Production Modules
Do you need a step between laboratory trials and full-scale production? Or perhaps you need to produce small to medium quantities of high-value specialist product?
Our Production Module approach could be the answer. By building on the skid-mounted principle, it makes shipment, on-site installation, and commissioning as straightforward as possible.
A Production Module consists of a process vessel mounted on a skid, along with all the ancillaries, pipework and control system to make it work.
Our pilot grease kettle is designed for small-scale production of high-value specialist greases. It closely replicates a full-scale vessel, providing consistent results without the performance loss often found in smaller pilot units. Compact and easy to clean, it delivers the functionality of a full production system in miniature.
Features include:
- Batch temperature up to 220°C
- Pressure range from vacuum to 10 bar(g)
- Contra-rotating agitation with bronze or PTFE scrapers, and optional bottom-end disperser
- Controlled heating and cooling rates with full data logging
- Dilution oil tank and vacuum pump for de-aeration
- Integrated product pump and toothed colloid mill
- Capacity options from 25–100 kg
- 304-grade stainless steel contact surfaces, with optional 316-grade
- Fitted with forklift sockets for easy handling
Developed for producing one pallet of complex, mixed soap or single soap grease per batch, this 1-tonne kettle module offers both versatility and performance. Built from 304-grade stainless steel, it includes triple-action agitation with a bottom-end disperser to prevent acid build-up and create an effective milling action. The kettle features side and bottom jackets and operates from full vacuum to +1 bar pressure.
The skid holds the product pump, mill and thermal oil heater. A cooler connects externally to the heater, while the fume extraction system is installed as a separate outdoor module. The customer’s mezzanine floor supports the vacuum pump for batch de-aeration.
Features include:
- Batch temperature up to 220°C
- Pressure range from vacuum to 1 bar(g)
- Contra-rotating agitation with bronze or PTFE scrapers and bottom-end disperser
- Controlled heating and cooling with data logging built into the control panel
- Optional dilution oil tank
- Vacuum pump for de-aeration
- Product pump and toothed colloid mill
- Capacity options from 1–2 tonnes
- 304-grade stainless steel contact surfaces, with optional 316-grade
- Skid-mounted with adjustable leg length to suit mezzanine height
For non-melting, clay-based greases where heat is not required, the Bentone Grease Production Module offers a cost-effective solution. It includes a 2-tonne, skid-mounted, unheated contra-rotating mixer, product pump, filter and in-line mill.
This module is designed for easy transport and installation. It fits within a 20-foot shipping container, with the mixer laid horizontally and the access platform disassembled for delivery.
Developed for a customer with a limited budget, this 250 kg Lithium Grease production module was built around a re-purposed vessel modified to include an anchor and incorporator. It features a double-motion, jacketed atmospheric kettle, product pump and an electrically powered thermoregulator.
The thermoregulator, originally designed for the injection moulding industry, is an efficient solution for heating and cooling small process vessels. It circulates thermal oil, which can be heated by an internal electrical element or cooled through an inbuilt heat exchanger transferring heat to water.
A single control panel, equipped with inverter drives and a temperature controller, manages the entire module. The unit was delivered fully assembled on a flatbed lorry, with gear motors removed for transport.