Industry: Personal Care
Solution: CIP System + Mixproof Valve Technology
Results: Improved sanitation, streamlined batching, and scalable processing capacity
The Challenge
A global personal care manufacturer was struggling to meet modern production standards. As demand grew for antibacterial hand soaps and body washes, the limitations of their setup became increasingly costly.
The challenges included:
- Inconsistent manual cleaning and contamination risks
- Long batch cycle times (up to 6 hours per batch)
- Delays and downtime due to inefficient ingredient addition
- Lost batches and unnecessary waste
- Inflexible infrastructure that limited production growth
- Outdated piping and materials that did not meet sanitary standards, including dead legs and improper fittings
The personal care manufacturer needed a cleaner, more compliant, and scalable solution—one that replaced outdated infrastructure with a fully engineered sanitary process system.
The Solution
Oliver M. Dean began with a collaborative, boots-on-the-ground approach: observing production firsthand to identify challenges in real time.
Oliver M. Dean began with a collaborative, boots-on-the-ground approach: observing production firsthand to identify challenges in real time.
The project included:
- A complete facility mapping to document every tank, line, valve, and hose
- The facility’s first clean-in-place (CIP) system, enabling safe, automated cleaning
- A custom-engineered matrix of mixproof valve technology—built to allow precise, contamination-free batching between 30+ ingredients and 9 mixing tanks
- Recirculation loops to eliminate stagnant product and improve cleanability
- Full batch flexibility—allowing different products to run simultaneously without downtime
- Upgraded to sanitary stainless-steel tubing and corrected piping issues such as dead legs and properly oriented reducers
This wasn’t just an equipment upgrade—it was a holistic move to a sanitary process system that future-proofed the personal care manufacturer’s operations.
The Results
- Enhanced product safety and compliance
- Improved cleanability and sanitation
- Addressed microbial-related concerns with validated sanitation processes
- Enabled full CIP cleaning across tanks and lines
- Cleanliness validated by quality assurance protocols
- Greater efficiency and flexibility
- Reduced batch cycle times drastically
- Enabled overlapping production, cleaning, and filling—unlocking continuous operation
- Adjusted easily to new product lines such as foaming soaps
- Scalable infrastructure
- System built to accommodate new tanks, products, and formulas without rework
- Enabled fast onboarding of products such as men’s body wash and exfoliating soaps
The Conclusion
This project exemplifies Oliver M. Dean’s ability to transform legacy production environments into hygienic, flexible, and future-ready operations. By starting with real-time observation and listening closely to the client’s team, OMD engineered a phased solution that dramatically improved performance and compliance—positioning the client to lead in an evolving personal care market.
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