Bar Soap Finishing - Luis Spitz 4-5-2006

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

mailto:[email protected]

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


◊ 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





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


◊ Mixing - Amalgamator, Double-Arm Mixer & Mixer-Kneader






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








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








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








IRREGULARROUNDIRREGULARROUND

OVALRECTANGULAROVALRECTANGULAR

BANDLESSBANDED

BAR SOAP SHAPES

SOAP WRAPPERS

MAKE MODEL SPEEDBAR SOAP TRANSFER

ACMA

7250 250 Turret with 4 Cups



731 300 Flat Belt


BINACCHI

BSW-220 250 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 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.

Bar Soap Finishing - Luis Spitz 4-5-2006

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