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The modern day soap mixer machines are carefully designed to develop soap chips in a uniform
texture with color and perfume.
MIXER MACHINE
The mixing action is attained by using the specially shaped "Z" blades that are fitted on parallel
shafts mounted with close clearance in a double 'U' shaped trough.
With the help of blades, the mass is rolled; folded back and pushed down to join the separate
layers.
This action is repeated till the time the desired uniformity is obtained.
The tilting arrangement in small unit is achieve through manual procedure and in larger units it
is further incorporated with a gearbox and motor that are operated by electric control.
SOAP CUTTING MACHINE
Soap cutting machine is the equipment used in soap manufacturing
process to cut soap bars into desired lengths, sizes and forms.
In these machines, soap cutters are usually placed downstream from a
plodding machine and the soap bars that come from the plodder enter the
cutter and come into contact with an incremental encoder, which sends a
signal to the cutting system.
The cutting system provides a horizontal and vertical blade shift, to cut
bars into the specified lengths and sizes.
The soap cutting machines are designed and manufactured with two
conveyors for separate cutting unit, which are used to feed the soap bars
into the cutter and then carry them out of the cutter.
Types of Soap Cutting Machines
Soap cutting machines are only one category of soap manufacturing machines.
However, they too are available in many varieties nowadays. The available soap cutting
machines can be categorized as:
Air powered soap cutter
Manual soap cutter
Loaf soap cutter
Double cutting machine
Bar size-cutting machines
Rotary soap cutting machine
Air Powered Soap Cutter
These soap making machines are ideal for cold processed soap cutting, the Air Powered Soap
Cutters can be used to produce thousands of perfect bars a day by a single person.
Completely boiled saponification for producing high quality soap is done in kettles.
This is the most common method of soap making and can be used to make laundry or toilet
soap.
Batch Method
The completely boiled soap is washed during the process to remove any glycerin or impurities.
Batch size is usually 25 to 50 tonnes and 3 to 5 kettles are used in this process.
The plant outputs are generally 1 to 5 tonnes per hour.
The technique can be used to produce soap of international quality standards.
Some wastes may require to be discharged to the drain if glycerin is not recovered from these
wastes (called lye).
Continuous Process
Continuous saponification process is suitable for producing different grades of soap of different
quality standards.
This system is not suitable to manufacture soaps at the production rate of less than 50 tonnes of
soap per day.
The system can be designed to achieve soap production rates in excess of 200 tonnes per day.
In the continuous process technique, raw materials are accurately metered using a special pump
to the saponification reactor.
Continuous Process
Following the reaction, the clean soap is separated from the by-product of the reaction (rich in
glycerin).
The separation occurs in two main stages, at first in the rotating disk column, and secondly
through centrifuge separation.
The clean soap can be pumped to the storage, or directly to the vacuum spray drying section.
Because of the high value of glycerin, the plants generally come with a glycerin recovery section
to purify and retain the glycerin