluidized bed of material, providing exceptionally fast and accurate contacting of the acid and powder. High speed impact choppers supply localized high shear fields required for the thorough dispersion of the acid, and aid in deagglomeration and densification of the product. Blending of the dry neutralized surfactant with the remaining components of the detergent formulation is then done. Using the same vessel for both the dry neutralization and final blending is yet another advantage of using Littleford Day Technology.

6. The Advantages: Wet and Dry Neutralization A Comparison between two Processes: The Wet-Type Process. In the wet formulation, the product of the sulfonation (a heavy liquid acid) is added to a caustic solution. The resulting surfac- tant is in a slurry form. This slurry is then homogenized with the other components of the mix in a vertical stirred tank. The resulting material is a heavy paste, which is pumped to a spray drying tower where the moisture is removed. The dry, low den- sity, hollow granules are formed. Since the trend in today´s market is towards densi- fied detergents, this low density product is often densified in additional equipment. The Dry-Type Process. The surfactant is prepared by spraying the liquid acid onto sodium carbonate. This is known as Dry Neutralization. The resulting surfactant is a dry granu- lar powder. The dry surfactant may then be blended with the other dry compo- nents of the mix. Since the resulting mix is dry, the costly spray drying ope- ration is eliminated. A Non-Ionic sur- factant is sometimes sprayed onto the product to enhance flowability and reduce dusting. No need for costly spray drying. Simpler, less expensive system. Single Vessel for Neutralization and Mixing of final detergent components.

7. The unique action created by the movement of the mixing elements produce intense but gentle inter- mingling of the materials of the mix in a mechani- cally fluidized bed. Liquid dispersion is done by spraying liquids against fluidized powder, by Top and / or Bottom Mounted Nozzles. Mixing elements are designed to force the product into appro- piate components of axial & radial motion. High-Speed Blending Choppers enhance mixing action by controlling particle size and trace ingredient dispersion, usually without the need for additional process steps. The “Fluidized Bed” Operation for Mixing & Drying: The unique mixing action of the FKM series mixers is accomplished by a ho- rizontal shaft which revol- ves at a high rate of speed rapidly projecting and hur- ling the mix materials away from the vessel wall into free space, filling the entire vessel. The mixing action causes the materials to crisscross in the direc- tion of the vessel walls and inversely back again, pro- viding a high volume rate of material transfer. The mechanically fluidized bed of particles is the basis of it´s mixing efficiency and accuracy, including combi- nations with diverse speci- fic gravities as well as other problems such as liquid incorporation and heat transfer.

8. Chopper Action, sending fluidized particles upward, against sprayed liquids flowing in the opposite direction. Superb Liquids Dispersion into Powders, through high speed Choppers (Showing Top Injection Type. Bottom Liquids Injection also available)

9. Manufacturing Options: Vacuum System: Stack (s) Pulse Back Filter (s) Condenser, Receivers. Vacuum Pumps. Material: C.Steel, 304 S.S., 316 SS., Special. Interior: Std. #120 Grit or higher. Liquid Injection: Tower, Manifold. Top and / or Bottom Mountings. Vessel Construction: Atmospheric Std., Vacuum Rated, Pressure Rated, Sanitary Construction. FDA Ratings. Electric's: H.P., TEFC,Expl.Proof. Feeding Ports Drive Type. Sanitary or Welded Design RPM´s: 1 or 2 Speeds, Variable Speed. Hydraulic Coupling. Seals: Std. Packing, Positive Pressure Mechanical. Plows: Std.,Heat Transfer, Becker Jacket. Std. 75 PSI Other PSI Ratings Heating & Cooling Special Bases, Load Cells. Choppers: H.P., TEFC, Expl.Proof Blade Types Discharge Valve : Manual,Pneumatic. Ball type, Butterfly, Sphericals & Slide Options. Control Panels: Manual, Automatic. RPM Control Batch Times, Amp,Power,Reports

10. Standard or Sanitary Construction. TEFC or Explosion Proof Electric's. Full Vacuum or rated for several Internal Pressure Ratings. Single or Variable Speeds. Vacuum Systems Liquid Disper- sion Systems. Shell in Carbon Steel 304 SS or 316 SS #120 Grit finish. Access ports with safety limit switches. Reinforced Shafts and Drives. Std.Packing, Air type & Mechanical Seals Jacket designed for high rates of thermal transference. 75 PSIG Littleford High Speed Choppers, for granulation control, lump breaking & dispersion Mixing Plows designed to create a fluidized bed and excellent thermal transfer. Contour discharge Valve, for No-Dead Spots How do we build them: Pulse Back Filters.

11. TOTAL CAPACITY DIMENSIONS * Model Liters Gallons Cu.Ft. A B C FKM-300-D 300 79 11 39” 28” 35” FKM-600-D 600 159 22 49” 34” 43” FKM-1200-D 1200 317 42 98” 34” 43” FKM-1200-E 1200 317 42 67” 42” 50” FKM-2000-D 2000 530 71 117” 42” 51” FKM-2000-E 2000 530 71 79” 50” 60” FKM-3000-D 3000 792 106 117” 50” 60” FKM-4200-D 4200 1109 148 136” 54” 68” FKM-6000-D 6000 1584 212 117” 68” 80” FKM-8000-D 8000 2113 283 157” 68” 80” FKM-10000-D 10000 2642 353 198” 68” 80” FKM-13500-D 13500 3555 495 198” 79” 92” FKM-15000-D 15000 3960 530 198” 85” 96” FKM-20000-D 20000 5284 706 198” 95” 107” FKM-25000-D 25000 6605 883 234” 99” 110” C B A Littleford Day Inc. * Aprox. Vessel Dimensions Our regular FM/ FKM sizes: Working capacity depends on the process, and is normally between 50% and 70% of total capacity.

12. Densification of Dry Powdered Detergents: Until recently, the manufacture of most dry detergent products relied on the Spray Drying Process to produce a light density powder product (18-22 Lb/Ft3, Aprox). The Spray dried powder consisted of homogeneous, hollow, spherical particles. Reducing the overall cost of producing dry detergents provided the driving force behind the development of more densified products. Densification of the detergent results in reduced packaging costs and waste, reducing shipping costs and smaller shelf space requirements at the point sale. When leaders in the detergent industry began searching for a process to densify detergents, they quickly arrived at the concept of using a high speed continuous mixer to achieve their goals. A mixer densifies the product by adding work energy to the product via mechanical shear. The continuous mixer/mixing systems best satisfying industry´s needs are the Littleford CB Series High Speed Processor (as a stand-alone unit), and the CB used in combination with a l arger KM Series Littleford Continuous Ploghshare Mixer. The desired level of densification determines which equipment configuration is used. The CB Processor features a jacketed, horizontal, clam shell-type mixing chamber, with a horizontal shaft with a significant quantity of specially designed feeding and mixing tools arranged in a spiral-like pattern, to supply high shear mixing rates and material transport. Liquid may be added via a manifold system located at the lower half of the shell. The typical retention time of detergent product in the CB Processor is 15 to 20 Seconds. During that time the product is subjected to intense mechanical shear causing the fragile spray dried granules to break up and densify. Increases in product density of up to 50% are common (or an increase to 25 to 30 Lb/Ft3). If further densification is required, product is then transferred to a Littleford KM Mixer, which provides additional mechanical shear via the rolling/agglomerating action of the curve-sided mixing tools. Liquids can also be added in this unit, and high speed impact choppers are used to aid in both liquid dispersion and lumps breaking. Common retention times in the KM Mixers are 5-10 Min. Final product densities of 45 Lb/Ft3, or greater are achieved, increasing original density up to 100%.

13. Throughput (Lbs/Hr) Model No. Minimum Maximum CB-30 900 4,500 CB-50 5,400 27,000 CB-60 9,900 49,000 CB-75 19,000 95,000 CB-100 30,000 150,000 Littleford CB High Speed Processor: Densification of Detergents through addition of high shear input rates. Ideal for the densification of detergent powders. Typical retention time of detergent productis 15 to 20 seconds. During that time the product is subjected to intense mechanical shear, causing the fragile spray dried granules to break up and densify. Increases in product density of up to 50% If further densification is required, product is then transferred to a KM series continuous mixer, delivering up to 100% density increase. High Shear Densification Zone Mixing & Predensification Zone Charge Chute Heating/Cooling Jacket (Top & Bottom Shell) Charging Zone Double Row Spherical Bearings Dinamically Balanced High Speed Shaft. Pneumatic Control of Discharge Gate Tangential Liquid Lances on Bottom- Top, Optional Littleford Day Inc. To an optional KM Continuous Mixer, for up to 100% Densification

14. Dry Product Advanced Drying Technology 1.-High efficiency drying of Suspensions, pastes, and bulk materials. 2.-Fast drying cycles and discharge. 3.-Allows efficient drying of sensitive materials at low Temperatures. 4.-Complete dispersion of agglomerates, lumps and fiber bundles. 5.-Homogeneous mixing of dissimilar ingredients. 6.-Drying operations from liquid state to free-flowing powder in one vessel. 7.-Allows liquid addition during processing. 8.-Adapts itself to effective recovery of costly solvents. 9.-Eliminates need for additional processing equipment. The Key to this State-of-the Art drying technology is the unique, mechanically fluidized ploughshare action which agi- tates and individualize the solid parti- cles to be dried. The ploughshare action forces the product into a 3-dimensions motion that individualizes each particle, continuosly exposing tremendous surface area for drying. The particles constantly contact one another, and the heated inte- rior walls of the jacketed vessel furthering the drying process. Our dryers are also equipped with independently operated, high shear choppers, to reduce the particle size of the lumps or agglomerates, to expo- se undried materials and ensure thoroughly dried particle interior. Deagglomeration further shortens drying time. Heated Pulse Back Filter with Stack. Wet Product Condenser Littleford Dryer. Recovery Tank. Vacuum Pump.

15. PASTE GRANULE POWDER M O I S T U R E Internal Drying without Choppers External Drying with Choppers DRYING TIME Advanced Drying: The Chopper Advantages. Advance Drying: The action of the turbulent plows and the high shear choppers reduce the forming lumps to smaller granules, thus exposing large amounts of new surface area for drying.

16. Granulation Validation Cycle Time vs Power (Watts) Stop Liquid Addition P o Large Granules Medium Granules Small Granules w e r D e m a n d Start Dry Mix Cycle Time Start Liquid Addition Granulation Littleford mixers/granulators, equipped with plow-like mixing tools, develop an intermediate intensity mix action, which is gentle, yet thorough. This action is supplemented by high shear choppers, which quickly disperse minor liquid, or powder ingredients. In a typical run, the excipient and the powdered active ingredient are charged to the static granulator and mixed, with choppers, for several minutes, until the power curve levels off, indicating that dispersion is complete. Then the agglo- merating liquids are sprayed into the active chopper field, where t hey are quickly dispersed into the batch. The degree of granulation, and thus the amount of power utilized, is dependent upon the amount of liquid added to the batch, so as of the wet mix batch time. The action of the plows causes “snow- balling”; the choppers generates small, granules. For a Given: Liquid Level: More Wet-Mix Time = Material more wet out, Higher Power used & More uniform particles. Wet-Mix Time: Higher Liquid Level = Material more wet out, Higher Power used & larger granule size.

17. Batch Mixing / Processing Ploughshare Units, both for atmospheric / vacuum and Pressure Ops. : From Table-Top 5 & 20 Lts units to Pilot 130 Lts. Machines Larger sizes are available. W-10 High - Intensity vertical mixer, for PVC Compounding and /or other applications req- uiring High-Shear Op. Ten Liters Capacity. Daymax # 10 Dispersers, for high quality dispersions of solids into liquids, such as plastisol, varnish, paint, and other applications. FA-3.5 Mixer, Nauta-Type, for special mixing / drying requirements. 24.6 Gallons Working Capacity. Rental Programs In addition to our Process Development & Testing Programs, our Rental Program offers a unique opportunity to test our processing equipment in your own Plant. A portion of the rental cost, under this program, will be applied to the purchase of any related Littleford Day Equipment.

18. Exclusive Dept. for customer assistance. Laboratory for formulations & optimization. Specialized Field Service Engineers. Stock of common required parts. Top American Mfrd. Parts: SKF, Falk, Chesterton, etc.,etc. Assistance in Spanish, if required. Service & Spare Parts

19. To Cincinnati I-75 I-275 Donaldson Rd. Turfway Rd. U.S. 42 Greater Cincinnati Airport Industrial Road (1 Mi) Exit 180 Florence Union (1/2 Mi) 7451 Empire Drive Florence, KY. 41042-2985 To Lexington Process Development & Testing Main Office: Florence, Ky. Ph.- (606) 525-7600. Fax: 525-1446 Latin America: Mexico Cy.Ph.- (52-5)550-9459. Fax: 550-9459 Minutes away from Greater Cincinnati Airport, Our Lab. Center is fully equipped with all the required machinery for product development: Mixers, Dryers, Reactors, Granulators, Intensive Mixers-Coolers and support equipment such as filtering and vacuum drying systems. Cosmetics Detergents & Soaps Foundry Additives Pharmaceutical Ceramics Fertilizers/Seeds Rubber Mortar Mixes Brake Linings Powdered Metals Herbicides Flame Retardant Chemicals Pigments & Color Flushing BMC & SMC Plastics. Color Concentrates PVC Compounding Coatings Plastisols Adhesives & Caulks Inks & Varnish ChemicalReactions & Drying Cellulose Reactions Spices Chocolate processing Gelatin & Powdered drinks Bakery Mixes Instantanization Technical Center Main Equipment: FM-130 Mixer/Processor Ploughshare DVT-130 Polyphase Reactor KM-150 Continuous Mixer/Processor M-5 Lab. Mixer & Dryer W-180/K-300 PVC Compounder W-10 High Intensity Mixer Daymax 10 Pastes Disperser Daymax 100 Pastes Disperser Mixtruder Sigma Double-Arm Mixer Mogul Tangential Sigma Mixer Cincinnatus Overlapping Sigma Mixer FA-10 Nauta Processor Bring Us Your Toughest Mixing, Drying & Reacting Problems.