DESMET BALLESTRA S.p.A. – ITALY (DBI)
A 60-year journey in the design of detergent plants and more Ilio Sebastiani
Head of Research and Development
Detergents Surfactants Soap & Chemicals
PRESENTATION INSIGHTS
RESILIENCE – from 1960 to future … VISION – for success WIN TOGETHER – a mantra
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SUPPLY-CHAIN IN DETERGENT INDUSTRY HOW WE SUPPORT THE BUSINESS RAW MATERIALS
CHEMICAL PRODUCER (es. SURFACTANTS)
DETERGENT MANUFACTUR ING
DISTRIBUTION
DESMET BALLESTRA ITALY SUPPLIES TECHNOLOGIES AND RETAILERS
PROCESSES (INDUSTRIAL PLANTS) FOR THE TRANSFORMATION OF THE RAW-MATERIALS IN SURFACTANTS and SOAPS AND FOR THE FORMULATED DETERGENT MANUFACTURING.
CONSUMER
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DBI CORE TECHNOLOGIES CHEMICAL PLANTS
SULFONATION PLANTS
[INORGANIC ACIDS
[ANIONIC SURFACTANTS]
HF, H3PO4, H2SO4 AND FERTILIZERS]
MULTI-PURPOSE PLANTS
DETERGENT PLANTS
DBI TECHNOLOGIES
[CATIONIC AND AMPHOTERIC SURFACTANT, ESTERS SPECIALTIES]
[POWDER AND LIQUIDS]
SOAP AND DETERGENT BARS
ALKOXYLATION PLANTS
FINISHING LINE MACHINES
[NON-IONIC SURFACTANTS AND SPECIALTIES]
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DBI BUSINESS SEGMENTS - DSSC SURFACTANTS & DETERGENTS (The core business of Ballestra since its start-up in 1960) • Typical value of projects (EP basis, w/out field services): 1 ÷ 10 M€ • Average duration of projects: 15 to 30 months (up to plant start-up) • Main products: • Anionic, non-ionic, amphoteric, cationic surfactants (liquid, viscous paste, powder/solid formats) • Liquid, powders, solid format detergents
INORGANIC CHEMICALS (business expansion, from 2000) • Main products: • Sulphuric and Phosphoric acids, P-Fertilizers, various compounds for the detergent and fertilizers industry. • Typical value of projects (EP basis, w/out field services): 5 ÷ 100 M€ • Average duration of projects: 20 to 30 months (up to plant start-up)
SOAP (New business from 2017 with acquisition of MAZZONI co.) • Main products: • Natural and Synthetic Soaps • Detergent bars • Typical value of projects (EP basis, w/out field services): 0.5 ÷ 2 M€ • Average duration of projects: 6 -12 months
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DESMET BALLESTRA GROUP STRUCTURE International footprint
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DBI REFERENCES WORLDWIDE 1800 plants in over 120 countries *
* Not including Mazzoni LB plants
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TECHNOLOGICAL MILESTONES MISSION: production of detergents and then sell them in Italy and abroad.
DOUBLE STEPNEUTRALIZATION TECHNOLOGY
NEW HEADQUARTER FOUNDATION OF R&D DEPARTMENT
BALLESTRA FOUNDATION
1960
STRATEGY: development, implementation and launch of ultramodern and updated technologies in the field of Anionic Surfactant
SO3 STIRRER CASCADE SULPHONATION TECHNOLOGY
1972-73
1978-80 SO3 FALLING FILM SULPHONATION TECHNOLOGY (SULFUREX)
SPRAY-DRYING DETERGENT TECHNOLOGY
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1981
1982 NON-TOWER DETERGENT TECHNOLOGY KETTEMIX)
TECHNOLOGICAL MILESTONES The time was now ripe to launch a diversification strategy. Serving world class partners.
1983 LAUNCH OF NEW STANDARD PLANT FULLY AUTOMATED
1987
Along the path of innovation.
Entering the chemical plants business.
TECHNOLOGY FOR CONTINUOUS ESTERIFICATION OF OILS VACUUM NEUTRALIZATION (BIO-DIESEL PLANTS) TECHNOLOGY
1995
1989
ACQUISITION OF CMB COMPANY (OLECHEMICAL PLANTS)
1998
2000-2005 NEW EPCM BUSINESS MODEL (TURN-KEY PLANTS)
FIRST ETHOXYLATION PLANTS (STIRRED REACTOR)
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TECHNOLOGICAL MILESTONES Expansion and diversification moved forward at a frenetic pace, launching the company into new technological fields.
Continue to modernize and look to the future
ACQUISITION OF PRESSINDUSTRIA ETHOXYLATION TECHNOLOGY (EXPANSION IN NON-IONIC SURFACTANTS AND SPECIALTIES SEGMENTS)
CONSTRUCTION OF FIRST LINEAR ALKYL BENZENE PRODUCTION PLANT (PETROCHEMICAL PLANTS)
2000 FIRST SULFURIC ACID PLANT (START ALLIANCE WITH MECS EX. MONSANTO ENVIROTEC)
2001
2006-2008
2005 ALLIANCE WITH THE BELGIAN GROUP DESMET AND FUONDATION OF MULTINATIONAL “DESMET BALLESTRA GROUP”
NEW INTEGRATED SULFURIC ACID SODIUM/POTASSIUM SULPHATE MANNHEIM FURNACE AND FERTILIZER PLANTS (EXPANSION OF CHEMICAL BUSINESS SEGMENT)
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2009
TECHNOLOGICAL MILESTONES Continue the Technology Portfolio expansion
FIRST PHOSPHORIC ACID PLANT (MERCHANT AND PURIFIED GRADE) LAUNCH OF ULTRA-LOW DIOXANE TECHNOLOGY FOR ETHOXY-SULPHATE PRODUCTS
MES TECHNOLOGY
2010
2011
2017
2019
2020
2021
ACQUISITION OF MAZZONI GROUP ACQUISITION OF BUSS TECHNOLOGY LEADER IN SOAP TECHNOLOGY DRIED FORMULATED LABSNA PLANT (RIM-BLOCK AND SYNDET BARS)
FOTO KLK
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SURFACTANT TECHNOLOGIES SOURCE
PRUDUCTS
DESMET BALLESTRA ITALY TECHNOLOGIES
RAW MATERIALS
PETROL-BASE LAB
AO
EO/PO
TECHNOLOGIES DESMET BALLESTRA OLEOCHEMICALS
BIO-BASED (OIL) GLYCOLS
FA
FFA
ME
GLYCERIDES
GLYCEROL
FA + NH3
BIO-MASS
AMINES
GLUCOSE
SULPHONATION
SAPONIFICATION
MULTIPURPOSE REACTOR
NEUTRALIZATION (Vacuum and Loop)
VACUUM DRYING
QUALITY ADJUSTMENT
DRYING - EXTRUSION
EXTRUSION - REFINING
PURIFICATION
HYDROLYSIS
STAMPING
ALKOXYLATION
AOS LABS MES FAS FAES SFA (LIQUID, NEEDLES, POWDER, GRANULES)
*TECHNOLOGY UNDER DEVELOPMENT PROGRAM
FAE ETHOXYLATED AMINES ETHOXYLATED FA ETHOXYLATED OILS ETHOXYLATED POLYOLS ETHOXYLATED ALKYLAMIDES MEE PEG
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SOAP NOODLES SOAP BARS
BETAINES AMIDES AMINE OXIDES ESTERS PARTIAL GLYCERIDES SULPHATE-FREE* ESTER-QUATS* APG*
OTHER SPECIALTIES (NON-DETERGENTS)
RAW MATERIALS
DESMET BALLESTRA ITALY TECHNOLOGIES
FA
OIL/FFA/ME
GLYCEROL
ALKOXYLATION REACTOR
EO
MULTIPURPOSE REACTOR
QUALITY CONTROL AND ADJUSTEMENTS
PURIFICATION
PRODUCTS
ESTERS POLYETHER POLYOLS POLY-ESTERS POLYETHYLENE GLYCOLS POLYETHER MONOMERS EO/PO Co-Polymers (Lubricants, etc…)
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PO
WORLD DETERGENTS AND SURFACTANTS HOT SPOTS World market figures support a positive trend of the sector
Detergents and surfactants show uninterrupted technical development
Surfactant types are undergoing expansion and diversification for both their sources and chemical families
Detergent formats are more and more focused on local and specific market demand
Surfactants and formulated products for personal care and sanitizing applications have acquired outstanding importance 14
WORLD ANIONIC SURFACTANT TREND
ANIONIC SURFACTANT ARE STILL THE WORKHORSE OF THE DETERGENCE INDUSTRY
ANIONIC RANGE IS MORE AND MORE EXTENTED TO NATURAL RAW MATERIALS [BIO-BASED SURFACTANTS]
LABS STABLE BUT QUALITY-WISE IS STILL UNDER IMPROVEMENT
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FAS AND FAES STRONGLY INCREASING SPECIFICALLY IN PERSONAL CARE SEGMENT
MES IS STABLE BUT CONFINED TO A FEW AREAS / PRODUCERS
AOS IS NOT INCREASING BUT WIDELY USED IN SOME MARKETS
WORLD NON-IONIC SURFACTANT TREND
ETHOXYLATES ARE STILL THE MOST WIDELY USED TYPE
EO CONTENT DECREASING
OVERALL CONSUMPTION SUPPORTED BY THE GENERAL INCREASE OF LIQUID FORMULATIONS
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INCREASING IMPORTANCE FOR «NON-DETERGENT» APPLICATIONS
DETERGENT TECHNOLOGIES NON-IONICS
CATIONICS AMPHOTERICS
OTHER RAW MATERIALS
AOS LABS MES FAS FAES SFA SOAP
FAE POLYOLS ETHOXYLATED AMMINES* MEE PEG
BETAINES AMIDES AMINE OXIDE ESTER-QUATS* APG* SULPHATE-FREE*
SODIUM SILICATE ZEOLITE CMC NaCARBONATE NaOH NaSULPHATE
LIQUID DETERGENT PLANTS
FORMULATED LABSNA TECHNOLOGY
BATCH & CONTINUOUS
PRILLING
PR0DUCTS
DESMET BALLESTRA ITALY TECHNOLOGIES
RAW MATERIALS
ANIONICS
SPRAY-DRYING VACUUM-DRYING
EXTRUTION PLANTS
LAUNDRY HOUSEHOLD CARE HOME-CARE PERSONAL CARE INSTITUTIONAL CLEANING AND SANITATION (I&I) DISHWASHING HARD SURFACE CLEANING
AGGLOMERATION (NON-TOWER DETERGENTS)
HYGIENE FOOD AND BEVERAGE PROCESSING VEHICLE AND TRANSPORTATION CARE INDUSTRIAL CLEANING TRIGGERS SYNDET BARS RIM-BLOCKS
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WORLD POWDER DETERGENT TREND
MARKET VOLUME IS NOT DECLINING
PREFERRED FORMAT IN EMERGING COUNTRIES
ACTIVE INGREDIENT COMPOSITION NOT INCREASING
BULK DENSITY GETTING IMPORTANCE EVERYWHERE
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PRICE IS THE MAIN FACTOR TO MAINTAIN COMPETITIVITY
IN LAUNDRY OVERALL PERFORMANCE RECOGNIZED AS SUPERIOR VS. OTHER TYPES
PACK SIZE NOT INCREASING
WORLD LIQUID DETERGENT TREND
LEADING THE MARKET IN DEVELOPED AREAS
INCREASING SHARE ALMOST EVERYWHERE
FORMULATION TECHNOLOGY CONTINUOUSLY UNDER DEVELOPMENT
SPECIALIZATION IS THE MAIN DRIVER FOR THE CONSUMERS
ATTENTION ON SAFETY AND ENVIRONMENT INCREASING WORLDWIDE
HIGH QUALITY OF SURFACTANT IN SYNERGY WITH CHEMICAL BOOSTER
COMPETITION WITH POWDERS IS STILL IMPORTANT
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PACKAGING SIZE, SHAPE AND MATERIALS BECOMING EXTREMELY IMPORTANT
Thank you for your kind attention!!! Let’s networking to win together
Ing. Ilio Sebastiani PhD: ISebastiani@DesmetBallestra.com
Detergents Surfactants Soap & Chemicals