1. SAPONIFICATION :
The Batch Method
Semi Boiled Saponification for the production of medium quality soap is made by a simple mixing and heating process in a Crutcher (soap mixer) and is used for making small (1 to 5 tonnes) batches of laundry or household soap. Any impurities in the raw materials will be present in the finished soap and there is no wasted discharge to drain.
Fully Boiled Saponification for production of good to high quality soaps is made in kettles. This is the commonest form of soap making. It can be used for laundry soap or toilet soap. The Fully Boiled Soap is washed during the process to remove any impurities or glycerine. Batch size is typically 25 to 50 tonnes and 3 to 5 kettles are used. Typical plant outputs are 1 to 5 tonnes per hour. The fully boiled and washed soap (called neat soap) produces soap to international quality standards. Some wastes may need to be discharged to drain if glycerine is not recovered from these wastes (called lye).
The Continuous Process
Continuous Saponification is suitable for the production of all grades of soap up to the highest quality levels. This system is not suitable for production rates of less than 50 tonnes of soap per day. The system can be sized up to soap production rates in excess of 200 tonnes per day.
In the process, raw materials are accurately metered via a special pump to the saponification reactor. Following reaction, the neat soap is separated from the glycerine rich by-product of the reaction. The separation takes place in two main stages, firstly in the rotating disk column, secondly via centrifuge separation. The neat soap is pumped to storage, or directly to vacuum spray drying section.
Since glycerine is valuable, the plant will often include a glycerine recovery section to purify the recovered glycerine.
Continuous Neutralisation is a also a continuous process, but it is significantly simpler than the saponification process. The fatty raw materials in this process are fatty acids rather than palm oil (blends) or tallow.Once again raw materials are accurately metered to a neutralisation reactor. There is no by-product to the neutralisation process, therefore there is no separation stage. The neat soap is pumped to storage, or directly to vacuum spray drying section.
2. DRYING STAGE :
Chilling Roll Method
This process uses chilled rolls to dry the liquid neat soap into soap ribbons. The liquid soap is pumped onto chilled cooling rolls, and immediately solidifies. The solid soap is continuously scraped off the chilling roller as a ribbon or flake and drops into a wooden or plastic tray. When all the trays are full they are placed in racks or trolleys and moved into a Drying Room where they are left for a period to dry or cool.
Vacuum Spray Drying Method
The liquid neat soap is pumped through the heat exchanger and then it is sprayed into the v
acuum chamber. The water vapour is extracted by a vacuum system and the final water content of the soap is controlled by adjusting the heat exchanger temperature and the level of vacuum. Typical final moisture levels are 22 % moisture for laundry soap and 13 % for toilet soap.
The soap dries as it passes across the vacuum chamber and sticks to the internal surfaces. It is scraped off by a set of slowly rotating knives and falls into a plodder on which the vacuum spray chamber is mounted. The plodder continuously extrudes soap whilst maintaining the vacuum seal and can deliver noodles for toilet soap or a continuous extrusion for laundry bars.
3. FINISHING STAGE :
The finishing process varies whether the final product is Laundry Soap or Toilet Soap. The customer can choose between semi-automatic and fully-automatic levels of operation, both for individual machines or for complete production lines.
The Batch Method
Semi Boiled Saponification for the production of medium quality soap is made by a simple mixing and heating process in a Crutcher (soap mixer) and is used for making small (1 to 5 tonnes) batches of laundry or household soap. Any impurities in the raw materials will be present in the finished soap and there is no wasted discharge to drain.
Fully Boiled Saponification for production of good to high quality soaps is made in kettles. This is the commonest form of soap making. It can be used for laundry soap or toilet soap. The Fully Boiled Soap is washed during the process to remove any impurities or glycerine. Batch size is typically 25 to 50 tonnes and 3 to 5 kettles are used. Typical plant outputs are 1 to 5 tonnes per hour. The fully boiled and washed soap (called neat soap) produces soap to international quality standards. Some wastes may need to be discharged to drain if glycerine is not recovered from these wastes (called lye).
The Continuous Process
Continuous Saponification is suitable for the production of all grades of soap up to the highest quality levels. This system is not suitable for production rates of less than 50 tonnes of soap per day. The system can be sized up to soap production rates in excess of 200 tonnes per day.
In the process, raw materials are accurately metered via a special pump to the saponification reactor. Following reaction, the neat soap is separated from the glycerine rich by-product of the reaction. The separation takes place in two main stages, firstly in the rotating disk column, secondly via centrifuge separation. The neat soap is pumped to storage, or directly to vacuum spray drying section.
Since glycerine is valuable, the plant will often include a glycerine recovery section to purify the recovered glycerine.
Continuous Neutralisation is a also a continuous process, but it is significantly simpler than the saponification process. The fatty raw materials in this process are fatty acids rather than palm oil (blends) or tallow.Once again raw materials are accurately metered to a neutralisation reactor. There is no by-product to the neutralisation process, therefore there is no separation stage. The neat soap is pumped to storage, or directly to vacuum spray drying section.
2. DRYING STAGE :
Chilling Roll Method
This process uses chilled rolls to dry the liquid neat soap into soap ribbons. The liquid soap is pumped onto chilled cooling rolls, and immediately solidifies. The solid soap is continuously scraped off the chilling roller as a ribbon or flake and drops into a wooden or plastic tray. When all the trays are full they are placed in racks or trolleys and moved into a Drying Room where they are left for a period to dry or cool.
Vacuum Spray Drying Method
The liquid neat soap is pumped through the heat exchanger and then it is sprayed into the v
acuum chamber. The water vapour is extracted by a vacuum system and the final water content of the soap is controlled by adjusting the heat exchanger temperature and the level of vacuum. Typical final moisture levels are 22 % moisture for laundry soap and 13 % for toilet soap.The soap dries as it passes across the vacuum chamber and sticks to the internal surfaces. It is scraped off by a set of slowly rotating knives and falls into a plodder on which the vacuum spray chamber is mounted. The plodder continuously extrudes soap whilst maintaining the vacuum seal and can deliver noodles for toilet soap or a continuous extrusion for laundry bars.
3. FINISHING STAGE :
The finishing process varies whether the final product is Laundry Soap or Toilet Soap. The customer can choose between semi-automatic and fully-automatic levels of operation, both for individual machines or for complete production lines.
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