Bar Soap Finishing

Luis Spitz
1. Spitz, Inc., Highland Park, Illinois, USA

Introduction
Bar soap finishing consists ofsix processingsteps for the production of standard, superfatted, translucent, soap/synthetic (combo), and synthetic products into a solid bar (tablet) form packaged in various styles. The processing steps, the equipment used in each step, and bar soap finishing-line classification and selection are presented.

Processing Steps and Equipment

Processing Steps
Mixing the main dry soap base, mostly in pellet form, with minor liquid and solid ingredients.
ReJning the fully formulated mixture into a uniform, homogeneous product.

Extruding the finished product into a compact predetermined shape and size slug (billet). Cumngthe extruded slugs into individud lengths as required by the soap press model used. Stamping the cut slug (billet) into a specified weight and shaped bar (tablet). Packaging the finished stamped bars.
Miring
Mixing has no precise definition or measuring criteria in the soap industry. Macro and micro terms are used in other industries, and one can apply them to soap mixing. One can call the mixing of 1% or higher quantities of solid and liquid ingredients with the dry pelletized soap base in standard mixers macro mixing. During macro mixing, the additives only coat the outer surface of the pellets. Intensive or micro mixing is achieved when the pellets are broken up to expose more surface area, helping the ingredients to penetrate into the pellets.

Refining Refining is the work done on soap by the combined action of pressure and shear. The purpose of refining is threefold:
1.

To produce a hlly homogeneous, uniform product.

2. To improve bar feel by eliminating low solubility hard particles.

3. To enhance product lather, solubility, and firmness by affecting crystalline structure change.
Refining is performed with plodders, roll mills, or both units used in combination.

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BAR SOAP FINISHING

PROCESSING STEPS AND EQUIPMENT

Fig. 11.1. Bar soap finishing: Processing steps and equipment.

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Plodder Refining One full stage of refining is achieved when a plodder is fitted with a 50-mesh sized refining screen (Fig. 11.2) When 20 or 30 US mesh size sized screens are used, the degree of refining is reduced. ?he most widely used refining screen is the square mesh wire type. Screen suppliers offer the same mesh-number screens with different wire diameters, widths of opening, and percentages of open area (Table 1 1.1).

Soap Pellets

Refined Soap Pellets

Refining Screen

Drilled Plate with 8 mm holes and 9.5 mm counterbore

1 pass through a 50 mesh screen represents 1 Stage of Refining

Fig. 11.2. Plodder refining.

Table 11.1. Refining Screen Specifications

US Mesh Number
10 Wire Diamenter (inlmm) 0.0471 1.19 Width of Opening (inlmm) 0.059 / 1.so 0.068 1 1.73 0.075 I 1.91 0.030 10.76 Open Area

(%I
34.8 46.2 56.3 36.0 41.O 46.2 30.1 37.1 40.8 36.0 30.3 39.1

0.032 10.81
0.025 10.64 0.020 10.508

20

0.018 I 0.320 0.01 6 I 0.406 0.01 5 10.3ai

0.032 10.81
0.034 10.86 0.01a 10.47 0.020 10.52 0.02 1 I 0.54
0.01 2 10.31

30

0.013 10.330 0.01 2 10.305

0.008 10.203
50

0.009 10.229
0.0075 10.191

0.01 1 10.28 0.0125 10.32

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Roll-Mill Refining
The degree of refining (homogenization and dispersion) of the minor ingredients into the main soap base by a roll mill depends on two variables: the roll gap (clearance or nip) which determines the soap flake thickness and the shear generated by the roll speed differentials. For most products, the gap between the last two rolls should be set at 0.15 to 0.20 mrn for maximal performance. One must note that the actual flake (ribbon) thickness will be 0.05 to 0.06 mm more than the actual gap setting. This is due to the mechanical tolerance of the roller bearings. The gap setting and speed differential between the last two rolls determine the degree of refining and the control of the product temperature. Unlike plodders, which always increase the product temperature during refining, roll mills are capable of maintaining and even reducing the product temperature. Soap pellets passing through a roll mill are usually converted into thin flakes which are then usually formed into crimped flakes for easier subsequent conveying. The flaker knife (take-off) is a blade designed with multiple cuts and angles to produce a thin flake. The crimped, compacted flakes are formed with a scraper blade and a crimping bar (Fig. 11.3).

Fig. 11.3. Roll-mill refining.

Plodder and Roff-MiU--Refining Stages Comparison A general comparison guide for the stages of refining between plodders and roll mills is presented; the classification of finishing lines is based on the number of refining stages (Table 11.2).

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Table 11.2. Plodder and Roll-Mill-Refining Stages Comparison Number of RefiningStages

1H

Plodder Refining Screen Mesh Number

80

Roll Mill Flake Thickness (mm)

015 .

1
%4

H
,/4

50 30 20
10

0.20 0.25 03 .0
0.40

The use of finer than 50 mesh screens (such as 80 mesh) is not recommended due to an excessive product temperature rise and a potential production rate reduction.

Methodrfir Measuring tbe D e p e of Rc$ning Washdown Temperature he washdown-temperature test is used to measure the degree of refining-evaluating the presence of hard particles (specks) by soap feel (grittiness, sandiness, roughness). The bar is washed with both hands for 1 minute in a sink with 30C water. Once the bar surface is smooth and all protruding lettering and designs are washed away, the water temperature is decreased. Washdown temperature is the temperature at which one can detect the first hard specks.

A smooth bar without any hard specks has a 22C washdown temperature.

A slightly gritty feel appears at 23 to 24C.

A moderately gritty feel appears at 25 to 26C.

A gritty feel appears at 26 to 27C. A very gritty feel occurs when the washdown temperature reaches 28C or higher.
Photo-EvaluationScale One can also use a visual method for roughness evaluation. The bar is washed for 1 minute in 20C water and then left to dry. If the bar is held at an angle in front of a high-intensity light source and below eye level, one can easily see the dry specks. By using photographic standards, one can grade the bar as 0, 1,2, 3 , 4 , or 5. Zero represents a smooth product, whereas five refers to a very gritty bar (Fig. 11.4).

Pre-retining Pre-refining is a refining step performed before the addition of any minor liquid and solid additives to an old (filly aged) or to a new (fresh or partially aged) dry soap base. The use of a pre-refining step is especially advantageous for aged soap, low-moisture-content syndet, and high-titer soap. The main advantages of pre-refining are:
Easier processing of hard, low-moisture-content syndet, high titer, and translucent soap. Better mixing of the liquid additives with the plasticized, higher temperature, partially refined base. This facilitates the refining action in the subsequent processing stages. Improved refining (lower washdown temperature of the finished product).

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Soap Base Aging If the soap base (with or without additives) is stored and aged before final refining, extrusion, and stamping, line efficiency increases considerably. During aging, soap crystallization is completed, and soap temperature is reduced. The optimal aging time has to be determined experimentally for each specific soap formula.

Fig. 11.4. Photo-evaluation scale.

Finishing-Line Equipment
Mixers
Amalgamator with Open-Ann Sigma Blahs The most popular and widely used mixer, called amalgamator in the soap industry, is a top-loading, bottom-discharging, non-tilting unit with open-arm type Sigma profile blades. This easy-to-clean, efficient blade design is derived from the Sigma blade, which is the universal mixing blade in the chemical industry. These mixers mainly coat the outer surface of the pellets with the additives. Mixers only partially break up the pellets, thereby limiting the penetration of the additives (Fig. 1 1.5).

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Soap Pellets, Perfume, Color & other Additivies

"Open Sigma" Blades

Mixture to Refining

Fig. 11.5. Amalgamator.

Double-Arm Mkers with Sigma Bladcs

The double-arm mixers with two counter-rotating tangential or overlapping Sigma blades (Z blades) are very efficient units; in spite of their higher cost, they are gaining increased acceptance in the soap industry. They are mainly used for synthetic and combo toilet soaps, synthetic laundry bars, and translucent soap production. They are offered in fixed- and tilting-type discharge versions (Fig. 11.6).

MkeKneadcrs
A mixer-kneader consists of a double-arm mixer with wo tangential Sigma blades and a discharge extruder screw. The extruder is located at the bottom of the mixer vessel trough (bowl), and is fitted with a pelletizing head similar to a plodder. The rotation of the two Sigma blades creates intensive mixing/kneading action. Intensive mixing/kneading action is achieved by the countercurrently rotating Sigma blades (one rotating twice as fast as the other) and the screw pushing the product up into the blades. At the end of the mixing cycle, the screw rotation is reversed to facilitate product discharge and pelletizing. Mixer-kneaders for soap applications were introduced in the 1960s by Miag from Germany. They have not gained much acceptance over the years because of their high cost and because they do not offer real advantages over the use of a batch amalgamator followed by a separate simplex refiner. Binacchi recently reintroduced these mixers to the soap industry. Mixer-kneaders are especially suited for translucent-soap production lines (Fig. 1 1.7). Ribbon blender, paddle, and plow type mixers have found limited use in the soap industry.

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Fig. 11.6. Double-arm sigma mixer.

Fig. 11.7. Mixer-kneader. Source: Binacchi & Co.

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Roll Mills
Soap mills were always available in three-, four-, and five-roll variations. Over the last decade, the four- and five-roll mills practically disappeared; three-roll mills became the industry standard for the following rcasons: Contact areas are large enough to ensure proper product refining and cooling. Most of the total power absorbed, that is, the heat input to the soap, takes place between the last two rolls. Gap-clearance-setting adjustment and control are easier. Three-roll mills have lower operating costs due to lower power and cooling-water requirements. Roll-configuration geometry is very important because it determines the total contact area available for refining and cooling (Fig. 11.8). Binacchi's model BRM-V three-roll mill was introduced this year. This novel design with a V-shaped roll positioning has a 510" total contact surfice area higher than other three-roll mills. Also, this design is claimed to assure that no soap MIS to the ground. No soap contamination occurs, and optimal temperature control is achieved. Each roll has an independent drive and gear box, features which allow the speed of each roll to be changed as required (Fig. 1 1.9).

265O

THREE-ROLL MILL CONTACT AREAS

235O

Total Contact Area = 490

Total Contact Area = 415O

Fig. 11.8.Three-roll mill contact areas.

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Fig. 11.9. Binacchi BRM-VThree-Roll Mill. Source: Binacchi & Co.

Roll Design Metallurgy

Standard quality rolls are made of compound, chilled cast iron with 500-550 HB (Brinell) hardness. For reduced corrosion and wear, high-chromium cast-iron rolls are indicated with 520-580 HB to a depth of chill of 15 to 20 mm. The cooling efficiency depends on the minimal thickness of the chilled white-iron outer layer of the cast-iron rolls, which has a thermal conductivity of 20 to 25 W/m"C. The thermal conductivity of the rolls' gray-iron core is higher, ranging from 45 to GO W/m"C.

Roll Cooling Systems

Several roll water-cooling systems are illustrated. The most widely used system sprays water onto the inside wall of the rolls (Fig. 1 1.10). The standard and the more expensive, seldom used, high-efficiency peripheral roll cooling systems are shown in Fig. 1 1.1 1. The peripheral system with a temperature-control unit is shown in Fig. 11.12.

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Water Discharge

Fig. 11.1 2. Peripheral roll-mill cooling system with temperature-control unit.

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Plodder Types
The soap industry uses three basic types of plodders, each of which is available in single-worm and twin-worm versions:

Simplex Ref;ners A simplex refiner consists of one plodder designed to operate with a 50-mesh refining screen at a maximal pressure of GO bar. Duplex Re$ners A Duplex Refiner consists of two Simplex Refiners mounted in tandem. Duplex ficuurn Ph&s A Duplex Vacuum Plodder consists of two plodders mounted in tandem and connected by a vacuum
chamber. The preliminary stage plodder is exactly the same as a simplex refiner, and one can use it with a 50 mesh refining screen. In the final-stage plodder, the refined pellets are compacted and extruded as a continuous slug (billet), free from any entrapped air (Fig. 11.13). One must note that a plodder functions as a refiner only when it is fitted with a 50-mesh screen. When 30 or 20 screens are used, the refining degree is reduced. The IO-mesh and coarser screens are used at times as backup, protective screens for the finer 30- or 50-mesh refining screens.

PLODDER TYPES
Simplex Refiner
One Plodder designec t o operate with a 50 mesh refining screen at 12-15 rpm worm speed and 60 bar maximum pressure.

Duplex Refiner
Two Simplex Refines mounted in tandem.

Duplex Vacuum Plodder

The first stage is a Simplex Refiner and final stage is an Extruder. The two plodders mounted in tandem are connected by a vacuum chamber.
Fig. 11.1 3. Plodder types.

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Plodder Refining and Pelletizing Group

'The refining stage of any plodder has a refining and pelletizing group as shown in Fig. 1 1.14, 16 and 17.

Fig. 11.14. Plodder refining and pelletizinggroup.

Plodder Extrusion Group

All of the components of the extrusion group of a Duplex Vacuum Plodder are illustrated in Fig.
11.15.

Fig. 11.1 5. Plodder extrusion group.

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Fig. 11.16. Refining/PelletizingStage details.

Fig, 11.17. Refining/PelletizingStage details.

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Plodder Worms
Plodder worms are designed to perform refining, compression, and extrusion functions.

W o r m Types Three types of worms are available: (i) single-worm (ii) tangential twin-worm and (iii) nontangential twin-worm:
Twin-worm plodders are available with tangential (touching) counter-rotating worms in a single barrel or nontangential (nontouching) counter-rotating worms in two separate barrels. Twin-worm plodders with tangential (touching) counter-rotating worms in a single barrel are recommended for processing sticky products and for high-capacity production lines. Nontangential twin-worm plodders are used for high-speed lines and multicolored soaps (Fig. 11.18).

Terminology Lc is the closed barrel section and D is the worm diameter. Please note that the Lc/D ratio is not the same as the L/D ratio, which is the total worm length L to the D worm-diameter ratio (Fig. 1 1.19).
Worm Styks Several worm styles are available with different profiles suitable for various applications. A summary of Binacchi, Mazzoni LB, and Sela worms is shown in Figures 1 1.20, 1 1.2 1, and 1 1.22. Optimizing a plodder-worm design depends on extensive testing with different products. This is an ongoing challenge for equipment suppliers.

Fig. 11.1 8. Plodder worm types.

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Fig. 11.19. Plodder-wormterminology.

Recommendedfor Toilet and Syndet Products SQ Profile

Recommended for Laundry Soap Applications

SW Profile
Fig. 11.20. Binacchi plodder worms. Source: Binacchi 81Co.

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Mazzoni LB Plodder Worms

4:l Lc/D Ratio

Fig. 11.21. Mauoni LB plodder worms. Source: Mauoni LB, SPA.

Short- and Long-LdD-Ratio Plodders : Conventional plodders are designed with 3 l Lc/D ratios, and operate at 12-15 rpm worm speeds. 'The 4 l types operate at 18-20 rpm, and the long 9 l Lc/D ratio units operate at up to 50 rpm worm : :
speeds. The first 4l Lc/D ratio NOVA plodders were introduced in 1984 by G. Mazmni SPA. In 1988 : Binacchi & Co. launched the Extenda models. Currently all suppliers offer mostly 4 l Lc/D-ratio : plodders.

Special New Plodders

Two special plodders with long Lc/D ratios, special worm designs, and refining and milling options were introduced by Mazzoni LB and SAS.

Maeeoni LB Mdti@ning Pbddrr (MW) The multirefining plodder (MRP) is also a Duplex Vacuum Plodder designed to refine, homogenize, and extrude. It is claimed that the special characteristics permit its use in a finishing line without the
need of any additional equipment. The MRP's first refining stage is a 4 l Lc/D-ratio twin-worm plodder with H E style worms. The : final multirefining stage consists of a single-worm plodder in two separate sections. The first section has a 7: 1 Lc/D ratio, and the second section has a 2: 1 LdD ratio. Both are HE-type worms. The second section is removable to ficilitate cleaning (Figs. 11.23,24).

Pl
Recommended for Combo Bars and Rim Blocks

P2
Constant Pitch P1= P2

Pl
Recommended for Toilet, Syndet, and Laundry Soaps

P2
Single Decreasing Pitch Pl:P2 = 1.61

ww
PI

P2
Double DecreasingPitch Pl:P2 = 2.51

Recommended for Translucent Soaps

4.-

VI

2 r n

Fig. 1122. Sela plodder worms. Source: SELA GmbH.

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Fig. 11.23. Mauoni LB MRP (Multirefining Plodder).Source: Mauoni LB, SPA. For more details see Fig. 1 1.24.

Fig. 11.24. Mauoni LB MRP (MultirefiningPlodder) final stage. Source: Mauoni LB, SPA.

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SAS Transavon Dupkx Vacuum Plodder The first Transavon units were offered for the production of translucent soap, starting with properly formulated opaque soaps. Now the Transavon Duplex Vacuum Plodder is offered for the production of any type of toilet soap. Due to its enhanced refining action, one can use the Transavon Duplex Vacuum Plodder as the sole machine in a finishing line in the substitution for a conventional Simplex Refiner plus a Duplex Vacuum Plodder. The SAS Transavon Duplex Vacuum Plodder consists of:
A refining-stage plodder with either a long 9: 1 LdD-ratio single-worm combo-screw or a 7:1 LdDratio standard twin-worm. A refining- and extruding-stage plodder with a long 9: 1 LdD-ratio single-worm combo-screw. ?he special profile combo-screw has a conventional diameter in the feed area, a tapered section, and a small diameter in the compression section. The find-stage plodder has the unique adjustable milling-valve for extra refining function. The adjustable opening (gap setting) defines the achievable degree of refining. An extrusion cone completes the last stage (Figs. 11.25,26).

Fig. 11.25. SAS Transavon Duplex Vacuum Plodder. Source: SAS.

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Fig. 11.26. SAS Transavon Duplex Vacuum Plodder details. Source: SAS.

Cutters
The extruded slugs (billets) from the Duplex Vacuum Plodders are cut into predetermined-length single slugs when traditional soap presses are used. ?he flashstamping presses require multiple-length slugs. During the last decade, the mechanical multiblade cutters with fixed and manually adjustable chains were replaced by the electronidpneumatic and fully electronic cutters. Due to constantly advancing electronic technology, todays cutters operate with ever increasing speed and cutting accuracy of: single length, multiple length, and short slugs which facilitate handling of recycle (reprocessing). The Mazzoni LB model TE electronic cutter was introduced in 1994 followed by the TVE type in 1998 (Fig. 1 1.27). The application of engraving rollers to cutters is increasing for the natural-looking unstamped soaps, laundry soaps, and hotel soaps. Engraving the top, bottom, and sides of the extruded product is an economical alternative to soap stamping (Fig. 1 1.28). The new Binacchi ECM-2000cutter is illustrated in Fig. 11.29. The new SAS Easycut is shown in Fig. 11.30.

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"TE" Cutter

Head

Extruded Slug

Cutting Blade

'BE

-_,........... """'

cut MuIti ple Length Slugs

Cutting BIade

Extrusion Head

Slug

Id

I-

Short Slugs Cutting Mode

Short Cut Slugs For Recycling

Fig.ll.27. Mauoni LB single-blade electronic cutters. Source: Mauoni LB, SPA.

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Bar Soap Finishing 0 325

Extruded Slugs from Plodder

2 Engraving Rollers for Top Embossing

2 Engraving Rollers for Side Embossing

4 Engraving Rollers for Embossing Soaps on Top, Bottom and Sides

Fig. 11.28. Engraving rollers for cutters. Source: M a u o n i LB, SPA.

Continuous Rotation Group withlwo Cutting Blades

ExtrudedSoap Slugs (Billets)from Plodder

Encoderfor Slug Cutting length Control

Operator Panel for in Operation Cuttinglength Change

Fig. 11.29. Binacchi ETC-2000 electronic cutter. Source: Binacchi 81Co.