Introduction to the Flakes Process
Welcome to Qazi Engineering Private Limited, a leading name in the realm of Laundry & toilet soap making machines. It is our pleasure to present our state-of-the-art Laundry & Toilet Soap Manufacturing Plants .
The flakes process, also known as the semi-boiled soap manufacturing process, distinguishes itself from the cold process soap manufacturing process utilising a heated saponification crutcher. This method is commonly employed for the industrial-scale production of low to medium-grade soaps, which are widely marketed.
Key Manufacturing Operations Supported by Qazi’s Toilet/Laundry Flakes Plants
The manufacturing operation is set up entirely according to the product recipe and programmed in the PLC placed in MCC to meet customised requirements. Sophisticated electrical and automation instruments are equipped with variable speed drives to synchronise the equipment. High-quality instruments and equipment are provided for efficient and maintenance free operation and desired quality production. The step-vise manufacturing operation is:
1. Saponification
The soap manufacturing process begins with the saponification reaction, where caustic soda lye and other raw materials are mixed in a heated saponification crutcher. The crutcher is heated to 70-90°C using a steam-heated jacket, which accelerates and ensures the completion of the saponification reaction.
2. Addition of Dyes, Perfumes, and Additives
Towards the end of the process, dyes, perfumes, and additives are added to the mixture. This prevents their evaporation and ensures their effective incorporation into the soap flakes.
3. Adjustment of Caustic Soda Lye
The process allows for the adjustment of the quantity of caustic soda lye used in saponification before extracting the crude soap. This flexibility enables fine-tuning of the soap’s properties and characteristics.
4. Recycling of Manufacturing Waste
The soap manufacturing process incorporates the recycling of manufacturing waste. This helps minimise waste generation and optimise resource utilisation.
5. Hardening of Crude Soap
The crude soap obtained from the crutcher is further processed to achieve the desired hardness. This is achieved through Chilled Roll flakers. The crude soap is poured at the centre of moving rolls, which contain chilled water flowing inside them. As a result, the soap loses temperature and dries immediately, forming the desired hardened flakes.
6. Duplex Vacuum Plodder
The soap flakes are then passed through a Duplex Vacuum Plodder. This equipment further refines the flakes, ensuring proper consistency and quality. At the discharge of the final plodder, soap bars in the desired shape are produced.
7. Soap Stamping
If manufacturing toilet soap on the same line, the hardened soap bars are fed into a soap stamper. Soap moulds are fitted into the stamper to produce soap bars in the desired shape. This step adds branding and aesthetic value to the soap bars.
8. Wrapping and Packaging
The soap bars, whether toilet soap or laundry soap, are then fed into a wrapping machine for the final packaging. The wrapping machine packages the soap bars, ensuring they are ready for distribution and sale.
Moisture Content Adjustment
The moisture content in the soap can be adjusted to the desired level:
- For Laundry Soap: the final bar moisture is kept at 22%.
- For Toilet soap: the moisture content should be between 12% and 16%. This moisture level is controlled during water addition in the Crutcher.
Equipment Solutions for Flakes Process by Qazi Engineering Pvt. Ltd.
The saponification Crutcher is a heated vessel where caustic soda lye and other raw materials are mixed, initiating the saponification reaction to produce soap flakes with optimal properties.
Sigma mixer comes with its efficient mixing, customizable controls, energy efficiency, and robust construction, this product is a reliable choice for those seeking excellence in soap production and beyond.
The soap flaker, equipped with chilling rolls, rapidly cools the soap mixture, transforming it into hardened flakes with the desired texture and consistency.
This specialized equipment is integral to soap flake production, where it crushes and grinds soap into thin flakes. It plays a crucial role in achieving the desired consistency and texture of soap flakes for further processing.
The Refiner / Noodler is an essential machine in soap production plants, used to refine and homogenize the soap mixture by breaking down lumps and impurities, resulting in a smoother and more uniform soap product.
A practical conveyor system used in soap plants to transport soap materials and products efficiently throughout the production process, facilitating smooth and continuous workflow.
The Soap Bar Cutter is a precision cutting machine used to shape and size soap bars or flakes, allowing for the creation of soap products with consistent dimensions.
The evolution of soap manufacturing has witnessed remarkable advancements, with automation playing a pivotal role in enhancing production efficiency and quality.
This advanced equipment refines and homogenised soap flakes, removing air bubbles and ensuring consistent quality. It plays a vital role in achieving soap bars’ desired texture and smoothness.
An automated device used to emboss or mark soap bars with logos, patterns, or brand information, adding a professional and customized touch to the final soap products.
The Motor Control Center (MCC) Panel is the nerve center of the soap plant, managing and controlling the various motors and electrical components, ensuring safe and precise operation of the equipment.
Advantages of Qazi Engineering Pvt. Ltd.'s Toilet/Laundry Flakes Soap Manufacturing Plant
Flexibility
The semi-boiled process employed in our bathing soap making machine offers great flexibility. It allows for the production of a wide range of toilet and laundry soap flakes, catering to various market demands and consumer preferences.
Shorter Production Cycles
The semi-boiled process significantly reduces the production time compared to traditional cold process methods. This results in shorter production cycles, enabling manufacturers to meet customer demands more efficiently and quickly.
Reasonable Soap Manufacturing Plant Cost
Our laundry & Toilet Soap Manufacturing Plant is specifically designed to maximise resource utilisation and minimise wastage. Thereby reducing soap manufacturing plant costs. By employing the semi-boiled process, we achieve efficient production, making it a financially feasible choice for soap manufacturers.
Customization
With the semi-boiled process, manufacturers have the flexibility to adjust the properties and characteristics of the soap flakes. This customization capability allows for the creation of unique formulations, fragrances, and colours to cater to specific market segments and customer preferences.
Suitable for Developing Countries
The semi-boiled process, with its shorter production cycles and reasonable production costs, is particularly well-suited for developing countries. It offers an affordable and efficient method for soap production, contributing to economic growth and providing employment opportunities.
Environmentally Friendly
The semi-boiled process does not release any effluent into the environment, making it an environmentally friendly soap manufacturing method. By adopting this process, manufacturers can contribute to sustainable practices and minimise their ecological footprint. process, we achieve efficient production, making it a financially feasible choice for soap manufacturers.
High-Quality Soap Flakes
Our Flakes Soap Manufacturing Plant, combined with our advanced equipment and meticulous manufacturing processes, ensures the production of high-quality soap flakes. The flakes have excellent consistency, texture, and cleaning properties, meeting the expectations of customers and end-users.
Reliable and Efficient Equipment
Qazi Engineering Pvt. Ltd. provides state-of-the-art equipment and instruments for our Laundry & Toilet Soap manufacturing plant. These equipment highlights ensure efficient and reliable soap production, minimising downtime and optimising productivity.
Sustainable Resource Utilisation
The soap manufacturing process incorporates the recycling of manufacturing waste, optimising resource utilisation and minimising waste generation. This commitment to sustainability is an essential aspect of our soap manufacturing approach.
Global Market Access
With Qazi Engineering’s toilet soap making machine, manufacturers can produce soap flakes that meet international quality standards. This opens up opportunities for exporting soap products to global markets, expanding their reach, and increasing business growth.
Connect with Our Team
When it comes to our Toilet Soap making machines, we are committed to providing exceptional customer support and personalised service every step of the way. By connecting with our team, you will have the opportunity to collaborate with industry experts who possess extensive knowledge and experience in the field of bar soap manufacturing. Our dedicated professionals are passionate about delivering excellence and ensuring your success in implementing a state-of-the-art Toilet Laundry Flakes Plant.
Whether you have inquiries about the plant’s technical specifications, customization options, or production capabilities, our team is here to provide you with prompt and reliable assistance. We are eager to understand your specific requirements and tailor our solutions to meet your unique needs.
Frequently Asked Question
The flakes process is a semi-boiled soap manufacturing method that uses a heated saponification crutcher to produce soap flakes.
The saponification reaction occurs when caustic soda lye and other raw materials are mixed in a heated crutcher, ensuring the completion of the reaction.
The flakes process allows for the adjustment of soap properties and characteristics by fine-tuning the quantity of caustic soda lye used in saponification, resulting in customised soap formulations.
The incorporation of recycling in the manufacturing process minimises waste generation and optimises resource utilisation, promoting sustainability in soap production.
The Duplex Vacuum Plodder refines and homogenised soap flakes, removing air bubbles and ensuring consistent quality, leading to the production of soap bars with the desired texture and smoothness.
Soap stamping adds branding and aesthetic designs to soap bars, enhancing their visual appeal and market value.
Wrapping and packaging are essential steps in the soap manufacturing process as they prepare the soap bars for distribution and sale, ensuring their protection and presentation.
The moisture content for laundry soap is maintained at 22% in the final bar, while for toilet soap, it should be between 12% and 16%, controlled during water addition in the Crutcher.
The soap filtration pump filters and removes impurities from the soap mixture, ensuring the production of high-quality soap flakes.
The soap feed variable speed pump controls the precise flow of the soap mixture during the manufacturing process, enabling accurate and consistent production of soap flakes.
Bar soap making machine price depends on factors such as its capacity, automation, level, brand reputation, and additional accessories.