BAR SOAP FINISHING Luis Spitz L. Spitz, Inc. e-mail:
[email protected] phone: 847/965-5151
Soaps, Detergents, Oleochemicals & Personal Care Products April 5, 2006 Hollywood, 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 Sigma (Z) Blades Heating/Cooling Jacket Extruder Screw Drilled Plate Multiblade Knife with Safety Ring
Source: Binacchi & Co.
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.
PLODDER REFINING
with Refining/Pelletizing Group
Refined Soap Pellets
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
ROLL MILL REFINING
Gap Setting 0.10 - 0.15 mm
0.15- 0.20 mm Crimped or Thin Soap Flakes
Soap Pellets
Blade & Crimping Device
Gap Setting 0.30 - 0.40 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
Plodder Refining Screen Mesh Number
Roll Mill Flake 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 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 30°C 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 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 highintensity 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 of any 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-evaluation scale) 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 One Plodder designed to operate with a 50 mesh refining screen at 12-15 rpm worm speed and 60 bar maximum pressure.
Duplex Refiner Two Simplex Refiners 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.
PLODDER REFINING/PELLETIZING GROUP
with Standard and Interchangeable Pelletizing Drilled Plates Refining Screen
Worm Support
Rotating Pelletizing Knife
Worm Support Interchangeable Drilled Plate
Refining Screen Rotating Pelletizing Knife
Standard Drilled Plate
Drilled Plate Support
REFINING PLODDER DETAILS Worm Support Plate
Multiblade Rotating Pelletizing Knife
Worm
Drilled Plate
Plodder Barrel
Cooling Water Jacket
Cooling Water Inlet
Refining Screen
REFINING PLODDER DETAILS
PLODDER EXTRUSION GROUP
Temperature & Pressure Transducers
Small Cone (Optional) Die Orifice
Worm Support Plate Oil Thermostat
Complete Extrusion Head (Cone) Group
Oil Heated Section
Die Orifice Support & Locking Ring
PLODDER WORM TYPES
Single Worm
Tangential Twin-Worm
Non-Tangential Twin-Worm
PLODDER WORM TERMINOLOGY
BINACCHI PLODDER WORMS 4:1 Lc/D Ratio
Recommended for Toilet and Syndet Products SQ Profile
Recommended for Laundry Soap Applications
SW Profile
HE (High Efficiency) Recommended for All Types of Products
Constant Root Diameter Decreasing Pitch
HV (High Volume) Toilet and Laundry Soaps Large Capacity Dyers
Increasing Root Diameter Decreasing Pitch
CT (Constant) For Products which Require Reduced Mechanical Work
Constant Root Diameter Constant Pitch
SELA PLODDER WORMS 3.5 Lc/D Ratio P1
P2
Recommended for Combo Bars and Rim Blocks
Constant Pitch P1=P2
P1
P2 Single Decreasing Pitch P1:P2 = 1.6:1
Recommended for Toilet, Syndet and Laundry Soaps
P1 Recommended for Translucent Soaps
P2 Double Decreasing Pitch P1:P2 = 2.5:1
265°
THREE-ROLL MILL CONTACT AREAS
235°
180°
Total Contact Area = 415°
225°
Total Contact Area = 490°
BINACCHI BRM-V THREE-ROLL MILL Feed Hopper
Flakes Crimping Blade
510 Degree Contact Area (70% of Total Surface Area)
“V” Shape Roll Configuration
Totally Enclosed “Drops-Clean” Design Bottom Product Discharge
Peripheral Roll Cooling Channels
ROLL MILL COOLING SYSTEMS Standard System
Roll Shell Rotary Joint
Roll Shaft Roll Shell
In
Out
Cooling Water
HighOld Efficiency Spray Peripheral System System
Source: SELA GmbH
PERIPHERAL ROLL COOLING SYSTEM with Temperature Control Unit
Water Recycle Pump
Water Inlet TT
TIC
TCV
Water Discharge Source: Binacchi & Co.
PERIPHERAL ROLL COOLING SYSTEM
Source: SAS
SPRAY ROLL MILL COOLING SYSTEM
Traditional Old System
Source: SELA GmbH
SAS TRANSAVON DUPLEX VACUUM PLODDER
Milling/Refining Pelletizing Group
Combo Screw
Extrusion Head
SAS TRANSAVON MILLING/REFINING STAGE with Milling Valve and Refining/Pelletizing Head
Feed Hopper
Milling Valve
Combo Screw
Refining/Pelletizing Head with Rotating Knife
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 ETC-2000 CONTINUOUS MOTION ELECTRONIC CUTTER Continuous Rotation Group with Two Cutting Blades Extruded Soap Slugs (Billets) from Plodder
Encoder for Slug Cutting Length Control Operator Panel for in Operation Cutting Length Change
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 Pick & Place Infeed Group
Moving Upper Dies Group
Stamped Bars Pick & Place Discharge Group
Cut Long Slugs
Stamped Bars to Packaging
Fixed Lower Dies Group Flashing
Flashing
Flashing Recycle Conveyor
BINACCHI USN-2000 SERIES SOAP PRESSES with DPT Direct Product Transfer Group
Pick & Place Infeed Group
Moving Upper Dies Group
Stamped Bars Pick & Place Discharge Group
Cut Long Slugs
Fixed Lower Dies Group
Flashing Recycle Conveyor
Flashing
Stamped Bars
Suction Cups Packaging Machine Pocketed Infeed Conveyor
SOAPTEC HEXA SOAP PRESS
for Stamping on 2, 4 and 6 Sides
Stamped Bars
Die Group Detail
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 SHAPES BANDED
BANDLESS
RECTANGULAR
OVAL
RECTANGULAR
OVAL
ROUND
IRREGULAR
ROUND
IRREGULAR
SOAP WRAPPERS MAKE
ACMA
BINACCHI
GUERZE
MODEL
SPEED
BAR SOAP TRANSFER
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
BSW-220
250
Direct from Press
BSW-330
350
Direct from Press
BSW-550
500
Direct from Press
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-Contact Transfer with 16 Suction Cups
YV
Non-Contact Transfer with 6 Suction Cups
ACMA TH NON-CONTACT SOAP TRANSFER with 16 Cups for Wrappers and Cartoners
TH
Non-Contact In-Line Rotary Transfer with 16 Suction Cups
Soaps from Press
Soap Lifting Smart Belts and Timing Belt Infeed Group
Wrapper or Cartoner Pocketed Infeed Conveyor 90 Degree Soap Rotation and Placement
ACMA 7250 – 7350 – 7700 SOAP WRAPPERS
Roll Fed Outerwrap with Splicer
Roll Fed Innerwrap with Splicer
YV Transfer with 4 Suction Cups
Wrapped Soaps Discharge
Soaps from Press Cooling Group Heating Group
Outerwrap and Innerwrap Cutting and Soap Positioning
Wrappers Folding
ACMA 771 SOAP WRAPPER with TH Non-Contact Transfer
Wrapped Bars
Outerwarp
Cooling Group Innerwrap
TH Non-Contact Transfer with 16 Suction Cups
Paper and Soap Grippers
90 Degree Soap Rotation and Placement into Wrapping Station Soap Lifting with Suction Cups Soaps from Press
Heating Group Wrapped Bars Spacer Belt Folders, Tuckers and Plows
SOAP CARTONERS MAKE
ACMA
CAM
JONES
GUERZE
MODEL
SPEED
PITCH
BAR SOAP TRANSFER
330/YV
240
95 mm
Turret with 4 Cups
330/YT
300
95 mm
Turret with 10 Cups
330/TH
350
95 mm
Turret with 16 Cups
770/TH
500
120 mm
Turret with 16 Cups
HV/1
200
127 mm
V-228 with 16 Grippers
HV/1
350
127 mm
V-520
KO
450
95 mm
V-520
KO
600
95 mm
Direct from Press
LEGACY
300
6 inches
2 Turrets with 5 Cups each
LEGACY
400
4 inches
2 Turrets with 5 Cups each
CRITERION
500
4.5 inches
Direct from Press
CRITERION
600
4 inches
Direct from Press
BOXSAVON
250
127 mm
Turret with 4 Cups
• 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
Cartoned Bars Compression Discharge Belts Pocketed Infeed Conveyor
Smart Belts Infeed System
Timing Belts
Soaps from Press Soaps from Press
Barrel Loader
YV
Transfer with 4 Suction Cups
Carton Magazine Turret Feeder
ACMA 770 SOAP CARTONER with TH Non-Contact Transfer
Carton Feeder Turret
Cartoned Bars Compression Discharge Belts
Carton Magazine Barrel Loader 1 or 2 Side by Side Bars in a Single Carton
TH
Soaps from Press
Non-Contact Rotary Transfer with 16 Suction Cups
CAM V-228 NON-CONTACT TRANSFER with 16 Mechanical Grippers
Smart Belts Infeed Group
Cartoner Article Buckets
FLOW-PACK WRAPPER (HORIZONTAL WRAPPER) with 3 Smart Belts In-Line Non-Contact Feeder Film Rolls
In-Line Non-Contact Feeder with Accumulator Metering and Timing Belts
Package Former Product Lug Chain
Rotary Crimping and Cutting Heads
Finwheels
Source: Guerze srl
Flow Wrapped Product Discharge Conveyor
ACMA DUAL PURPOSE SOAP WRAPPING & CARTONING LINE
BINACCHI STAMPING & PACKAGING SYSTEMS 1 Press with Direct Product Transfer and 2 Alternate Packaging Options BSW Wrapper
DPT
Conveyor USN-2000 Soap Press with DPT Direct Product Transfer
BSC Cartoner Transfer Unit
BSW or BSC
DPT
Conveyors Bar Twister
Non-Contact Infeed System
BFP Flow-Pack Wrapper
BINACCHI STAMPING AND PACKAGING SYSTEMS 1 Press with Direct Product Transfer and 3 Alternate Packaging Options
BSW Wrapper
USN-2000 Soap Press
DPT BSC Cartoner
DPT Direct Product Transfer System
DPT
BFP Flow-Pack Wrapper DPT
CARTON BLANK TERMINOLOGY
CARTON STYLES
Reverse Tuck
Straight Tuck
Glue Seal
PACKAGING MATERIAL DEFINITIONS & CONVERSION FACTORS Basis Weight
Gauge
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)
Film Thickness is expressed in terms of mils. 1 mil = 0.001 inch
Grammage
Example: a 90 gauge film is a 0.00090 inch thickness film
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
For thin films the term gauge is used. 100 gauge = 1 mil
Micron 1 micron = 0.001 mm 1 millimeter = 1000 microns
To Convert lbs/ream to g/m2
Multiply By 1.627
in2/lb to m2/kg
0.0014
reams to m2 mils to microns gauge to micron micron to gauge
278.7 25.4 0.254 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 of widely 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.
Acknowledgements This is the first update of Soap Finishing since the publication of Soaps and Detergents book in 1996 (Reference 2). To prepare this update, the major soap equipment suppliers were contacted. Drawings whose headings start with a company name were provided by the individual companies. Main titles and notations were modified to obtain uniformity. Those illustrations that do not have a company name have an indicated source. I wish to extend my appreciation to the companies who provided information and illustrations. This review would not have been possible without the assistance of: Acma S.p.A., Binacchi & Co., Guerze srl, Mazzoni LB S.p.A, R. A. Jones, SAS, Sela GmbH, and Soaptec srl. A special thank you to Andrea del Corno of Soaptec srl for his valuable assistance in the preparation of Solid Edge Softwarebased and other illustrations.
In 1879 Thomas Edison (1847-1931) unveiled his most famous invention, the electricity powered incandescent light bulb. The same year Procter & Gamble invented Ivory Soap (by accident).
I thank you all very much for allowing me to share with you this Bar Soap Finishing Review.
I wish everybody good luck and a happy “bubble with quality” future. Good bye for now…until we meet again….
