The Design of an Intensified Process and Production Plant for Cosmetic Emulsions Using Amazonian Oils

The cosmetic industry in the Ecuadorian Amazon region faces the challenge of competitively integrating locally sourced plant-based raw materials into efficient and sustainable production processes. This study proposes the design of a pilot plant for the production of a cosmetic emulsion (CE), using oils extracted from Morete (Mauritia flexuosa) and Ungurahua (Oenocarpus bataua), with a focus on process intensification to reduce both capital investment and resource consumption. Process design methodologies and computational simulation (SuperPro Designer V10) were applied, along with Systematic Layout Planning (SLP) principles to optimize spatial configuration. The intensified scheme enabled the integration of extraction lines, reducing the number of major equipment units from 12 to 9 and lowering the investment from USD 1,016,000 to USD 719,000. Energy and environmental indicators showed consumption levels of 5.86 kWh and 48.4 kg of water per kg of cream, which are lower than those reported for other natural cosmetics plants. The intensified design achieved a Net Present Value (NPV) of USD 577,000 and a payback period of 3.93 years. Furthermore, solid by-products were valorized through circular economy principles. This approach offers a feasible, viable, and sustainable solution for the utilization of these Amazonian oils in the cosmetic industry.