COMPANY OUTLINE

www.mazzonilb.it
 Mazzoni headquarter

Mazzoni LB S.p.A. Tel +39 0331 356111

Corso Sempione 212, bis Fax +39 0331 684511
21052 Busto Arsizio – ITALY e-mail: sales.soap@mazzonilb.it
 Who we are?
Mazzoni was founded in 1946 by Mazzoni
family and as from 1990 has been associated
to the Ballestra Group. The core activity of
Mazzoni has always been focused on
innovative process technology to produce
soap and glycerine.
Mazzoni has supplied more than 2,400 plants MAZZONI plants in the World.
in over 130 countries: every year Mazzoni Over 2400 process plants in 130 countries
continuous saponification plants produce up
Over 2400 process plants in 130 countries
to 4,500,000 tons of liquid soap, and their finishing lines up to 14,000,000 tons of
laundry soap and up to 4,500,000 tons of toilet soap. Mazzoni glycerine plants
evaporate up to 2,000,000 tons of water and distillate over 200,000 tons of
pharmaceutical grade glycerine.

All major multinationals are Mazzoni clients as Procter and Gamble, Colgate,
Henkel, PZ Cussons, Reckitt Benckiser and Unilever as well as the most
important soap manufacturers all over the world.
 Mazzoni technologies
SGA: Bleaching Plants
Fats and Oils
Pretreatment

SCNT: Continuous Neutral Fats/Oils Saponification Plants

SCT: Continuous Fatty Acids Neutralization Plants
Saponification SCT-C: Combined F.A. Neutralization & Drying Plant
SSCT: Continu. Neutr. F/O Sapon. without Glycerine extraction

DCA: Spent Soap Lyes Treatment Plants

CSL: Industrial Glycerine Plants
Glycerine Refining DGA/GR: Pharmaceutical Glycerine Plants

SC+C, SSCT+C: Integrated Saponification/Drying Systems

CL: Laundry Soap Drying Plants
Vacuum Drying Ecodryers: Toilet Soap Drying Plants

LBC: Laundry Soap Finishing Lines

LTC: Toilet Soap Finishing Lines
Finishing SLB: Synthetic Soap Finishing Lines
MP: Milling Plodder Finishing Lines

RBL: Rim Blocks Manufacturing Lines

Rim Blocks
 Mazzoni technologies
Beside the core soap plant business, Mazzoni has been involved over the year in
the design and supply of plants for the production of:

- personal care and cosmetics;

- food processing;

so acquiring and excellent capability to engineer also a wide range of chemical

and industrial plants, as well as the relevant offsites facilities (steam, cooling
water, power distribution, tank farm, etc.).
 Mazzoni shareholding
The Mazzoni shareholding is:
80%: Sagittario S.p.A.
10%: Paolo Tovaglieri, Sales Director
10%: Enrico Tovaglieri, Technical Director

Sagittario S.p.A. is the holding company which has developed and managed from
1990 up to 2007 the companies:

 Ballestra S.p.A./Milan, today Desmet Ballestra S.p.A., world leader in the

design and supply of plants for the detergents, surfactants, biodiesel and
chemical industries, which presently owns a participation of 20% of Mazzoni;
 CMB S.p.A./Rome, today Desmet Ballestra Oleo S.p.A., leader in design and
supply of plants for the oleochemical industry, which is fully owned by Desmet
Ballestra S.p.A.

Sagittario shareholders still retain important management position in Desmet

Ballestra S.p.A.
 Mazzoni world presence
Beside its own sale dept which coordinates all the sale activities providing also the
necessary technical support, Mazzoni has a network or representative offices, the
main ones in Russia and China, and the collaboration of Desmet Ballestra Group
worldwide sales network.
Mazzoni network or representative offices Desmet Ballestra Group sales network

China Russia

Algeria Japan Sudan

Bangladesh Mexico South Africa

Brazil Nigeria Sri Lanka

Egypt Pakistan Venezuela

Germany Poland UK

Indonesia Portugal
 Mazzoni Organization Chart
CEO
Giuseppe di Carpegna

Controller Quality Assurance & IT

R&D Customer Service

Ferrari/Montanari

Sales dpt. Engineering dpt. Admin & Finance

P. Tovaglieri E. Tovaglieri E. Imperiali

Sales & Proposal Project mgt Admin/H&R

Marketing Purchase Dpt Export/Finance

Spare Parts Process Tech Health & Safety

Finish. line Tech

Automation Dpt

Workshop
 Mazzoni Personnel
Mazzoni personnel includes 6 senior managers, 61 employees, 31 workers
for an overall amount of 98 persons divided as follows.

31 23
PM, Tech Dpt., R&D
Sales & Proposal
8
Procurement
6 Spare parts & Customer Service
9 Manag., Admin. & Accounting
12
Workshop
Food Division
 Mazzoni turnover

35,000
€ x 1.000
30,000

25,000

20,000

15,000

10,000

5,000

0
2007 2008 2009 2010 2011

Mazzoni has constantly

maintained a market share exceeding 50%.
 Production Distribution (geographic area)

2007 2008
AMERICA
27% AMERICA EUROPE
EUROPE
12% 36% 8%
ASIA
ASIA 28%
30%
AFRICA
31% AFRICA
28%

2009
AMERICA
EUROPE
24%
4% Mazzoni sells yearly to customers
ASIA located in over 100 different countries
39%
AFRICA
33%
 Production Distribution (products)

2007 2008
Spare Spare
Parts Parts
14% Plants 13% Plants
42% 38%

Machinery
Machinery
44%
49%

2009 2010
Spare Spare
Parts Parts
14% Plants 14%
31% Plants
46%
Machinery
40%
Machinery
55%
 Mazzoni services
Research & Process Development
Process and detailed engineering
Feasibility studies
Products testing on Pilot Plants
Equipment fabrication and procurement
Supervision to plant installation and start up
Turn-key projects
Training of operators
Spare parts supply
After sale technical assistance
Plants revamping/upgrading/capacity increase
Project financing
 Mazzoni after sale services

 Troubleshooting.
 Plant performance (product quality, energy
consumption, plant operation reliability)
evaluation and optimization.
 Evaluation of plant equipment operating conditions for planned
maintenance (mechanical, electrical, instrumentation & control).
 Customer’s personnel training.
 Advisory services on new technologies, new equipment available on
the market, improvements of plant operation, safety ...
 Study and proposal for plant revamping and capacity increase.
 R&D - Latest Innovations - Process

Saponification plants
The Tubular Reactor:

-Static multi tube reactor

-Saponification conditions: pressure (3-3.5 bar) and

temperature (135/140 °C) .

-Holding time reduced to 8 min vs. 20/30 min. of the

traditional reactor

-Easy formula changeover

-Versatility: the Tubular Reactor can saponify Neutral

Fats/Oils and Fatty Acids

-Reduced maintenance and space requirement

39 Units installed world-wide.

 R&D - Latest Innovations - Process

Saponification plants

Integrated Toilet Soap Plants “SCT + C” and “SSCT-C” the

ideal solution for producing high quality soap noodles from Fatty
Acids or from Neutral Oils/Fats (SWING).

The liquid soap is directly fed from the Tubular Reactor to the
Vacuum Chamber allowing to manufacture all types of laundry
and toilet soap noodles at the required final TFM content with a
remarkable energy saving:

11 Units installed world-wide.

 R&D - Latest Innovations

Vacuum Dryers

”NO SPRAY” vacuum chamber with tangential soap

injection vs. conventional Spray Nozzle system.

•Reduced soap fines formation by 50%

•Improved soap chips quality: less grits

•Overall equipment simplification: minimal maintenance

•Easy operations: all regulations outside the chamber

38 Units installed world-wide.

 R&D - Latest Innovations

Soap Drier: VLS (Vapour Liquid

Separator)
Pre-concentrate neat soap prior to the vacuum chamber

-50% recovery of the steam generated in the dryer fro:

- Drive the booster
- Pre-heat of raw materials
- Pre-heat liquid soap

-40-50% reduction of water requirement to the barometric group

-Reduced fines formation (approx. 40-50%)

VLS is retro-fittable in existing dryers

Over 50 Units installed world-wide.

 R&D - Latest Innovations - Finishing

MRP Multi-refining Plodders

A-one-machine-configuration for toilet soap refining,
homogenizing and extrusion substituting two duplex
plodders (or rollmill) of conventional lines

•Process of all toilet soap bases (regular, translucent,

syndet and combo)

• Quick and easy formulas changeovers

•15-20% reduced energy requirement

• Reduced maintenance

•Reduced area required

•Reduced capital outlay

15 Units installed world-wide.

 R&D - Latest Innovations - Finishing

“DTS” Direct Transfer System

To “pitch” discharge the stamped tablets into the pocketed
belt of any packaging machine:
-flowpack – cartoners – wrappers

-“ONE TOUCH” transfer system: better finished tablets

appearance
-Inbuilt on the stamper frame: simplified and compact
unit’s design with easy operation and space saving
-10-15% Higher production speed vs. solutions with timing
systems
->5% superior overall line’s efficiency
-Reduced capital outlay

R&D Joint development with ACMA.

22 Units installed world-wide

 Environmentally Sustainable Production

•Completed installation of a 200KW Solar plant in Mazzoni roof size to produce

100% of workshop and offices power requirements.

•Ongoing Investment in increase of Mazzoni building heat efficiency as well as

machinery cleaning water recovery.

•Plan to mitigate CO2 emissions related to personnel travelling through

promoting and financing green projects in developing countries.