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BAR SOAP FINISHINGLuis Spitz
L. Spitz, Inc.e-mail: [email protected]
phone: 847/965-5151
Soaps, Detergents, Oleochemicals &Personal Care Products
April 5, 2006Hollywood, Florida
Bar Soap Finishing
Bar Soap Finishing - Processing Steps & Equipment
◊ Mixing – Amalgamator, Double-Arm Mixer & Mixer-Kneader
◊ Refining - Plodders & Roll Mills - Plodder and Roll Mill Refining Comparison - Methods for Measuring the Degree of Refining - Plodders - Refining Details, Worm Designs - Roll Mills - Contact Areas, Roll Cooling Systems - Special Plodders - “MP” Milling Plodder & Transavon
◊ Cutting - Electronic Cutters
◊ Stamping - Flashstamping Presses, Direct Transfers & New Presses
◊ Packaging - Wrappers, Cartoners, Transfer Systems & Stamping and Packaging Machinery Combinations
Bar Soap Finishing Line Types and Selection
Bar Soap Finishing
Bar Soap Finishing - Processing Steps & Equipment
◊ Mixing – Amalgamator, Double-Arm Mixer & Mixer-Kneader
◊ Refining - Plodders & Roll Mills
- Plodder and Roll Mill Refining Comparison - Methods for Measuring the Degree of Refining - Plodders, Refining Details, Worm Designs - Special Plodders - “MP” Milling Plodder & Transavon
◊ Cutting - Electronic Cutters
◊ Stamping - Flashstamping Presses, Direct Transfers & New Presses
◊ Packaging - Wrappers, Cartoners, Transfer Systems & Stamping and Packaging Machinery Combinations
Bar Soap Finishing Line Types and Selection
Mixing
There is no precise definition and measuring criteria for mixing in the soap industry. Macro and Micro terms are used in other industries and can be applied to soap mixing.
Mixing of 1% to 5% of solid and liquid ingredients with the dry pelletized soap base in standard mixers can be called 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. This allows the ingredients to penetrate inside the pellets.
AMALGAMATOR
“Open Sigma” Blades
DOUBLE ARM SIGMA MIXER
MIXER-KNEADER
Source: Binacchi & Co.
Sigma (Z) Blades
Heating/CoolingJacket
Extruder Screw
Drilled Plate
Multiblade Knife with Safety Ring
Bar Soap Finishing
Bar Soap Finishing - Processing Steps & Equipment
◊ Mixing - Amalgamator, Double-Arm Mixer & Mixer-Kneader
◊ Refining - Plodders & Roll Mills - Plodder and Roll Mill Refining Comparison - Methods for Measuring the Degree of Refining - Plodders - Refining Details, Worm Designs - Roll Mills - Contact Areas, Roll Cooling Systems - Special Plodders - “MP” Milling Plodder & Transavon
◊ Cutting - Electronic Cutters
◊ Stamping - Flashstamping Presses, Direct Transfers & New Presses
◊ Packaging - Wrappers, Cartoners, Transfer Systems & Stamping and Packaging Machinery Combinations
Bar Soap Finishing Line Types and Selection
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 fully 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 and roll mills.
Drilled Platewith 8 mm holes and9.5 mm counterbore
Refining Screen
SoapPellets
RefinedSoap
Pellets
PLODDER REFINING with Refining/Pelletizing Group
1 pass through a 50 mesh screen represents 1 Stage of Refining
ROLL MILL REFINING
Soap Pellets
0.15- 0.20 mm Crimped or
Thin Soap Flakes
Blade &CrimpingDevice
Gap Setting 0.30 - 0.40 mm
Gap Setting 0.10 - 0.15 mm
ROLL MILL FLAKE TYPES
Crimped,(Compacted)
Flakes
Thin Flakes
REFINING SCREEN SPECIFICATIONS SQUARE MESH WIRE CLOTH
US Mesh Number
Wire
Diameter (inches/ mm)
Width of Opening
(inches/ mm)
Open Area (% )
10
0.047 / 1.19 0.032 / 0.81 0.025 / 0.64
0.059 / 1.50 0.068 / 1.73 0.075 / 1.91
34.8 46.2 56.3
20
0.020 / 0.508 0.018 / 0.320 0.016 / 0.406
0.030 / 0.76 0.032 / 0.81 0.034 / 0.86
36.0 41.0 46.2
30
0.015 / 0.381 0.013 / 0.330 0.012 / 0.305
0.018 / 0.47 0.020 / 0.52 0.021 / 0.54
30.1 37.1 40.8
50
0.008 / 0.203 0.009 / 0.229
0.0075 / 0.191
0.012 / 0.31 0.011 / 0.28 0.0125 / 0.32
36.0 30.3 39.1
PLODDER AND ROLL MILL REFINING STAGES COMPARISON
Number of Refining Stages
PlodderRefining Screen Mesh Number
Roll MillFlake Thickness
(mm)
1½ 80 0.10-0.15
1 50 0.15-0.20
¾ 30 0.30
½ 20 0.40
¼ 10 0.50
One refining stage is achieved when a plodder is fitted with a 50 mesh screen. Partial refining is obtained utilizing coarser screens.
The use of finer than 50 mesh screens will increase product temperature and might result in production rate reduction.
Methods for Measuring the Degree of Refining
Washdown Temperature
The washdown temperature test is used to measure thedegree of refining, evaluating the presence of hard particles (specks) by soap feel (grittiness, sandiness, roughness). Thebar is washed with both hands for 1 minute in a sink with30°C water. Once the bar surface is smooth and allprotruding lettering and designs are washed away, the watertemperature is decreased. Washdown temperature is the temperature at which the first hard specks can be detected.
• A smooth bar without any hard specks has a 22°C washdown temperature.
• A “slightly gritty” feel appears at 23 to 24°C.
• A “moderately gritty” feel appears at 25 to 26°C.
• A “gritty” feel appears at 26 to 27°C.
• A “very gritty” feel occurs when the washdown temperature reaches 28°C or higher.
Photo-Evaluation
A visual method can also be used for roughness evaluation. The bar is washed for 1 minute in 20°C 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, the dry specks can be easily seen.
Using photographic standards the bar can be graded as 0, 1, 2, 3, 4 or 5. Zero represents a smooth product, whereas five refers to a very gritty bar.
Photo-Evaluation Scale
Pre-Refining
Pre-Refining is a refining step performed before the addition ofany minor liquid and solid additives to old (fully aged) or to new (fresh or partially aged) dry soap base.
The main advantages of pre-refining are:
Easier processing of hard low moisture content syndet, high titer, and translucent soaps.
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).
The stage by stage washdown temperature (photo-evaluationscale) changes for a standard refining and for a pre-refining finishing line, each consisting of a total of four plodders, is shown in the graph.
PLODDER TYPES
Simplex Refiner
Duplex Refiner
Duplex Vacuum Plodder
One Plodder designed to operate with a 50 mesh refining screen at 12-15 rpm worm speed and 60 bar maximum pressure.
Two Simplex Refiners mounted in tandem.
The first stage is a Simplex Refiner and final stageis an Extruder. The two plodders mounted in tandem
are connected by a vacuum chamber.
PLODDER REFINING/PELLETIZING GROUPwith Standard and Interchangeable Pelletizing Drilled Plates
Worm Support
Refining Screen
InterchangeableDrilled Plate
Rotating Pelletizing
Knife
Drilled Plate
Support
Worm Support
Refining Screen
Rotating Pelletizing
KnifeStandard
Drilled Plate
Worm
REFINING PLODDER DETAILS
Refining Screen
Drilled Plate
Cooling Water Jacket
Plodder Barrel
MultibladeRotating
Pelletizing Knife
Worm SupportPlate
Cooling Water Inlet
REFINING PLODDER DETAILS
PLODDER EXTRUSION GROUP
Complete Extrusion Head (Cone) Group
DieOrifice
Die OrificeSupport &
Locking Ring
Worm Support
Plate
Temperature & Pressure
Transducers
Oil Heated Section
Small Cone (Optional)
OilThermostat
Tangential Twin-Worm
Non-Tangential Twin-Worm
Single Worm
PLODDER WORM TYPES
PLODDER WORM TERMINOLOGY
SQ Profile
SW Profile
BINACCHI PLODDER WORMS
4:1 Lc/D Ratio
Recommended for Toilet and Syndet
Products
Recommended for Laundry Soap
Applications
HE (High Efficiency)Recommended for All
Types of Products
HV (High Volume)Toilet and Laundry Soaps
Large Capacity Dyers
CT (Constant)For Products which Require Reduced Mechanical Work
Constant Root Diameter
Decreasing Pitch
Increasing Root Diameter
Decreasing Pitch
Constant Root Diameter Constant Pitch
SELA PLODDER WORMS3.5 Lc/D Ratio
P1 P2
P1 P2
P2P1
Recommendedfor Combo Bars and Rim Blocks
Recommended for Toilet,
Syndet and Laundry Soaps
Recommended for Translucent
Soaps
Constant PitchConstant PitchP1=P2
Single Single Decreasing Decreasing
PitchPitchP1:P2 = 1.6:1
Double Double Decreasing Decreasing
PitchPitchP1:P2 = 2.5:1
THREE-ROLL MILL CONTACT AREAS
235°
180°
Total Contact Area = 415°
Total Contact Area = 490°
225°
265°
BINACCHI BRM-V THREE-ROLL MILL
Totally Enclosed “Drops-Clean”
Design
Bottom Product Discharge Peripheral Roll Cooling Channels
Feed Hopper
Flakes Crimping
Blade
510 DegreeContact Area (70% of Total Surface Area)
“V” Shape Roll
Configuration
ROLL MILL COOLING SYSTEMS
Roll Shell
Roll Shell
Rotary Joint
Cooling Water
In
StandardSystem
Roll Shaft
Out
Old Spray System
High Efficiency Peripheral
System
Source: SELA GmbH
Source: Binacchi & Co.
Water RecyclePump Water Inlet
Water Discharge
TT TIC TCV
PERIPHERAL ROLL COOLING SYSTEMwith Temperature Control Unit
Source: SAS
PERIPHERAL ROLL COOLING SYSTEM
Traditional Old System
SPRAY ROLL MILL COOLING SYSTEM
Source: SELA GmbH
SASTRANSAVON
DUPLEXVACUUMPLODDER
Combo Screw
Milling/RefiningPelletizing Group
ExtrusionHead
SAS TRANSAVON MILLING/REFINING STAGE with Milling Valve and Refining/Pelletizing Head
Combo Screw
Milling Valve
Refining/PelletizingHead with Rotating
Knife
Feed Hopper
Bar Soap Finishing
Bar Soap Finishing - Processing Steps & Equipment
◊ Mixing - Amalgamator, Double-Arm Mixer & Mixer-Kneader
◊ Refining - Plodders & Roll Mills - Plodder and Roll Mill Refining Comparison - Methods for Measuring the Degree of Refining - Plodders - Refining Details, Worm Designs - Roll Mills - Contact Areas, Roll Cooling Systems - Special Plodders - “MP” Milling Plodder & Transavon
◊ Cutting - Electronic Cutters
◊ Stamping - Flashstamping Presses, Direct Transfers & New Presses
◊ Packaging - Wrappers, Cartoners, Transfer Systems & Stamping and Packaging Machinery Combinations
Bar Soap Finishing Line Types and Selection
Extruded Soap Slugs (Billets) from Plodder
Operator Panel for in Operation Cutting Length Change
Encoder for Slug Cutting Length Control
BI NACCHI ETC-2000
CONTI NUOUS MOTI ON ELECTRONI C CUTTER
Continuous Rotation Group with Two Cutting Blades
SAS EASYCUT ELECTRONIC CUTTER
Bar Soap Finishing
Bar Soap Finishing - Processing Steps & Equipment
◊ Mixing - Amalgamator, Double-Arm Mixer & Mixer-Kneader
◊ Refining - Plodders & Roll Mills - Plodder and Roll Mill Refining Comparison - Methods for Measuring the Degree of Refining - Plodders - Refining Details, Worm Designs - Roll Mills - Contact Areas, Roll Cooling Systems - Special Plodders - “MP” Milling Plodder & Transavon
◊ Cutting - Electronic Cutters
◊ Stamping - Flashstamping Presses, Direct Transfers & New Presses
◊ Packaging - Wrappers, Cartoners, Transfer Systems & Stamping and Packaging Machinery Combinations
Bar Soap Finishing Line Types and Selection
BINACCHI USN-2000 SERIES SOAP PRESSES
Cut Long Slugs
Moving UpperDies Group
Stamped BarsPick & Place
Discharge Group
Pick & PlaceInfeed Group
Flashing Recycle
Conveyor
Flashing
Flashing
StampedBars to
PackagingFixed LowerDies Group
BINACCHI USN-2000 SERIES SOAP PRESSES with DPT Direct Product Transfer Group
Pick & PlaceInfeed Group
Moving Upper Dies
Group
Fixed LowerDies Group
Flashing Recycle
Conveyor
Flashing
SuctionCups
StampedBars
Stamped BarsPick & Place
Discharge Group
DPT
Direc
t Tr
ansf
er S
yste
m
Packaging Machine Pocketed Infeed
Conveyor
Cut LongSlugs
SOAPTEC HEXA SOAP PRESSfor Stamping on 2, 4 and 6 Sides
Die GroupDetail
Stamped Bars
Bar Soap Finishing
Bar Soap Finishing - Processing Steps & Equipment
◊ Mixing - Amalgamator, Double-Arm Mixer & Mixer-Kneader
◊ Refining - Plodders & Roll Mills - Plodder and Roll Mill Refining Comparison - Methods for Measuring the Degree of Refining - Plodders - Refining Details, Worm Designs - Roll Mills - Contact Areas, Roll Cooling Systems - Special Plodders - “MP” Milling Plodder & Transavon
◊ Cutting - Electronic Cutters
◊ Stamping - Flashstamping Presses, Direct Transfers & New Presses
◊ Packaging - Wrappers, Cartoners, Transfer Systems & Stamping and Packaging Machinery Combinations
Bar Soap Finishing Line Types and Selection
IRREGULARROUNDIRREGULARROUND
OVALRECTANGULAROVALRECTANGULAR
BANDLESSBANDED
BAR SOAP SHAPES
SOAP WRAPPERS
MAKE MODEL SPEEDBAR SOAP TRANSFER
ACMA
7250 250 Turret with 4 Cups
7350 350 Turret with 4 Cups
7700 500 Turret with 6 Cups
731 300 Flat Belt
771 500 Turret with 16 Cups
BINACCHI
BSW-220 250 Direct from Press
BSW-330 350 Direct from Press
BSW-550 500 Direct from Press
GUERZE PACKSAVON 250 Turret with 4 Cups
• Speed: Wrapped bars per minute
• Cups : Vacuum Suction Cups
• Direct Product Transfer is an integral part of the Soap Press
ACMA ROTARY TRANSFER (INFEED) SYSTEMS for Soap Wrappers and Cartoners
YT Transfer with 4 Suction Cups
TH Non-ContactTransfer with
16 Suction Cups
YVNon-Contact Transferwith 6 Suction Cups
ACMA TH NON-CONTACT SOAP TRANSFER
with 16 Cups for Wrappers and Cartoners
TH Non-Contact
In-Line Rotary Transferwith 16 Suction Cups
Wrapper or Cartoner
Pocketed Infeed Conveyor
Smart Belts andTiming Belt
Infeed Group
SoapsfromPress
90 Degree Soap Rotation and Placement
Soap Lifting
ACMA 7250 – 7350 – 7700 SOAP WRAPPERS
YV Transfer with4 Suction Cups
Soaps from Press
Roll Fed Outerwrap with Splicer
Roll Fed Innerwrap with Splicer
Heating Group
Cooling Group
WrappedSoaps
Discharge
Outerwrap and InnerwrapCutting and Soap Positioning
Wrappers Folding
ACMA 771 SOAP WRAPPERwith TH Non-Contact Transfer
TH Non-Contact Transfer with 16
Suction Cups
Outerwarp
Innerwrap
Soap Lifting with Suction Cups
90 Degree Soap Rotation and Placement into Wrapping Station
Soaps from Press
Paper and Soap Grippers
Folders, Tuckersand Plows
Heating Group
Cooling Group
Wrapped Bars Spacer Belt
Wrapped Bars
Direct from Press4 inches600CRITERION
Direct from Press4.5 inches500CRITERION
2 Turrets with 5 Cups each6 inches300LEGACY
J ONES
Direct from Press95 mm600KO
V-52095 mm450KO
V-520127 mm350HV/1
2 Turrets with 5 Cups each4 inches400LEGACY
V-228 with 16 Grippers127 mm200HV/1
CAM
Turret with 16 Cups120 mm500770/TH
Turret with 16 Cups95 mm350330/TH
Turret with 10 Cups95 mm300330/YT
Turret with 4 Cups95 mm240330/YV
ACMA
Turret with 4 Cups127 mm250BOXSAVONGUERZE
BAR SOAP TRANSFERPITCHSPEEDMODELMAKE
SOAP CARTONERS
• Speed: Cartons per minute • Cups: Vacuum Suction Cups• Direct from Press: Transfer System is an integral part of the Soap Press• JONES Legacy can also be supplied with the Direct from Press option• The Horizontal Motion CAM V-520 Transfer is available with 16 Mechanical Grippers or 16 Cups
ACMA 330 SOAP CARTONER with YT and YV Transfers
YT Non-Contact Transfer with 10 Suction Cups
YV Transfer
with 4 Suction Cups
Smart BeltsInfeed System
Pocketed Infeed Conveyor
Carton Magazine
Turret Feeder
Barrel Loader
Cartoned Bars Compression
Discharge Belts
Soaps fromPress
Soaps fromPress
Timing Belts
ACMA 770 SOAP CARTONERwith TH Non-Contact Transfer
Carton Magazine
Carton FeederTurret
Barrel Loader
Cartoned BarsCompression
Discharge Belts
1 or 2 Side by Side Bars in a Single Carton
TH Non-Contact
Rotary Transfer with 16 Suction Cups
Soaps from Press
CAM V-228 NON-CONTACT TRANSFER with 16 Mechanical Grippers
Smart BeltsInfeed Group
Cartoner ArticleBuckets
FLOW-PACK WRAPPER (HORIZONTAL WRAPPER) with 3 Smart Belts In-Line Non-Contact Feeder
In-Line Non-ContactFeeder withAccumulatorMetering andTiming Belts
Film Rolls
Rotary Crimping and Cutting Heads
Finwheels
Package Former
Flow Wrapped Product Discharge
Conveyor
Product Lug
Chain
Source: Guerze srl
ACMA DUAL PURPOSE SOAP
WRAPPING & CARTONINGLINE
BINACCHI STAMPING & PACKAGING SYSTEMS1 Press with Direct Product Transfer and
2 Alternate Packaging Options
BSW or BSC
BSC Cartoner
Transfer Unit
DPT
DPT
BSW Wrapper
Bar Twister
USN-2000Soap Press
with DPT Direct Product Transfer
ConveyorsBFP
Flow-Pack Wrapper
Non-ContactInfeedSystem
Conveyor
BSW Wrapper
DPT
DPTDPT Direct Product
Transfer System
DPT
BI NACCHI STAMPING AND PACKAGING SYSTEMS1 Press with Direct Product Transfer and
3 Alternate Packaging Options
BSC Cartoner
BFP Flow-Pack Wrapper
USN-2000 Soap Press
CARTON BLANK TERMINOLOGY
CARTON STYLES
Reverse Tuck Straight Tuck Glue Seal
PACKAGING MATERIAL DEFINITIONS & CONVERSION FACTORS
Basis Weight
In the USA basis weight refers to the weight expressed in pounds of 500 sheets of 24 x 36 inches size paper (24” x 36” = 3,000 ft2 = 270 m2)
Grammage
Grammage is the basis weight expressed in g/m2 (grams per square meter)
Caliper/Point
Caliper or Point is the thickness of paper or board expressed in thousands of an inch
1 caliper or 1 point = 0.001 inch
Example: a 15 point board is a 0.015 inch thick board
Gauge
Film Thickness is expressed in terms of mils. 1 mil = 0.001 inch
For thin films the term gauge is used. 100 gauge = 1 mil
Example: a 90 gauge film is a 0.00090 inch thickness film
Micron1 micron = 0.001 mm
1 millimeter = 1000 microns
To Convert Multiply By
lbs/ream to g/m2 1.627
in2/lb to m2/kg 0.0014
reams to m2 278.7
mils to microns 25.4
gauge to micron 0.254
micron to gauge 3.937
Bar Soap Finishing
Bar Soap Finishing - Processing Steps & Equipment
◊ Mixing - Amalgamator, Double-Arm Mixer & Mixer-Kneader
◊ Refining - Plodders & Roll Mills - Plodder and Roll Mill Refining Comparison - Methods for Measuring the Degree of Refining - Plodders - Refining Details, Worm Designs - Roll Mills - Contact Areas, Roll Cooling Systems - Special Plodders - “MP” Milling Plodder & Transavon
◊ Cutting - Electronic Cutters
◊ Stamping - Flashstamping Presses, Direct Transfers & New Presses
◊ Packaging - Wrappers, Cartoners, Transfer Systems & Stamping and Packaging Machinery Combinations
Bar Soap Finishing Line Types and Selection
Bar Soap Finishing Line Types
The processing steps and the various machines used in each step have been previously described. There are three types ofwidely used bar soap finishing lines in various layout configurations:
■ Line with 3 Plodders (2 Refining Stages) Simplex Refiner and a Duplex Vacuum Plodder
■ Line with 4 Plodders (3 Refining Stages) Duplex Refiner and a Duplex Vacuum Plodder
■ Line with 3 Plodders and 1 Roll Mill (3 Refining Stages) Simplex Refiner, Three-Roll Mill, and a Duplex Vacuum Plodder
Pre-Refining Lines
Any line can be made into a pre-refining line by placing a Simplex Refiner or, alternatively, a Roll Mill before the Mixer.
AcknowledgementsAcknowledgementsThis is the first update of Soap Finishing since the publication of This is the first update of Soap Finishing since the publication of Soaps and Detergents book in 1996 (Reference 2).Soaps and Detergents book in 1996 (Reference 2).
To prepare this update, the major soap equipment suppliers were To prepare this update, the major soap equipment suppliers were contacted. Drawings whose headings start with a company name contacted. Drawings whose headings start with a company name were provided by the individual companies. Main titles and were provided by the individual companies. Main titles and notations were modified to obtain uniformity. Those illustrations notations were modified to obtain uniformity. Those illustrations that do not have a company name have an indicated source. that do not have a company name have an indicated source.
I wish to extend my appreciation to the companies who provided I wish to extend my appreciation to the companies who provided information and illustrations. This review would not have been information and illustrations. This review would not have been possible without the assistance of:possible without the assistance of:Acma S.p.A., Binacchi & Co., Guerze srl, Mazzoni LB S.p.A, R. A. Acma S.p.A., Binacchi & Co., Guerze srl, Mazzoni LB S.p.A, R. A. Jones, SAS, Sela GmbH, and Soaptec srl. Jones, SAS, Sela GmbH, and Soaptec srl.
A special thank you to Andrea del Corno of Soaptec srl for his A special thank you to Andrea del Corno of Soaptec srl for his valuable assistance in the preparation of Solid Edge Software-valuable assistance in the preparation of Solid Edge Software-based and other illustrations.based and other illustrations.
In 1879 Thomas Edison (1847-1931) unveiled his most famous In 1879 Thomas Edison (1847-1931) unveiled his most famous invention, the electricity powered incandescent light bulb.invention, the electricity powered incandescent light bulb.
The same year Procter & Gamble invented Ivory Soap (by accident).The same year Procter & Gamble invented Ivory Soap (by accident).
I wish everybody wish everybody good luck and a good luck and a happy “happy “bubble bubble with quality” with quality” future.future.
Good bye for Good bye for now…until we now…until we meet again….meet again….
I thank you I thank you all very much all very much for allowing for allowing me to share me to share with you thiswith you thisBar Soap Bar Soap FinishingFinishingReview.Review.