Production capacity/annum : 600 M.T.
Oil from drums is stored in oil storage tanks. The oil is then pumped to the soap pans.Caustic soda with bleaching powder(if necessary) is added to the oil and the mix is steam heated for saponification. After saponification the neat soap floats at the top while lye gets collected at the bottom.
The Lye is tapped from the bottom and the neat soap left in the soap pan is washed with the water and is transferred to the crutchcr. After obtaining the homogenous mass in the crutcher, it is shifted in the moulds for drying. The dried soap blocks are removed from the moulds and are cut into bars, which are used for forming the chips. The chips obtained are dried and transferred to amalgamator for mixing. Colouring pigments and perfumes are added and mixing is continued for sometime. The material is then transferred to triple roll mill for homogeneous mixing of colour and perfumes. The soap ribbons so obtained are fed into plodder where by compacting screw action soap bars arc formed. The bars are then cut to standard sizes and brand name etc. is stamped on each of the cakes with the help of stamping machine. The soap cakes are then packed with the help of wrapping jigs and sent for dispatch.
The tapped lye is strengthened with fresh supply of caustic soda and is recycled into the soap pan for next batch process. The process goes on till the lye becomes weak and cannot be recycled.
Machinery & equipment required
• Full Boiling Pan.
• Boiler with water softener and water tank.
• Caustic Dye tank.
• Chipping machine.
• Set of Amalgamates Milling machine & Plodder.
• Cutting Table.
• Stamping machine.
Raw material/consumables required
• Oils. • Fillers.
• Caustic Soda • Peaking Materials.
• Perfumes • Common Salt.
• Colouring Agents. • Bleaching Earth etc.
Power required (load) : 50 K.W.
Water required (per shift basis) : 2K.L.
Man power required
• Supervisor : 1 No.
• Skilled Workers : 8 Nos
• Unskilled Workers : 15 Nos
Total Area : 500 Sq.Mtr
Covered Area : 400Sq.Mtr.
Machinery & Equipment
Working Capital for 3 Months : Rs 36.25 lakhs
(Raw material, utilities & salary)