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T h e T h ir d M i l l e n i u m Co m p a n y LY
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Dear Sirs, Index:

-Raw materials treatment Pag. 3
Allow us a few moments for a brief presentation.
-Saponification Pag. 5
Soaptec is an Italian, third millennium company, spe- Crutcher Pag. 7
cialized in soap making equipment, start ed on a great Reactor column Pag. 9
experience in the fi eld accumulated by our staff. Washing column Pag. 11

This privileged position allows us to design and pro- -Dryer Pag. 13

duce soap making machines and plants of exceptional Toilet dryer Pag. 15
reliability, functionality and flexibility required in to- Green dryer Pag. 16
day’s market. Laundry Pag. 17
Soap filter Pag. 19
Size of the company combined with most recent de- Soap tank Pag. 21
sign and manufacturing procedures results in a prod- Heat exchanger Pag. 23
uct that is extreme value for money and yet, tailor Vacuum spray chamber Pag. 25
made to suit your precise purpose. Fines separator Pag. 27
Fines extruder and conveyor Pag. 29
Our aim is to develop a rel ationship with every cus- Vacuum system Pag. 31
tomer in order to better understand their individual
needs and fulfil their requirements with minimum - Pne u matic co nveyo r Pag. 33
expense.
-Finishing line Pag. 35
A great care for detail and sturdiness of construction Amalgamator Pag. 37
will assure many years of trouble free production and Double arm sigma mixer Pag. 39
guarantee that the v alue of equipment persists in Worm feeder Pag. 41
time. Refiner Pag. 43
Refining foils Pag. 45
Do not hesitate to contact us for further information. Three roll mull mechanical Pag. 47
Three roll mull hydraulic Pag. 49
Duplex vacuum plodder Pag. 51
SOAPTEC srl Cutter EMC Pag. 53
Cutter MBC-1 Pag. 55
Boris Radic Cutter MBC-P Pag. 57
Soap press MFS Pag. 59
Soap press HEXA Pag. 61
Conveyors Pag. 63

-Artisan Finishing line Pag. 65

Amalgamator AM-100B Pag. 67
Amalgamator AM-100T Pag. 69
Simplex refiner SRs-200 Pag. 71
Three roll mill M-200 Pag. 73
Duplex plodder DVs-200 Pag. 75
Soap press MFS-HY Pag. 77

-Pilot Finishing line Pag. 79

Amalgamator DASM-10P Pag. 81
Three roll mill M-100P Pag. 83
Duplex plodder DVs-100P Pag. 85
Soap press SP-2000 Pag. 87
Manual pleat wrapper Pag. 89

-Marbled soap system Pag. 91

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web site: www.s o apt ec .b iz

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RAW MATERIALS TREATMENT

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RAW MATERIALS TREATMENT

Raw materials, fats, soda, salt and wat er used in SODA MELTING AND SOLUTION
soap making need some treatments before being Soda used in saponification plants is
used. acquired in flakes delivered in sacks
or in barrels.
Soaptec supplies complete treat ment plants or, in It is melted inside the soda melting
alternativ e, materials, engineering and technical tank by addition of water, and then,
assistance for local construction. transfered to the soda solution tank:
here soda solution is adjusted to a
For raw mat erial treatment Soaptec proposes: desired concentration suited for
further use.Soda melting and soda
• SODA MELTING AND SOLUTION solution tanks are fitted with a filt er
• BRINE MAK ING inside so to avoid the contamination
• FATS M ELTING of soap and/or downstream equip-
ment.
• FATS BL EACHING
BRINE MAK ING
Salt, acquired in sacks, is dissolved in
SODA MELTING VESSEL
water before being used in saponifi-
CAPACITY DIMENSIONS cation plant.
TYPE Salt dissolving tank is also provided
m3 mm
SMV-3,5 3,5 2000x1200 H=1500 with a filter inside. Dissolving of salt
SMV-5 5 2500x1350 H=1500 in water is accel erat ed by blowing
SMV-7 7 3400x1500 H=1500 the air flow inside the tank.

SODA SOLUTION VESSEL FATS M ELTING

CAPACITY DIMENSIONS Fats used in neutralization plants can
TYPE
m3 mm be purchased in barrels and have to
SSV-3,5 3,5 2000x1200 H=1500 be melted before use.
SSV-5 5 2500x1350 H=1500 Fats melting tank permits barreled-
SSV-7 7 3400x1500 H=1500 fats fusion by steam.
SSV-9 9 4000x1500 H=1500 The tank is completely built in aisi
SSV-18 18 6000x2000 H=1500 304 stainless steel. Is provided with a
heating-coil.
FATS MELTING VESSEL
CAPACITY DIMENSIONS FATS BL EACHING
TYPE
m3 mm For laundry or similar quality soap
FMV-4 4 3000x1350 H=1000 production, when using raw pal m oil
FMV-8 8 3600x1500 H=1500 (of deep red colour) that needs
FMV-12 12 4000x2000 H=1500 bleaching, it is possible to use
FMV-18 18 5000x2000 H=1800 bleaching tank, fitted with a heating
FMV-36 36 6000x3000 H=2000 coil. Air that is blown through
heated oil betacaroten e, the main
palm oil’s colouring.

For a complete fats whiten are used

whiten soils. The process can be
batch or continuous depending on
fats to whiten quantity.

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SAPONIFICATION

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SAPONIFICATION

Saponification process consist in dosing pre- NEUTRAL FATS

treated raw materi als in exact ratio for a
proper reaction in order to produce liquid The soap produced for neutral fats contains
soap. glycerin, in traces or in quantity. Glycerin is
an integral component of neutral fats. FULL
The choice of process is given by the raw BOILED process “washes” the soap in order
materi als availabl e: Fatty acids or Neutral to extract glycerin. HALF BOILED process
Fats. leaves the glycerin inside the soap. NEUTRAL
FATS n eutralization can be done in continu-
ous or in batch.
FATTY ACIDS
Batch full boiled
The soap produced for fatty acids is pure as This process requires a classic saponification
it normally doesn’t contain any glycerine or kettle where th e soap maker controls the
impurities. This process is also called netrali- whole process from raw materi als dosing to
zation. FATTY AC IDS saponification can be the final neat soap specs adjustment.
done continuous or batch.
Continuous full boiled
Batch Raw mat erials, neutral fats, soda, salt and
Batch type fatty acids neutralization is sim- water are dosed continuously into the sapo-
ple and flexible. Raw mat erials, fatty acids, nification reactor for a complete reaction
soda, salt and water are dosed in the under high pressure and temperature. A
Crutcher and mixed until their complete passage through the cooler brings the soap
reaction. Raw materi als can be dosed by and line mixture to a graining temperature.
means of flowmeters, coverelev ated tanks Soap, subsequently separated in static sepa-
or load cells. rator is countercurrently washed inside wa-
shing column. Last traces of lye are elimi-
Continuous nated from the soap inside centrifugal sepa-
The advantages of Soaptec continuous fatty rator. Ev entual excess alkali are neutralized
acids neutralization are: reduced volumes, in the neutralization section.
reaction under preassured and possibility of
production of concentrated soap. Batch half boiled
Batch type neutral fats neutralization is sim-
All raw materi als, fatty acids, soda, salt and ple and flexible. Raw mat erials, fatty acids,
water are dosed continuously in the Turbo soda, salt and water are dosed in the
Mixer located before the saponification Crutcher and mixed until their complete re-
reactor where the reaction is completed action. Raw mat erials can be dosed by
under intense and continuous mixing. means of flowmeters, over- elevat ed tanks or
Raw mat erials can be dosed by massflow load cells.
meters or proportioning pumps.
Continuous half boiled
The advantages of Soaptec continuous neu-
tral fats neutralization are: reduced voumes,
reaction under preassured and possibility of
production of concentrated soap. All raw
materi als, neutral fats, soda, salt and water
are dosed continuously in the Turbo Mixer
located before the saponification reactor
where th e reaction is completed under in-
tense and continuous mixing. Raw materi als
can be dosed by massflow meters or propor-
tioning pumps.

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CRUTCHER

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CRUTCHER

The Crutcher is a vertical mixer used in the semi- Crutcher controls can be included in
boiled batch saponification, for fatty acids neutrali- a general control panel. Screw rota-
zation with Caustic soda and for neutral fats saponi- tional speed can be varied by means
fication. It is also used for additives feeding such as of a frequency inverter.
caoline silicate and for colouring laundry soap in the
drying plant. It also prepares detergent soaps base
solution.
The screw is driven by a ‘Rossi’ gear-
It is possible to place the Crutcher on load cells for
box with load capacity verified ac-
raw mat erials direct dosing.
cording to UNI, DIN, AFNOR, AGMA
and ISO. The soap seal is assured by
The Crutcher can operate either at atmospheric
a double mechanical seal.
pressure or pressurized. For pressurized use, Soap-
tec supplies manufactured Crutchers certified ac-
cording to ASME, SECTION VIII, DIVISION 1 stan-
dards. The helical screw is centred at the
bottom of the Crutcher through a
The Crutcher is provided wi th a v ertical mixing bushing easily accessible by disas-
screw placed inside a draft tube that assures a sembling its support.
strong mixing . This screw draws the materi al into
the draft tube from the bottom of the Crutcher and
expels it out through the top of the tube. This action
creates a vigorous flow of mat erial across the ma-
The bottom anchor blade, rotating
chine resulting in excellent mixing.
along with the worm, prev ents the
processed material to remain on the
Bottom of the screw is fitted with an anchor type
bottom and keeps the discharge
blade that scrapes the bottom of the vessel, thus
preventing depositing of the material . nozzle free and clean.

Usually Soaptec manufactures Crutchers completely

built in AISI 304 stainless steel. On request, it is pos- The Crutcher is provided with all
sible to manufacture the part in contact with the necessary connections to the proc-
product in AISI 316 stainless steel and the jacket in ess. Usually the flanges are UNI stan-
AISI 304, or manufacturing completely in carbon dards, but can also be built accord-
steel. ing to different standards on re-
quest.

Connection nozzles, inspection door

and sight glass with lamp and wiper
are foreseen on Crutcher’s cover.

CRUTCHER
TOILET LAUNDRY
INSTALLED
PRODUCTION PRODUCTION
TYPE POWER
80-82% TFM 7O-72% TFM
kW
KG/H KG/H For the process Soaptec proposes
CR-3 750 1000 15 high quality instruments and valves.
CR-6 1500 2000 30
Normally the instruments are
CR-9 2500 3000 37
“Endress+Hauser” and the valves
No.2 CR-6 3000 4000 30x2
No.2 CR-9 5000 6000 37x2
“Samson”.
CR-12 5000 6000 37

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REACTOR COLUMN

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REACTOR COLUMN

The reactor column (RC) is a versatile pressurized Control panel is provided with an
reactor used for fatty acids neutralisation and/or for inverter to vary the agitator r.p.m.
neutral fats (half or full boiled) continuous saponifi- Soap composition control is per-
cation. formed by PH-meter or differential
The main characteristic of the reactor column is its pressure controler.
small internal volume, which allows much flexibility
regarding soap formulation changeover.
Agitator rating driv en by ‘Rossi’ gear-
RC is provided with a special internal agitator so to
box with load capacity v erified ac-
allow a strong mixing and impose an upwards flow
cording to UNI, DIN, AFNOR, AGMA
to the processed material. This fluent movement is
and ISO standards. Soap seal assured
increased by means of a pump in the recycle loop.
by a double mechanical seal.
Raw mat erials are homogenized inside an intensive
mixer placed b efore the reactor column. Complet e
saponification comes inside the RC where raw mat e- Recycle loop guarantees an intensive
rials wait for reaction. mixing and the saponification/
neutralization reaction accomplish-
Composition of liquid soap can be controlled using ment.
the PH-meter installed in the recycle loop, or moni-
toring the differential pressure through the recycl e
pump.
Recycle pump is a high volumetric
FATTY ACIDS NEUTRALISATION
capacity lobe pump. All parts in con-
Fatty acids, caustic soda and brine are saponified
tact with th e product built in AISI
inside the reactor column, where they remain the
316 stainless steel
time nec essary for the complet e reaction. It is ob-
tained 62% to 72% TFM neat soap.

NEUTRAL FATS CONTINUOUS SAPONIFICATION is Special agitator, manufactured in

done by two different processes: half boiled and full AISI 316 stainless steel gives a strong
boiled. mixing and imposes the upwards
flow to the processed material.
In half boiled process all mat erials used in th e
saponification remain inside the neat soap. It is ob-
tained 62%-66% TFM neat soap. Laundry and trans-
lucent. Soaptec supplies reactor columns
manufactured and certified accord-
In full boiled process we obtain crude soap to be ing standards ASME, SECTION VIII,
conveyed to downstream washing phase, necessary DIVISION 1. All parts in contact with
to remove the gl ycerine. the product are in AISI316, jacket in
AISI304.
REACTOR COLUMN
LIQUID SOAP PRODUCTION INSTALLED POWER
TYPE Soaptec proposes high quality “E+H”
KG/H kW
instruments and “Samson” operated
RC-138 2500 7,5
valves.
RC-230 4000 11
RC-380 6500 15 PH-meters can be “Endress+Hauser”
RC-580 10000 18,5 or “Metler Toledo”.
RC-900 18000 30

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WASHING COLUMN

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WASHING COLUMN

“The targets of soap washing are to remove all the Rotor is driven by a ‘Rossi’ gearbox
soluble impurities in the lyes and to recover th e with load capacity verified according
glycerine liberated by the saponification reaction. to UNI, DIN, AFNOR, AGMA and ISO
The washing column is a counter-current extractor standards.
mechanically agitat ed., with a set of stator rings
fixed inside the vertical shell and a v ertical shaft
with equipped rotating discs.” Intermediat e area rotor is supported
by a bushing fitted on a spider, pro-
Ref: Spitz L., ed. Soaps and Detergents vided with radial adjustment, easily
A theoretical and pratical review,
AOCS press, Champaign, Illinois, 1996, pp. 157.
accessible for inspection and mainte-
nance.
Soaptec proposes a set of Rotating Disc Contactor
Washing Column denominated RDC, dedicated to
the washing with counter-current soap flow coming
from the saponification.
Bottom rotor is supported by a bush-
Soap to be washed comes from th e saponification ing fitted on the spider, provided
by a pouring nozzle placed on the bottom side of with radial adjustment, easily acces-
the washing column. Washing ly es inlet is placed on sible for inspection and mainte-
the upper side of the washing column. nance.

The washing occurs by near contact due to the

counter-current passage of the washing lyes inside An electric al control panel with push
the soap itself, pushed by the rotating action of the -buttons is provided with an invert er
discs fixed to the washing column shaft. in order to vary r.p.m of the rotor.

The interfac e l evel b etween soap and lyes is auto-

matically controlled by d edicated instrumentation
and also by sight glasses placed on the bottom of
the washing column. Clean soap comes out from the
top of the column through a particular overflowing All parts in contact with the product
that assures its balanced exit. are manufactured in AISI 316
stainless steel. The jack et is built in
AISI 304 stainless steel.

Usually Soaptec supplies washing

columns manufactured and (on re-
quest) certified according to ASME,
SECTION VIII, DIVISION 1 standards.

WASHING COLUMN
PRODUCTION INST. POWER
TYPE
KG/H kW Soaptec proposes high quality “E+H”
RDC-4 4000 7,5 instruments and “Samson” operated
RDC-6 6000 11 valves avai lable at international mar-
RDC-8 8000 15 ket.
RDC-10 10000 15
RDC-12 12000 18,5
RDC-16 16000 22

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DRYER

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DRYER

Dryer plant is used for continuous drying of The soap filter is basket type, intended
laundry and/or toilet base soap, and it has five for horizontal installation. Body and
different stages: basket are made of AISI 316 stainless
steel and the jacket in AISI 304 stainless
steel. Design pressure: shell 4 bar, jacket
1. NEAT SOAP FIL TRATION 1 bar. Filtration degree 08, mm.
Liquid soap is pumped through a soap filter into
the soap feed tank.
Heat Exchanger Sh ell & Tube typ e, tubes
2. NEAT SOAP HEATING in AISI 316 stainless steel. Shell and
Liquid soap is fed by the feeding pump into the cones in AISI 304 stainless steel com-
heat exchanger where it will b e heat ed. plete with expansion joints. Built and
certificated according to ASME codes,
3. DRYING section VIII, division I. Design pressure:
Heated liquid soap is sprayed inside the atom- shell 10 bar, tubes 10 bar.
izer. Vapors liberated inside (ones preformed
inside heat exchanger and those flashed off) are
sucked out by the vacuum system. Sprayed soap Soap Vapors separator used in our
becomes dry, cold and solid on the walls of the Green Dryer Plant drastically reduces
atomizer. It is scrapped off the wall by the rotary fines formation carrying them over and
scrappers action. Scrapped soap falls on the transferring them in the vacuum system.
worms of the plodder and is extruded out in It can be retro fitted on existing dryers in
form of pellets or continuous bar. order to obtain above mentioned bene-
fits. Being an equipment that works
4. SOAP FINES SEP ARATION AND RECOVERY under pressure, Soaptec foreseen the
Soap dust formed during spraying are conveyed manufacture and certification according
together with vapors out of the atomizer by to ASME, SECTION VIII, DIVISION 1 Stan-
means of the cyclones which will separat e them dards.
recovering soap dust from its bottom.

5. VAPORS CONDENSATION Atomizer’s equipped with spring loaded

Vapors are condensed inside barometric con- scrapers on the cone, on the cylinder
denser. Vacuum pump produces and maintains and on the top, with bridge breaker arm
the vacuum degree inside the plant by removing on the bottom. Built in AISI 304 stainless
all uncondensables. steel, on request, in AISI 316. Mechani-
cal seals are installed on soap and vac-
Soaptec proposes different kind of Dryer plants, uum sides.
offers consulting and supply for existing plants
revamping.

Our plodders are single worm or tangent

twin-worms, with single or double stage.
Length/diamet er ratio cylinder is four.
All parts in contact with soap are manu-
factured in Aisi 304 Stainless steel. Extru-
sion group with drilled plate for chips
production or with conical head for soap
bar production.

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TOILET DRYER

In the Toilet Dryer th e liquid soap coming from the saponification plant is dried by two
main processes:

Pre-evaporation in the heat exchanger and Flashing in the Atomizer.

All vapors produced are removed from the atomizer, sucked by the vacuum group
and then condensed by the barometric condenser.

Soaptec’s Toilet Dryer plants are distinguished for user-friendly system thanks to the pro-
duction/recycle sequence and automatic atomizer nozzle cleaning.

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GREEN DRYER

In the Green Dryer, the l iquid soap coming from the saponification plant is dried by two
main mechanisms:

Pre-evaporation in the heat exchanger and Flashing in the Atomizer.

Vapors produced inside the Heat Exchanger are separat ed in the Soap/Vapor separator.

This operation drastically reduce the load on the v acuum system, fines formation and their
carry over.

Separat ed vapors can be used as motive steams to th e booster or for v arious heating pur-
poses.

Main characteristics of this system are high energy savings and environment-friendly per-
formance, hence the name Green.

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LAUNDRY DRYER

In the laundry dryer the main intention is not to dry but to cool down and
consequently solidify the soap.

For this reason Laundry Dryer can be furnished without the heat ex-
changer, or, if installed, it is usually used for small corrections of soap tem-
perature before th e flash in the atomizer.

Considering the reduced dust formation, Soaptec proposes a high efficiency

mono-cyclone for fines separation.

Plodder placed under the atomizer is a Duplex Vacuum Plodder which ex-
trudes the soap in a continuous soap bar ready to be stamped and cut at
the desired length by the cutter.

Our cutters can be easily equipped with engraving rolls for the production
of high quality finish stamped-looking soap bars.

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SOAP FILTER

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SOAP FILTER

In the drying plant the filter is positioned between Cleaning is done by opening the
the filtration pump and the soap tank and keeps hinged cover and extracting the
soap free from impurities that can contaminate it. basket from the body.

Soap filter protects not only the downstream ma-

chines but soap’s ultimate consumer as well.
It is good practice to install two fil-
ters, one in operation and another in
Soaptec proposes basket soap filters for horizontal stand by. This way it is not necessary
installation. Body and basket built in stainless steel to stop the plant for filter cleaning.
AISI 316, heating jacket in stainless steel AISI 304.

Inlet and outlet flanges for both soap and steam ar e

usually built following UNI standards. On request Another useful thing is to install two
also built according ANSI standards. pressure gauges for each filter: one
before and one after. An increase in
pressure drop will tell you when is
Project pressure soap side 4 bar. time to clean the filt er.
Project pressure jacket 1 bar.
Filtration degree 0,8 mm.

Soaptec’s soap filters are installed

horizontally and are fitted with a
support to avoid tensions on the
piping.

The filter is also very important in

raw materi als handling. It stops
eventual impurities present in raw
materi als from contaminating down-
stream machines or soap.

Soaptec proposes vertical basket

SOAP FILTER
filters for raw mat erials filtration. An
PRODUCTION FILTERING FILTERING
TYPE NEATSOAP SURFACE DEGREE installation of two filters will avoid
KG/H m2 mm stopping the plant for cleaning.
SF-1 3000 0,5 0,8
SF-2 6000 0,9 0,8
SF-3 10000 1,5 0,8

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SOAP TANK

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SOAP TANK

In a traditional Vacuum Dryer plant for continuous Inlet and outlet flanges for both soap
soap production, Soap Tank is located after soap and steam are usually built accord-
filter and before heat exchanger. ing to UNI standards. On request
also built to ANSI standards .

Soap tank is used as a buffer for neat soap after

saponification and before its pumping through heat
exchanger into the atomizer. The bottom of the soap tank can be
built conical or torospherical shaped.
The cover, bolted on the top, has a
Soap tank is built in AISI 304 stainless steel and has wide inspection door.
always heating jack et heated by means of vapour or
hot water.

On request it can be fitted with a gearbox driven Soap tank can be equipped with it’s
agitator so to keep the liquid soap in continuous and own legs or with supports for instal-
slow movement. lation on a platform.

Soap tanks are built in different sizes depending on

plant’s production capacity.
In case of steam heating it is impera-
tive to install a safety pressure re-
lieve valv e on the steam inlet line or
better, directly on the jacket.

Security valve prevents eventual

soap tank implosions that can hurt
people and machinery.

Soaptec’s Soap tanks are usually

built in measures that permit con-
tainer transport.
SOAP TANK
SEMI BOILED FULL BOILED CONTINUOUS
PRODUCTION PRODUCTION NEUTRALIZ.
TYPE
Kg/h Kg/h Kg/h
TOILET LAUNDRY TOILET LAUNDRY 62% TFM
CS-1 - - 1000 2000 -
CS-2 750 1000 1500 2500 2500
CS-4 1000 1500 4000 5000 5000
CS-6 1500 2000 6000 7000 7000
CS-8 2000 2500 7000 8000 8000
CS-10 2500 3500 8000 10000 10000
CS-12 3000 4000 10000 12000 12000

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HEAT EXCHANGER

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HEAT EXCHANGER

“Single-pass shell-and-tube heat exchangers for Within the vacuum dry er installa-
soap applications are simple in design. tion, heat exchanger allows the heat-
ing of neat soap and pre-evaporation
A number of straight tubes are sealed between two of some moisture before flash inside
perforated tube sheets. the Atomizer.

The tubes, plates, and cones are made of 304, 316,

or 316L AISI stainless steel. Soaptec supplies shell-and-tube heat
exchangers with O.D. 14 mm tubes
To avoid the problem of stress corrosion cracking th.1mm in AISI 316. The shell , the
for soap formulations with high salt content in the cones, the plates and the dia-
neat soap, high-nickel-content materials are recom- phragms are built in AISI 304.
mended.

Expansion joints should be used to prevent me-

chanical stresses. Soaptec’s heat exchangers are al-
The optimum diameter of the tubes is 12 mm inside ways fitted with expansion joint.
and 14 mm outside.”

Ref: Spitz L., ed. Soaps and Detergents

A theoretical and practical review,
AOCS press, Champaign, Illinois, 1996,
pp. 217.
Inlet and outlet flanges for both soap
and steam are usually built to UNI
standards. On request also built to
ANSI standards .

Soaptec’s heat exchanger project

pressure is 10 bar (both tube and
shell side).
Project temperature is 150° soap
side and 185° vapor side.
HEAT EXCHANGER
LAUNDRY TOILET TOILET
TIPO 66-72% TFM 76-78% TFM 78-82% TFM
Kg/h Kg/h Kg/h All heat exchanger pressure tests are
HE-05 500 - - done at 14 bar.
HE-10 1000 - -
HE-15 1500 750 500
HE-20 2000 1000 750
HE-30 3000 1500 1000
HE-40 4000 2000 1250
HE-45 4500 2000 1500
HE-60 6000 2500 2000 Soaptec supplies heat exchangers
HE-75 7500 3000 2500 completely built, and on request,
HE-90 - 4000 3000 certified according to ASME,
HE-120 - 6000 4000 SECTION VIII, 1 st DIVISION standards.
HE-150 - 7500 5000
HE-180 - - 6000
HE-240 - - 8000

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VACUUM SPRAY CHAMBER

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VACUUM SPRAY CHAMBER

“Since 1950’s vacuum spray drying for the continu- Vacuum spray chambers manufac-
ous production of laundry soap and for the drying of tured by Soaptec are supplied with
toilet soap base has become the most widely used scrapers on the cone, cylinder and
system world wide. ceiling. There is a bridge breaker arm
installed at the bottom of the atom-
The universal use of vacuum spray drying is due to izer.
unequalled versatility and flexibility in handling a
large v ariety of products.
Main shaft is driven by “Rossi” gear-
Toilet soap, soap/synthetic mixtures, synthetics and box, load capacity verified according
translucent bases can be dried by varying operating to UNI, DIN, AFNOR, AGMA e ISO
conditions. standard.

Laundry soap (filled and unfilled) is dried and ex-

truded continuously with vacuum spray dryers.”
Mechanical seals are installed on
Ref: Spitz L., ed. Soap Technology for the 1990’s both ,soap and vacuum sides. On
AOCS press, Champaign, Illinois, 1990, pp.154. request they can be replac ed with
gland packing.

Vacuum spray drying consists in spraying liquid soap

into the Atomizer. A combination of parameters
such as temperature and pressure will result in Scrapers are manufactured in
evaporation of excess moisture and cooling of the “formica”, spring loaded and adjust-
soap. able so to account for normal wear.

The vapours separat ed from soap are sucked by th e

barometric group and condensed.

The soap scraped off the internal wal ls of the Atom- Soaptec Atomizer is completely
izer, falls onto the screws of the plodder under- manufactured in AISI 304 stainless
neath and is extruded in form of pellets or continu- steel or, on request, in AISI 316
ous bar. stainless steel. The insides of the
machine are machined with a tool
Soaptec Atomizers are manufactured in AISI 304 machine on all its surfaces.
stainless steel, supplied with three different noz-
zles, two sight glasses with wiper and lamp, inspec-
tion door on the bottom, door on the connection
with dust separators, high level alarm probe and A big door placed on the connection
mechanical seals on both soap and vacuum side. duct to the underneath plodder
allows an easy internal inspection of
the Atomizer.
VACUUM SPRAY CHAMBER
TOILET LAUNDRY
INSTALLED
PRODUCTION PRODUCTION
TYPE POWER
80-82% TFM 7O-72% TFM
kW
KG/H KG/H
AT-900 1000 1500 1,5 Two sight glasses with wiper and
AT-1050 1500 2000 2,2 lamp are fitted on the top, the other
AT-1300 2500 3500 4 is fitted on the Atomizer bottom
AT-1550 4000 5000 4 respectively.
AT-1900 6000 7500 5,5
AT-2200 8000 10000 7,5

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 27

FINES SEPARATOR

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FINES SEPARATOR

“Four different cyclone-type recuperators are used Alternativ ely they can be fitted with
to recover and recycle, or not to recycle, the soap fines extruders or conveyors for soap
fines produced in the vacuum spray chamber. recuperation while the pl ant is run-
ning. Soap fines can be recycled
DUAL CYCLONE inside the atomizer or extruded/
Two cyclones connected in series is the commonly conveyed in atmosphere.
used traditional system for most small and medium-
size dryers. (…)
Fines separators can be single or
MULTICYCLONE double.
For large-capacity dryers, th e multicyclone system is
suggested due to its higher separation efficiency.
(…)

SINGLE CYCLONE
The lat est development is the application of a single Double fines separators, are two
large-size cyclone, pref erably in combinations with a separators connected in series by a
wet scrubber located downstream. (…)” rectangular shaped duct. Fines es-
caping the first separator are sepa-
Ref: Spitz L., ed. Soaps and Detergents rated by the second one. Double
A theoretical and pratical review,
AOCS press, Champaign, Illinois, 1996, pp. 219. separators are mostly used in toilet
soap production plants.

Vacuum dryer plant Fines Separators separate soap

fines from vapors produced during drying. Soaptec Single fines separator is usually used
produces different types of fines separators. They in laundry soap production plants.
can be fitted with fines collection drums that are
emptied by operator during plant shut downs.

A careful choice of separators ge-

SINGLE FINES SEPARATOR
ometry, their diamet er and speed of
TOILET LAUNDRY
vapors movement permit centrifugal
TYPE 80-82% TFM 70-72% TFM
Kg/h Kg/h separation of soap fines (which pre-
FS-960 1500 2000 cipitate) from vapors and uncon-
densables traveling on.
FS-1100 2500 3500
FS-1300 4000 5000
FS-1500 6000 7500
FS-1700 8000 10000 Fines separators are integrall y built
in AISI 304 stainless steel, but, on
request they could be supplied in
painted carbon steel.
DOUBLE FINES SEPARATOR
TOILET LAUNDRY
TYPE 80-82% TFM 70-72% TFM
Kg/h Kg/h We recommend to trace and insu-
FS-800 1500 2000 late the separators especially in
FS-960 2500 3500
colder climates.
FS-1100 4000 5000
FS-1300 6000 7500
FS-1500 8000 10000

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 29

FINES EXTRUDER

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FINES EXTRUDER

During drying operation, all soap fines separat ed FC-150 ends with a spider plate:
from vapors inside fines separators are recuperat ed. there are no drill ed plates nor
knives. This way the separat ed soap
Fines recuperation can be done by collecting them is just transported
into separators bottom drums which will be emp-
tied during shut-down periods of the plant and usu-
ally transferred into a k ettle or by using Fines ex-
truders/conveyors that allow recuperation whil e
the plant is running. Parts in contact with soap in both FC
-150 and FE-150 are built in AISI 304
Soap fines recuperation can be done by transporting stainless steel.
soap fines back to the atomizer by means of Fines
Conveyors FC-150 or also extruding them in atmos-
phere using Fines Extruder FE-150.

Fines Conveyor FC-150 located between the first The screw is cast in aluminum and
separator and the Atomizer in order to transport then machined to tolerance.
separated fines into the atomizer.

If fines have to be extruded on the at mosphere,

then a Fines Extruder FE-150 will be set on the bot-
tom of Fines separators.

FC-150 is fitted with drilled plate and knife group The barrel is machined to guarantee
that will provide for vacuum seal and al low continu- correct positioning of the screw. It is
ous operation. provided with a cooling jacket. In
essence it is extremely similar to the
barrel of a normal soap plodder.

Top of the hopper is fitted with an

independently driven bridge breaker
FINES EXTRUDER AND CONVEYOR device.
INST. POWER
TYPE DESCRIPTION kW

FE-150 FINES EXTRUDER 4 + 0,37 Fines conveyor is driven by a worm

FC-150 FINES CONVEYOR 2,2 + 0,37 and wheel reducer and fines ex-
truder by a parallel shafts reducer.
Both gearboxes are made in Italy by
“Rossi”. Load capacity verified ac-
cording to UNI, DIN, AFNOR, AGMA
and ISO standards.

Mechanical seals fitted onto drive

shafts of both screw and bridge
breaker assure the vacuum seal.

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 31

VACUUM SYSTEM

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VACUUM SYSTEM

“The vacuum-producing systems for soap Cooling water can be efficiently used in
dryers consist of steam condensation equip- closed circuit using a cooling tower in con-
ment (barometric and surface condensers junction with a water chiller.
and cooling towers systems) and vacuum-
producing equipment (vacuum pumps and
steam jet ejectors).
VACUUM PUMPS

The sole purpose of a condenser is to con- Today liquid ring pumps are the preferred
tinuously convert the vapors generated dur- choice. They are avail able on the market as a
ing the drying process back into water. skid-mounted complete group with gas/
liquid separators and plate coolers, or shell-
and-tube heat exchangers to maintain the
Two basic types of condensers are used: seal wat er temperature.

Barometric condenser
Surface condensers
STEAM JET EJECTOR S

BAROMETR IC CONDENSERS Steam jet ejectors are very simple dev ices
consisting of a nozzle, a mixing chamber,
Barometric condensers are also call ed direct and a diffuser. Using motive steam, and
contact condensers because they condense according to the required operating vacuum
the vapors by direct contact with the cooling level in the dryer, a single-stage or multi-
water. stage ejector group is used.

SURFACE CONDENSER S COOLING TOWER SYSTEMS

Surface condensers are shell-and-tube heat Cooling Tower System is set for cooling the
exchangers. Vapors to be condensed flow hot condensing water from th e hot well and
inside the tubes while cooling water does it returning it to the barometric condenser.”
on the shell side.

Ref: Spitz L., ed. Soaps and Detergents

Cooling water is not contaminated with soap A theoretical and practical review,
fines because they never come in contact AOCS press, Champaign, Illinois, 1996, pp. 222.
with them.

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 33

PNEUMATIC CONVEYOR

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PNEUMATIC CONVEYOR

Pneumatic transport is mostly used for transporting The feed hopper has an AISI 304
soap pellets produced by the Dryer and their stock- stainless steel hopper and a manual
ing inside finishing lines feeding silos. lock gate upon a rotary valve. All
assembled on a single chase.

Soaptec offers pneumatic transport systems by-

pressure or by-suction with one or more withdraw-
ing points and one or more store points for different A flow indicator installed on pneu-
production capacities. matic transport delivery pipe per-
mits to control visually material
incoming from extruder and pellets
On pneumatic transport by-pressure soap pellets flow air-transported.
are pushed by the air-flow-generator-blower lo-
cated on pneumatic t ransport beginning. This air
blower is a powerful air compressor set in a sound-
proof cabin. Diverting valves, usually controlled
by pneumatic actuators, permit to
divert the pellets flow to different
stocking silos.
On pneumatic transport by-suction soap pellets are
suctioned by the air-flow-generator-aspirator lo-
cated at the end of pneumatic transport.
On the top of every silo there is a
centrifugal dust separator where
pellets are separated from air, and
discharged into the silo.
For avoiding pipes obstruction the transport air flow
should be cooled using the cold-water-exchanger.

Air discharge pipes are fitted with

butterfly valves controlled by pneu-
matic actuator to regulat e the air
flow.

Discharge air is filtered by a bag

filter. Bags of filter stop the soap
fines that are gathered at the bot-
tom of the filter and periodically
discharged.

Electrical control panel can be fitted

with a synoptic panel.

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 35

FINISHING LINE

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FINISHING LINE

“Bar soap finishing is the final processing step Soaptec most performed cutters are EMC
for the production of standard, super-fatted, cutters. They are built in different versions:
translucent, soap/synthetic (combo), and
synthetic products into a solid bar (tabled EMC-1 with cut height 80 mm
form). Bar soap finishing consists of mixing EMC-1L with cut height 100 mm
the main base with minor liquid and solid in- EMC-H with cut height 50 mm AM-500B
gredients, followed by refining the fully for-
mulated mixture into a uniform, homogene- Those machines can be supplied single or
ous product, extruding into a continuous slug double versioned with 450 mm inter axes.
(billet) form, cutting into individual length The blade movement that follows the ex-
slugs, and stamping into a final predeter- truded bar, is guided by a dedicated cam
mined weight and shape bar (tablet) ready for group, driven by a brushless motor con-
packaging.” nected to a precision gearbox.
DASM-500B

Ref: Spitz L., ed. Soap and Detergents MBC-1 cutter is quite different. It also com-
A theoretical and practical review, AOCS press, Champaign,
Illinois, 1996, pp. 243. bines electronics and mechanics but its verti-
cal component of the motion is given by its
Soaptec produces all the machines needed brushless motor and its drive, and horizontal
for the finishing line. movement is obtained by the soap bar itself.

Mixers range includes the AM series, with In third place we hav e MBC-P, a single blade M-320

opened blade and bottom product discharge pneumatic cutter, mostly used for cutting
through a pneumatic gate and also DASM se- soap bars subsequently fed to the stamper in
ries with a double arm sigma blade and prod- small Finishing lines.
uct discharge from the bottom of the tank
through a pneumatic gate or by means of a
discharging worm. Multi Flash Stamper MFS is a series of last
generation v ertical stamper that has been
SRt-300
Three Roll mill’s range includes Mechanic roll developed by putting together our ideas thus
mills built in five different sizes for different positive experiences obtaining an innovative
productions. For productions up to 2500 kg/h and reliable result.
and 4000 kg/h we propose the M-320 and the
M-400 with hydraulic system for gap regula- MFS stampers are completed with interface
tion. with touch screen that permits a simple and
intuitive control of all operational parame-
Soaptec’s finishing lines also include a wide ters. DVs-300

range of Refiners and Vacuum Plodders in

single or twin worm versions and single, dou- In-feed suction pads, discharge suction pads
ble or triple stage. Length/diamet er ratio of movement and main mandrel rotation are
the barrel is 4. Worm’s rotation speed is al- obtained by maintenance free sealed cam
ways driven by an inverter. Plodders can be boxes.
fitted with various optional systems such as
cooling water temperature regul ation system EMC-1
by Turbo flow, independently driven knifes for
pellets length vari ation or hydraulic locking
system for drilled plate instead of traditional
eye bolts.

MFS-6

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 37

AMALGAMATOR

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AMALGAMATOR

Soaptec's Amalgamators, called AM type, are mix- Electrical control panel is separated
ers with two open sigma blades for soap pellets, from the machine. PLC and Touch
solid additives and liquids like colours and perfume. screen permit to control the mixing
in automatic/manual cycle.
The blades, their movements and the tank have
been designed to create an intensive mixing of the
soap in order to break the pell ets into dust and to
speed up and increase the absorption of additives.
The blade is driven by parallel shaft
Amalgamation time is settable by means of a timer gearbox. Load capacity of the re-
installed on user's panel. ducer is verified according to UNI,
DIN, AFNOR, AGMA and ISO stan-
A gearbox commands the rotation of the blades. dards.

All parts in contact with soap are built in AISI 304

stainless steel.
Mixing arm is made of AISI 304
Discharging phase is done through a pneumatically stainless steel machined to toler-
operated gat e installed at the bottom of the amal- ance.
gamator.

Product falls down into the hopper of a Roll Mill, a

Refiner/Plodder or an Elevating Conveyor installed
under the amalgamator. The tank is completely manufac-
tured in AISI 304 stainless steel, op-
tionally supplied with jacket for the
cooling or heating of the soap to
mix.

In pneumatic bottom discharge ver-

sion, the tank is fixed to the base.
AMALGAM ATOR AM
Gate opening is driven by a pneu-
PRODUCTION INST.POWER BATCH CAPACITY
TYPE KG/H kW Kg Liters matic circuit with solenoid valve.
AM-50B Up to 375 4 50 205
AM-100B 750 7,5 100 399
AM-200B 1500 15 200 805
AM-400B 3000 22 400 1577
AM-500B 4000 37 500 2014 The cover of the mixer can be manu-
AM-800B 6000 37 800 3117
factured on Customer specification.

Well designed shape of the blades

and a correct good gap between
them and the t ank are the main
conditions for an intensive breaking
of the pellets.

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 39

DOUBLE ARM SIGMA MIXER

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DOUBLE ARM SIGMA MIXER

“In the soap industry a correct definition and meas- Electrical control panel is separated
urement criteri a for the mixing do not exist. from the machine. PLC and touch
screen permit to control the mixing
The solid additives mixing with the base soap pellets in automatic/manual cycle.
in a standard mixer is called macro-mix.

During the macro-mixing, the additives cover only

the pellets surface. Arms driving is given by two inde-
pendent parallel ax es gearboxes.
When the pell ets are crushed it is possible to obtain Load capacity of the reducers veri-
a micro-mix, or an intensive mixing, in order to pre- fied according to UNI, DIN, AFNOR,
sent larger surface to the additives and allo ws the AGMA and ISO standards.
same to pass trough the inside the soap pellet.”

Ref: Spitz L., ed. Soaps and Detergents

A theoretical and practical review,
AOCS press, Champaign, Illinois, 1996, pp. 243. Mixing arms are made of AISI 316
stainless steel casting, then polished
Double Arm Sigma M ixers DASM are manufactured and machined by machine tool. Both
in three versions: arms are in counter-rotation sense
at different r.p.m.
• Titling discharge driv en by hydraulic circuit
• Bottom discharge driven by pneumatic piston
• Worm discharge
Double housing tank is completely
manufactured in AISI 316 stainless
The tilting trough tank discharge v ersion is particu-
steel, supplied with jacket for cool-
larly indicated for the mixing of products with a
ing or heating the soap.
great quantity of liquid additives. Botto m discharge
can be used in normal solid soap. Worm discharge
also does a small first refining work on the soap.
On tilting discharge version, the tank
Double housing of the tank is machined with ma-
is fitted with two bronze bearings
chine tools in order to guarantee a right tolerance
fixed on the base. Rotation is driven
with the mixing arms. Special profile of the blad e
by an hydraulic circuit with pump
and correct tolerance bet ween tank housing and
and piston central station.
mixing arm are the main conditions for obtaining
best pellets crushing.
On bottom discharge version , the
DASM mixer can be provided with choppers for an
tank and the base are a single body.
intensive soap mixing.
A pneumatic circuit, supplied with
solenoid valve and piston, drives the
DOUBLE ARM SIGMA MIXER
PRODUCTION INST. POWER BATCH SIZE CAPACITY opening movement of the gate.
TYPE KG/H kW KG Liters
DASM-125 1000 7,5+4 125 375
DASM-250 2000 11+7,5 250 760
DASM-500 4000 18+15 500 1500
The cover of DASM mixer can be
DASM-1000 8000 37+18,5 1000 3000
DASM-1500 12000 55+37 1500 4500
manufactured according to the cus-
tomer needs.

Valid for soap pellets with density 0,6 Kg/lt

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WORM FEEDER

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WORM FEEDER

Worm feeder receives a batch of soap and minors Electric equipment and control panel
blend from mixer and feeds the roll mill continu- are usually integrated in the mix er
ously. control panel, or in any case, sepa-
rated from the machine.
As tilting discharge DASM (page 40), worm feed er is
particularly suited for synthetic soap production and
for high liquid addition formulas.
Twin worm feeders receive the com-
On request, worm feed er can be supplied with a mand from two coaxial gear boxes,
cooling or heating jacket and worms can be one for each worm, driven by in-
equipped with a cooling or heating circuit. verter.

For particularly precise and flexible regulation of

temperature of either barrel and/or worms the ma-
chine can be equipped with turbo-flow type regulat-
ing circuit. Gear boxes load capacity are v erified
according to UNI, DIN, AFNOR,
Soaptec offers twin or four worms feeders depend- AGMA and ISO standards.
ing on the production.

All parts in contact with soap are built in AISI 304

stainless steel. The wide in-feed hopper can receive
a complete charge of the mixer and
is provided with a safety cover on
the top and an inspection door on
the side.

Worms are built in AISI 304 stainless

steel, welded and machined to toler-
ance. They can be provided with
internal cooling or heating circuit.

A small locker (useful for putting

work tools) is fixed on worm feeder’s
frame, built in painted carbon steel.

WORM FEEDER
PRODUCTION INST. POWER
TYPE
KG/H kW
MW2x200 UP TO 1500 0,75 + 0,75
MW2x250 1500-3000 1,1 + 1,1
Extrusion group is completed with
MW4x250 3000-5000 3 +3
knives for pellets cutting and, on
demand, with drilled plat e.

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 43

REFINERS

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REFINERS

“Refining is the work done on soap by the combined Electrical control panel, completed
action of pressure and shear. with push-buttons and inverters, is
fitted in a frame that supports stairs
The purpose of refining is threefold: and working platform.

• To produce a fully homogeneous, uniform

product.
• To improve bar feel by eliminating low-solubility Main motor power controlled by
hard particles. inverter. Its brand can be chosen by
• To enhance product lather, solubility, and firm- the customer.
ness by affecting crystalline structure change

Refining is performed with plodders, roll mills, or

both units used in combination.”

Ref: Spitz L., ed. Soaps and Detergents Parallel ax es gearbox manufactured
A theoretical and practical review,
by ‘Rossi’ company. Load capacity
AOCS press, Champaign, Illinois, 1996, pp. 243.
verified according to UNI, DIN, AF-
NOR, AGMA and ISO standards.
The specific function of the Refiner plodder is the
soap refining obtaining the performances above
indicated.

Soaptec propose single-worm and tangent twin

Cylinder provided with jack et and
worms Refiners in both single and double stage
insulation for cooling, completely
versions.
manufactured in AISI 304 stainless
steel .
The length / di amet er ratio of cylinder is 4.

Refiners can be assembled with ri ght or left side

orientation for the operator
Screws are built out from casting,
polished and mechanically finished.
All parts in contact with the soap are manufactured
Generally made of aluminium alloy G
in AISI 304 stainless steel.
ALSI9, on request also in NI-Resist or
AISI 304.
SINGLE WORM
WORM DIA. PRODUCTION INST. POWER
mm KG/H kW
Extrusion through a drilled plate
150 500 7,5
200 1250 15
with diameter 8 mm holes and
250 2000 22 counter bore diameter 9.5 mm. In-
300 3000 30 novative refining foils of 25 and 40
350 4000 45 mesh, pelletizing knife, protection
400 5000 55 and hinge-pins.
TWIN WORM
WORM DIA. PRODUCTION INST. POWER
mm KG/H kW
150 1000 11 Standard water circuit preassem-
200 2000 22 bled, with solenoid valve and wat er
250 3500 37 temperature indicator at cylinder
300 5000 55
outlet.
350 7000 75
400 9000 90

Valid for opaque soap base at 78-82% TFM

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 45

REFINING FOILS

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REFINING FOILS

For an optimal refining a pass through refining In order to improve the soap refining
plates is needed. Historically exist different kinds of action through refiner plodder, there
this refining plates: is a choice of wire net screens and
drilled plates, that are supporting
• Wire mesh refining screens the screen and protecting it from
• Micro expanded wire mesh refining screens breakage.
and
• Perforated plates, which do a stronger refin-
ing work to the product. The refining action obtained by tra-
ditional wire mesh, built from com-
Soaptec has developed a new refining concept crea- mercial avail able mat erials, is minor
ting Refining foils. than the refining obtained by perfo-
rated plates.

This perforated plates are also built

from commercial av ailable mat erials,
SOAP FLOW PATTERN ACROSS R EFIN ING SCREEN but dimensions and shapes of holes
are limit ed.

Round section of the wire net

allows for a smooth flow of
Using innovative designing and
soap. Shear action is mini-
Soaptec improved one of the princi-
mal.
pal constituents of the refining proc-
ess by introducing refining foils.

Soaptec produces refining foils with

perfectly defined geometry, size and
SOAP FLOW PATTERN ACROSS SOAPTEC WIR E NET shape of the holes that are practi-
cally unlimited.

Sharp edges of the holes disturb

the flow. Shear action is maxi-
mized.

FOILS SPECIFICATIONS
HOLE DIAMETER HOLE AREA OPEN AREA THICKNESS
MESH NUMBER
mm mm2 % mm
25 0,72 0,41 40 % 0,3
40 0,45 0,16 40% 0,2

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 47

THREE ROLL MILL

MECHANICAL

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THREE ROLL MILL

MECHANICAL

As mentioned, refining work has a triple scope: The operator interface is a simple
push button panel for controlling all
• Fully homogeneous uniform product functions of the machine.
• Bar feel improving by eliminating low-solubility
particles
• Enhance product lather, solubility and firmness

Traditionally a perf ectly refined soap is obtained by

the passage of 3,5 refining levels: the first one is Power distribution given by a single
done by the refiner, the next 1.5 lev el happens in- motor, allows each roll to absorb the
side the Three Roll Mill Machine, the third and last power needed.
level t akes place on the first stage of the Duplex
Vacuum Plodder machine.

The specific function of the roll mill is soap refining

obtaining above mentioned performances by creat-
ing a thin coat of soap upon the rolls which is Gap regulation obtained by a me-
scrapped off the machine. This alters the structure chanical system based on eccentric
of the soap increasing its quality. flanges driven by a worm wheel set .

Soaptec manufacturing program includes Mechani-

cal Three Roll Mills typ e ‘M’, manufactured in fiv e
different sizes for different production needs.
The gap bet ween rolls is adjusted by
Rolls movement is obtained with a single motor means of a hand-wheel . Each turn
which distributes the necessary power to the three corresponds to a 1/100 mm. open-
rolls by means of timing belts, passing through a ing. It is possible to vary the gap with
speed reducer installed on each roll. the machine in operation.

Rotating speed of the rolls can be controlled by

means of an inverter. Pressurized cooling liquid is pumped
in each roll through the rotary cou-
pling. Temperature is controlled on
each roll by means of modulating
valves.

THREE ROLL MILL MECHANICAL External surface of the roll is a

PRODUCTION
INST. ROLLER ROLLER welded on lay er of mart ensitic
TYPE POWER DIA. LENGTH
KG/H stainless steel, hardened to 50 HRC,
kW mm mm
M-150 180 5,5 150 450 and grinded to 0,4 roughness.
M-200 750 15 200 700
M-250 1500 30 250 900
M-320 2500 55 320 1100
M-400 3500 75 400 1400
Roll Mill’s main optional are flaking
rolls, fitted on hydraulic pistons for a
Valid for outlet gap of 0,15 mm. fast engagement/disengagement.

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 49

THREE ROLL MILL

HYDRAULIC

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THREE ROLL MILL

HYDRAULIC

Roll mill is, as Refiners and Plodders, another refin- Control of automatic sequences and
ing machine. monitoring of different functions is
performed by a PLC interfaced to the
However, refining work performed by the Roll Mill is operator by a touch screen device.
much more powerful and intense than refiners be-
cause it affects soap’s crystalline structure by break-
ing the noodles and splattering a thin film of it upon
the rolls. Avoiding power overloads or lacks of
force while machine is working, the
Roll Mill enhances product leather, solubility and single motor power source, allows
firmness. each roll to absorb the power effec-
tively need ed.
As per mechanical Roll Mill, Soaptec manufacturing
program includes Hydraulic Roll Mills “M” type built
in three different sizes depending on production
capacity. Hydraulic closing system allows to
differentiate the closing force for
Rolls are driven by a single motor which distributes each couple of rolls.
the power to the three rolls by means of timing
belts, passing through the speed reducer installed
on each roll. Rolls r.p.m can be controlled by an
inverter. Gap between rolls is adjusted trough
a hand-wheel. Each turn corre-
In this particular Roll Mill the gap b etween rolls is sponds to an opening of 1/100 mm.
regulated by means of an hydraulic system: It is possible to vary the gap with the
machine in operation.
Rolls are supported by hinged flanges connected
together by hydraulics on one side and to the frame
on the other. Pressurized cooling liquid is pumped
in each roll through a rotary coupling
Rolls get closed into each other by means of hydrau- into spiralling cooling channels.
lic cylinders. Hydraulic system also controls side The temperature is controlled on
seals, scrappers and flaking rolls (if present). each roll by self regulating v alves.

THREE ROLL MILL HYDRAULIC

External surface of the roll is a 5 mm
INST. ROLLER ROLLER
PRODUCTION coated surface of martensitic
TYPE POWER DIA. LENGTH
KG/H
kW mm mm stainless steel, hardened to 50 HRC,
M-320 2500 55 320 1100 and grinded to 0,4 roughness.
M-400 3500 75 400 1400

Valid for outlet gap of 0,15 mm.

The main optional of the roll mill are

flaking rolls, which cut discharged
soap flakes. They’re mounted on
hydraulic pistons for a fast engage-
ment/disengagement.

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 51

DUPLEX VACUUM PLODDER

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DUPLEX VACUUM PLODDER

Duplex Vacuum Plodder consist of two plodders Electrical control panel completed
mounted in tandem generally in line between them with push-buttons and inverters is
and, on request, at ‘ L’ arrangement. fitted in a frame that supports stairs
and working platform.
The preliminary stage is a refiner plodder, complet e
with drilled plate, pell etizing knife and refining
screen.
Main motor is driven by an inverter.
Soap pellets refined by the preliminary stage of the The brand of the motor and inverter
plodder are compacted and extruded in a continu- can be chosen by the Customer.
ous bar by the final stage.

The connection between preliminary stage and final

stage is a vacuum chamber, heated by means of
electrical heaters immersed in diathermic oil.
Parallel ax es reducer manufactured
The level switch placed inside the vacuum chamber by ‘Rossi’ gearboxes. Load capacity
guarantees a correct soap pell ets in feed to the final verified according to UNI, DIN, AF-
stage. NOR, AGMA e ISO.

A continuous soap bar is extruded through a nose

cone, heated by means of electrical heaters im-
mersed in diathermic oil. Final temperature is regu-
lated by a thermostat. Cylinder is provided with jacket and
insulation for cooling, manufactured
Soaptec proposes single worm and tangential twin- completely in AISI 304 stainless
worm duplex vacuum plodders. The l enght / diame- steel .
ter ratio cylinder is four.

Plodders can be assembled with right or left side

orientation for the operator. Screws are built out from casting,
then polished and mechanically fin-
All parts in contact with soap are manufactured in ished. Generally made of aluminium
AISI 304 stainless steel. alloy G Alsi9, on request also in NI-
Resist or Aisi 304.

SINGLE WORM
WORM DIA. PRODUCTION INST. POWER
mm KG/H kW Final stage extrusion group with
150 500 7,5 heated conical head, die pl ate and
200 1250 15 die plate holder. Conical head fitted
250 2000 22 on hinge-pin or on castors.
300 3000 30
350 4000 45
400 5000 55

TWIN WORM Standard water circuit pre-

WORM DIA. PRODUCTION INST. POWER assembled, with solenoid valve and
mm KG/H kW water temperature indicator at cylin-
150 1000 11 der outlet.
200 2000 22
250 3500 37
300 5000 55
350 7000 75
400 9000 90

Valid for opaque soap base at 78-82% TFM

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web site: www.s o apt ec .b iz

 53

CUTTER EMC

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CUTTER EMC

EMC is the latest generation soap cutter operating Electronics, designed on purpose for
with a single blade. Paradromic cam movements the applicaRon, allows the operator
and dedicated electronics are employed to grant to control all operaRonal parameters
smooth and silent operation and a precise and or- through the Touch screen device.
thogonal cut even at high speeds

Cutting group is composed by a brushless motor of

7,7 Nmt at 3000 rpm, while the belt conveyor drive
is composed by an asynchrony three-phase 0,25 kW Programming and software are sim-
motor driven by inverter. ple and intuitive.

EMC Cutters are produced in three different sizes:

• EMC dedicated to the toilet soap cutting

• EMC-L dedicated to the laundry soap cutting
• EMC-H dedicated to the hotel soap cutting Cutting blade movement is obtained
through a brushless motor coupled
All machines are availabl e in Single or Double con- to a precision reducer and a cams
figuration with centre-line bet ween the two bars of group dedicated to the type of appli-
450 mm. cation.

EMC cutters can be configured with right or left

orientation for operator. Belt conveyor and worktop are one
single unit. Belt is locked with 6
Main accessory of EMC cutters is Engraving rolls screws and is easy to remove from
group which offers the possibility to engrave soap the frame for an ev entual repl ace-
bar on two horizontal sides two vertical ones or on ment of the belt.
four sides.

The cover of the EMC cutter, locked

with 4 screws on the conveyor belt,
is also the support of the auxiliary
groups, such as encoder, inlet and
outlet rolls, pusher roll and guides.

EMC-H EMC EMC-L

TECHNICAL SPECIFICATION HOTEL TOILET LAUNDRY An appreciated performance of the
SOAP SOAP SOAP
EMC cutters is the possibility of do-
CUTTING HEIGHT mm 50 80 100
ing all regulations regarding soap bar
CUTTING WIDTH mm 100 100 100
CUTTING FREQUENCY cut/min 600 400 260
from hand wheels and regulating
MAXIMUM EXTRUSION SPEED m/min 65 42 24 groups located outside during opera-
tion.
EMC-1 cutter for single line EMC-2 cutter for double line

EMC cutters are designed to operate

with Engraving rolls.
Cutting synchronisation with the
engraving is obtained through dedi-
cated electronics.

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 55

CUTTER MBC-1

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CUTTER MBC-1

MBC-1 Cutters are also included in last generation Electronics, designed on purpose for
single blade automatic soap cutters. the application, allows operator to
use all operational parameters
Continuous soap bar incoming from the previous through the touch screen.
plodder is cut “on fly” by a single blade.

Vertical component of the motion of the blade is All programming and software is
performed by a brushless motor and its drive. During simple and intuitive.
its motion the blade is always perpendicular to the
soap resulting in a remarkably precise cut ev en at
high speed. Vertical cutting movement is ob-
tained through a brushless motor, a
Its horizontal component is given by the movement reducer and a crank gear system and
of the soap itself during the cut and of a special horizontal movement is driven by
spring during return of the blade to zero position. the soap itself.
Special decel erators will gu arantee a loud less ma-
chine, long life and trouble free performance.
Belt conveyor and worktop, as per
The belt conveyor is driven by a gear-motoreducer EMC cutters, are a single unit. How-
(Rossi type) of 0,25 kW. The speed of this unit is pi- ever, b elt is easily removed from
loted by a well d esigned inverter. frame for ev entual replacements.

The machine can be fitted with engraving rolls for

the production of engraved (2 or 4 faces) soap bars. MBC-1 cutter’s cover is also the sup-
that is engraved on 2 or 4 faces. The system permits port of auxiliary groups, such as en-
a perfect centred engraving on bar, so soap pro- coder, inlet and outlet rolls, pusher
duced will be very similar to the stamped product.. roll and guides.
During this process a control unit is connected to the
rolls sensor and drives synchronized cuts.
Regulations regarding soap bars can
be done from outside the machine
while it is working.

MBC-1 cutters are designed to oper-

ate with Engraving rolls group. The
cutting synchronisation with the
engraving system is obtained
CUTTER
TECHNICAL SPECIFICATION through dedicated electronics
MBC-1
CUTTING HEIGTH mm 110
CUTTING WIDTH mm 100
CUTTING FREQUENCY cut/minute 250
MAXIMUM EXTRUSION SPEED m/minunte 21
MBC-1 cutter for single line MBC-2 cutter for double line

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 57

CUTTER MBC-P

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CUTTER MBC-P

MBC-P is also one of the latest generation of auto- Electronics designed for the applica-
matic soap cutter operating with single blade. tion, allows the operator to use all
the operational parameters through
a touch screen device.
The continuous soap bar incoming from the previ-
ous plodder is cut “on fly” by a single blade. Vertical
component of the motion of the blade is performed
by a pneumatic cylinder (Festo type). During its mo-
tion the blade is always perpendicular to the soap Programming, regulation and soft-
resulting in a remarkably precise cut ev en at high ware are simple and intuitive.
speed.

Its horizontal component is given by the movement

of the soap itself during the cut and of a special
spring during return of the blade to zero position.
Use of special hydraulic decelerators will guarant ee Vertical cutting movement is ob-
a loud less machine, long life and trouble free per- tained by means of a pneumatic
formance. actuator. Horizontal movement is
driven by the soap itself.
Belt conveyor is driven by a 0,25 kW gear-
motoreducer (Rossi type). The speed of this unit is
piloted by an inverter.
The belt conveyor and worktop are a
The machine can be fitted with engraving rolls for single unit. The belt can be easily
the production of soap bar that is engraved on 2 or removed from the frame.
4 faces. Engraving system is perfectly centred to the
soap bar and the soap produced will be very similar
to the stamped product.

The cover of the MBC-P cutter is also

the support of the auxiliary groups,
such as encoder, inlet and outlet
rolls, pusher roll and guides.

All regulations regarding soap bars

can be done from outside the ma-
chine while it’s working.

MBC-P cutters are designed to oper-

SPECIFICATIONS
CUTTER ate with engraving roll ers. In this
MBC-P
case, but, there will not be electroni-
CUTTING HEIGTH mm 110 cally synchronization so logo could
CUTTING WIDTH mm 100 not be perfectly centred on soap
MINIMUM CUTTING LENGTH mm 40
bar.
CUTTING FREQUENCY cut/minute 120
MAXIMUM EXTRUSION SPEED m/minunte 15

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 59

MULTI FLASH STAMPER

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MULTI FLASH STAMPER

Multi Flash Stamper is the very latest generation of Multi Flash Stamper is equipped
soap stampers. with a Touch screen interfac e that
allows all operational parameters
This series of machines has been developed with the control in an easy and intuitive
intention to bring together all the positive experi- mode.
ences and ideas availabl e and bundle them up in an
innovative yet reliable pack age.

Machine is built on a sturdy welded, carbon steel Reliable non proprietary el ectronic
frame that provides structural rigidity and guaran- allows for total control of the ma-
tees the alignment of subsystems. chine.

Complete transmission of the machine is situated on

the side of the frame, allowing total acc ess in case
of maintenance.
Power is transmitted “in speed”
Product zone, where all movements convey, is de- through pulleys and timing belts.
limited on one side by a transparent hinged door Speed reducers are mounted on
and on the other by the steel plates of the frame. input shafts of cam boxes.

Machine can be mounted in left or right configura-

tion.
Infeed motion produced by enclosed
Flashing from dies falls on the flat belt and is taken
cam group. Suction pad supports are
out of the machine through the back wall to recycl e
spring loaded to improve soap billet
belts. This feature greatly improves the lay out of
pick up.
the whole line allowing the undisturbed access to
machines.
MULTI FLASH STAMPER
DIE CAVITIES MAX CONVEYORS
NUMBER SOAP MAX OPERATING 60° die rotation given by dedicated
TYPE SPEED
OF LENGTH INFEED DISCHARGE cam group. Rotary mandrel fixed on
CAVITY mm stroke/min
2 161 75 cam shaft by a clamping element for
3 105 75 SINGLE extra rigidity .
MFS-3 SINGLE LINE
4 77 75 LINE
5 60 75
3 137 70
4 101 70 SINGLE
LINE
MFS-4 5 79 70 SINGLE LINE OR Discharge motion produced by an-
6 65 70 DOUBLE LINE
7 54 70
other group of cams, enclosed in the
4 156 65 same box with in feed movement.
5 123 65 SINGLE Suction pad spring loaded for gentle
LINE
MFS-6 6 102 65 SINGLE LINE
OR stamped tablet transfer.
7 86 65 DOUBLE LINE
8 75 65
6 138 60
7 117 60
MFS-8 8 102 60 DOUBLE LINEDOUBLE LINE
Flashing from dies falls on the flat
9 90 60 belt and is taken out of the machine
10 80 60 through the back wall. Machine can
8 156 60 be equipped with “Flashing cutting
10 123 60
device”
MFS-12 12 102 60 DOUBLE LINEDOUBLE LINE
14 86 60
16 75 60

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HEXA STAMPER

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HEXA STAMPER

HEXA stamper is designed to stamp soaps in all rec- Hexa Stamper is equipped with a
tangular and cubic forms on 2, 4 or 6 faces. Touch screen interface easy and
intuitive that allows for control of all
It has a touch screen that allows, thorough an intui- operational parameters.
tive control, all th e operational parameters and
work phases of the machine in function of required
stamping speed, presence or lack of soap and re-
quirements of up stream (plodders, cutters, flow
Reliable non proprietary electronics
regulating conveyors, etc..) and down stream
allows for total control of the ma-
(wrappers, cartoners, flow wrappers, etc..) installed
chine.
machines.
All moving parts ( except conveyors) are piloted by a
single asynchronous motor that drives the dies
through articulated mechanisms and cams opti-
mized for velocity and acceleration.
Charging phase of soaps is produced
Die box is composed of 2 fixed parts and 6 moving by means of a cam movement and a
dies: one upper die, one bottom die and four later al pneumatic actuator controlled by
dies. the software.
A good shaped soap is the sum of a correct
sequence of actions of the dies. During stamping the
four lateral dies are moving at first, and then the
upper die deforms the soap that fills free cavities Stamped soaps are discharged by
and creates the right shape. pneumatic grippers. Regulation of all
parts is easy and fast.
After this lateral dies rel ease the soap and the
bottom die extracts it. There are not wastes so
there’s not a deflashing plate nor recycling system.
HEXA stamper permits the utilization of existing die
box sets because command parts can be easily regu- The extractor has a graduat e scale to
lated. help the regulation for a proper
stroke during setting procedures.
Lateral dies can be also changed to
use existing die box set.

HEXA STAMPER All auxiliary circuits (vacuum, com-

MAX pressed air, cooling, lubrification)
SOAP BAR
OPERATING
WEIGHT
PRODUCTION are pre-piped on board machine.
SPEED KG/H
gr
STROKES/min
75 < 250 1125
65 260-900 950-3500

HEXA uses a new generation of die

box designed to reduce all deforma-
INSTALLED POWER tions during stamping and to im-
MAIN INFEED DISCHARGE prove their life cycle.
MOTOR CONVEYOR CONVEYOR
kW kW kW
3 0,25 0,25

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CONVEYORS

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CONVEYORS

Finishing lines require different kinds of Flow regulating conveyor RC is positioned

conveyor belts: to transport pellets from between the cutter and the stamper is built
one machine to another, to regulate the in different sizes depending on the size of
stamper in feed, to recycle soap from the the line.
cutter or deflashing from the stamper and to
transport it to the hopper of the Duplex This belt is fitted with photocells that send
Vacuum Plodder. Soaptec proposes 3 types signals to the stamper which will regulate
of conveyors: Elevator Conveyors (EC), Flow soap flow with an appropriate developed
Regulating Conveyors (RC) and Recycling software.
conveyors (RB).
Frame and guides of the belt are built in
Soaptec’s elevator conveyors series EC are stainless steel AISI 304.
used for transporting pellets and tak e it to
the high-situated hopper of the following Belt is driven by a gearbox “Rossi” controlled
machine. by inverter usually installed inside the el ec-
trical control panel of the stamper.
EC elev ator conveyors are produced in dif-
ferent sizes for different productions and FLOW REGULATOR CONVEYOR
different layout configuration. POWER INST.
TYPE Width x Length mm
kW
Frame and the support of the conveyor are RC-2000 110x2000 0,37
built in painted carbon steel. RC-2500 110x2500 0,37
RC-3000 110x3000 0,37
Belt is built in PVC with vulcanized cleats. RC-4000 110x4000 0,37
Lateral guides are made in stainless steel
AISI 304 same as containment box hanged Normally, a Complet e Finishing line includes
and locked on the frame. In f eed hopper and 3 Recycle Conveyors (RB); those are very
discharge guard are made in AISI 304 as similar to elev ator conveyors.
well.
First conveyor is a flat belt and receives
The drive roll is driv en by a worm screw flashings from the stamper to transport
gearbox “Rossi” designed according to UNI, them to the second recycle conveyor.
DIN, AFNOR, AGMA and ISO standards.
This conveyor is produced in cleated type
apt to transfer the soap into the hopper of
the duplex vacuum plodder. It also receives
ELEVA TOR CONVEYOR
soap recycled by the cutter carried by the
PRODUCTION POWER
TYPE
KG/H kW third transversally positioned recycle belt.
EC-200 UP TO 1000 0,37 All these conveyors can be fitted with trans-
EC-300 >1000-2000 0,55 parent lexan covers.
EC-400 >2000-4000 0,75
EC-500 >5000 0,75 RECYCLE CONVEYORS
POWER
TYPE DESCRIPTION
kW
On request the belts can be supplied with RB-300 HORIZONTAL 0,55
transparent lexan covers in order to avoid RB-300 ELEVATOR 0,55
cross contamination. RB-400 ELEVATOR 0,75
RB-200 CROSS 0,37

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 65

“Artisan”
SOAP FINISHING LINE

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“Artisan”
SOAP FINISHING LINE
Recognizing the genuine need for a fully automatic “Artisan” line comprises of these
production line but in a small scale than the indus- machines:
trial type capabilit y, Soaptec d esigned and produced
a new series of machines under the common de- AM-100T: Open sigma mixer that is
nomination “Artisan”. discharged via tilting device, manual
or motorized. AM-100T
Main characteristics for this line are:
• Ease of operation and quick maintenance. AM-100B (instead of AM-100T):
• Capability to produce whatever shape and size Open sigma mix er that has a pneu-
tablet. matically operated bottom discharge
• Modular design to allow for different line compo- unit.
sitions.
• Till 500 kg/h of production. M-200 : Three roll mil l.
AM-100B
• Low budget.
SRs-200: Single worm simplex re-
Ease of operation and quick maintenance finer

When designing “Artisan” line, Soaptec used the DVs-200 “Artisan”: Single worm
same philosophy and same kind of attention as duplex vacuum plodder
when building industrial units. This means great care
for the ergonomics, for easy production changes MBC-P : Pneumatic single blade M-200

and reduced maint enance requirements. The use of cutter

high quality industrial components such as electron-
ics, pneumatics, circuitry, etc. allows us to build MFS-HY: Vertical hydraulic stamper
reliable machines. with “multi flash” system.

Capability to produce whatever shape and size In addition, all necessary b elt con-
tablet veyors, el evating conveyors and
recycle belts as well as die chiller SRs-200

The machines are built for small production but they and water chiller for cooling plodder
are not dedicated only to small soap sizes. DVs-200 jackets and the roll mill rolls.
is a plodder that uses a screw diameter of 200mm.
This allows for extrusion of large section bars neces- Till 500 kg/h of production
sary for 200gr of toilet soap and also for 300gr of
laundry soap. This production capability seems to
be the best suited for two cat egories DVs-200

Same philosophy is applied to the other units. MFS- of producers: 1) newcomers starting
HY is a vertical stamper that uses same stamping set a new production in a very competi-
as MFS-3 stamper that is typically installed in a tive environment; 2) soap factories
200pz/min line. MFS-HY stamper is instead running that do not need bigger installation
at a fixed speed of 25rpm and it produces every but require a dedicated and particu-
type of soap like hotel, toilet or laundry. larly production.

MBC-P
Modular design to allow for different line composi- Low budget
tions.
Artisan machines are designed
Soaptec designed different line compositions so the through modern computing soft-
client can found whatever he needs for his refining ware so Soaptec c an produce a
purpose and automation of the soap production. whole finishing line with accessible
budget and very short delivering
time. MFS-HY

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 67

“Artisan”
MIXER AM-100B

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“Artisan”
MIXER AM-100B
AM-100B “Artisan” is a mixer with two open sigma Electrical control panel is integrated
blades for soap pellets, solid additives and liquids with the rest of the machine and it
like colours and perfume. has all necessary circuits for a total
control of mixing process, like a
All the ingredi ents are poured from above into the timer to program the working cycle.
tank of the mixer and they can be added also while
the machine is running.
The two blades are driven by a worm
AM-100B blades, their mov ements and th e tank are gear-motor that follows UNI, DIN,
designed to create an intensive mixing of soap in AFNOR, AGMA and ISO standards.
order to break the pellets into dust and to speed up
and increase the absorption of additives.

The volume of the tank is 400lt and it allows a 100

kg charge of soap pellets per batch.
Blades have an open sigma shape.
Two open sigma blades are driven by a worm gear- They are made of AISI 304 stainless
motor and its power is 7,5kW. steel and they are machined and
then polished.
The discharge of the mixed soap is done through the
bottom of the tank where there is a lock-gat e con-
trolled by a pneumatic actuator. When the gat e is
open, the soap falls into the in-feed hopper of the
machine installed beneath th e mixer (usually a Re- Tank is also made of AISI 304
finer, a Three Roll Mill or a Plodder). stainless steel, machined and totally
polished inside.

Discharge of mixed soap is obtained

by means of a lock gat e at th e bot-
tom.

The upside cover of the mixer is

installed in order to not disturb the
charging and the discharging of the
soap and it has a safety switch.

The well designed shape of the

blades and the good gap between
them and the t ank are the main
conditions for an intensive breaking
of the pellets.

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“Artisan”
MIXER AM-100T

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“Artisan”
MIXER AM-100T
AM-100T “Artisan” is a mixer with two open sigma Electrical control panel is integrated
blades for soap pellets, solid additives and liquids with the rest of the machine and it
like colours and perfume. has all necessary circuits for a total
control of the mixing process.
All the ingredi ents are poured from above into the
tank of the mixer and they can be added also while
the machine is working.
The blades are driven by a worm
The blades, thei r movements and the tank are de- gear-motor and it satisfies UNI, DIN,
signed to create an intensive mixing of the soap in AFNOR, AGMA and ISO standards.
order to break the pellets into dust and to speed up
and increase the absorption of additives.

The volume of the t ank is 400lt and it allows for a

charge of 100kg of soap pellets.
Blades have an opened sigma shape.
The t wo open sigma blades are driv en by a worm They are made of AISI304 stainless
gear-motor and its power is 7,5kW. steel and they are machined by con-
trol machines and then polished.
The discharge of the mixed soap is done by tilting
the tank on the in-feed hopper of the downstream
machine, usually a roll mill, a plodder or an elev ating
conveyor. Also the tank is made of stainless
steel AISI304 and is machined by
Titling discharge mix ers are usually used when there control machine and totally polished
is a high volume of liquid additives inside soap for- inside it.
mula which would not fall form the AM-100B dis-
charge hopper.

Discharging of mixed soap is ob-

tained through a hand-wheel re-
ducer or an electric motor (optional)

The upside cover of the mixer is

installed in order to not disturb the
charging and the discharging of the
soap and it has a safety switch.

The well designed shape of the

blades and the good gap between
them and the t ank are the main
conditions for an intensive breaking
of the pellets.

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Vi a San Luc io 69 21050 Lonate Ceppino Varese Italy IT
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Phone: +39-0331-852312 Fax: +39-0331-677792 E-mail: [email protected] A
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 71

“Artisan”
SIMPLEX REFINER SRs-200

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“Artisan”
SIMPLEX REFINER SRs-200
SRs-200 “Artisan” is a Simplex Refiner Plodder with On board, electric al control panel
a 200 mm screw that has a length /diamet er ratio of containing frequency inverters and
3. other electric al components, is fitted
with push-button type operator
The screw is driven by a 7,5 kW gear-motor. interface .

Production speed is variable via on-board Frequency

Inverter.
The worm is driven by a ‘Rossi’ paral-
Extrusion group consists of drilled plate, rotary knife lel axis unit . This gear-motor is built
and the new Soaptec refining foil. according to UNI, DIN, AFNOR,
AGMA and ISO standards.
All parts in contact with the product are built in
stainless steel AISI 304.

Cylinder is provided with cooling

jacket and insulated. All parts in
contact with the soap are built AISI
304 Stainless Steel.

The worms are Aluminum alloy cast-

ing machined to tolerance and pol-
ished. The alloy of choice is G Alsi9.

SRs-200 “Artisan” is provided with

the new Soaptec refining foil built
and designed with innovative tech-
nology.

Extrusion group (drilled plate, rotary

knife & refining foil) as well safety
cover are side hinged.

Extrusion group is completed with a

drilled plate, holes diameter 8 mm,
counter-bored with diameter of 9,5
mm.

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 73

“Artisan”
THREE ROLL MILL M-200

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“Artisan”
THREE ROLL MILL M-200
M-200 “Artisan” is a roll-mill with 3 rolls and their The el ectric panel is installed on
useful length is 700mm. board and it has few buttons and
power-meter to easily control and
The roll-mill is used: command the machine production.
• to obtain homogeneous and uniform soap;
• to improve soap quality and to clear dry points
inside the soap that are difficult to mixer;
• to increase foaming-agent, solubility and solidity Only one motor with gears is used to
due to the crystal structure changing. drive the 3 rolls so the power re-
quired is optimized and each roll
Milling uses two counter-rotating rolls to create a takes the power that n eeds.
shear stress in the soap, and this type of stress can
be considered as a union of different processes:
melting, pressurization and homogenization.

In M-200 there are 2 milling systems using 3 rolls, The gap bet ween the rolls can be
where the central roll takes part to both the milling changed by mean of eccentric parts.
processes. Soaptec uses a gap of 0,2mm be-
tween the l ast roll and the central
Soap must adhere one single roll in each milling one.
process to obtain a correct shear work, so the rolls
have different and increased speeds from the in-
feed hopper to the discharge hopper.
The flaker knife is commanded by a
Gear transmissions are used to rotate the rolls at a pneumatic actuator. The pressure of
particular ratio and the motor used to driv e them is the blade can be changed by a hand-
11 kW. wheel even if the machine is work-
ing.
The speed of the motor can b e changed by an in-
verter installed inside the electric panel. Changing
the speed of the rolls changes the production capac-
ity of the machine. Cooling system is pressurized and
every roll has a proper hydraulic
The gap between the rolls can be easily set modify- joint.
ing the position of the external rolls from the central
one.

A flaker knife is used to detach the soap from the

fastest roll. This knife is controlled by a pneumatic The outside surface of the rolls is
actuator that moves the blade only in presence of subjected to a special treatment of
soap in the machine. hard chromium plating. This treat-
The pressure of the blade on the roll can be easily ment is used to prevent corrosion
changed by a manual hand-wheel outside the ma- due to the addition of components
chine. in the soap.

Main optional of the roll-mill are the

flaking rolls for the production of
soap flakes.

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Vi a San Luc io 69 21050 Lonate Ceppino Varese Italy IT
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Phone: +39-0331-852312 Fax: +39-0331-677792 E-mail: [email protected] A
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web site: www.s o apt ec .b iz
 75

“Artisan”
DUPLEX VACUUM PLODDER DVs-200

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“Artisan”
DUPLEX VACUUM PLODDER DVs-200
DVs-200 is a Duplex Vacuum Plodder with one Electrical Control Panel installed on
screw for each stage. Th e screws have 200mm di- board with a push-button interface
ameter and their length /diamet er ratio is 3. on the cover and two invert ers with
all the el ectric components inside it.
There are two gear-motors to drive the screws and
the power installed is 7,5kW on each.

Rotation speeds of the screws, in both refining and The rotation of the worm is driven
extrusion stage, can be independently modified by by a Rossi gearbox unit with parallel
proper inverters. axis which follows UNI, DIN, AFNOR,
AGMA and ISO standards.
The first one is a refining stage: it has a drill ed plat e
fitted with a knife group that is driven by the screw
itself and it has also new Soaptec’s refining foil.

Soap pellets creat ed in the refining stage are com- The cylinder has a cooling jacket
pacted and extruded into a continuous bar through perfectly isolated from the rest of
the die plate of the final stage. the machine.

A vacuum chamber is used as a connection between

two stages: soap present in both stages act as a
vacuum seal to allow the removal of entrapped air.
Worms are obtained through casting
A level switch in the vacuum chamber is used to and then they are machined by con-
regulate th e quantity of soap produced by the first trol machines and polished. They are
stage into the final one. made of aluminium alloy and silicon
steel G Alsi9.
The nose cone is heated to guarantee the smooth-
ness of the bar and facilitate extrusion. The tem-
perature is read by a thermal-sensor inside the cone
and it can be easily changed. The refiner group of the preliminary
stage of the plodder uses the innova-
All parts in contact with th e product are built in AISI tive refining foils designed by Soap-
304 Stainless Steel. tec using latest technology.

Vacuum chamber is mounted be-

tween the t wo stages and it has a
wide transparent window with
safety switch installed.

The extrusion cone of the final stage

is heated and it has an ogive, a die
plate and its support. All these items
are d esigned on purpose for reduc-
ing changing times.

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Phone: +39-0331-852312 Fax: +39-0331-677792 E-mail: [email protected] M
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 77

“Artisan”
STAMPER MFS-HY

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“Artisan”
STAMPER MFS-HY

MFS is the lat est gen eration of soap presses using Multi Flash Stamper is equipped
“flash stamping” concept, perfect for high produc- with a Touch screen type operator
tion rates. Size and shape (and therefore th e interface that an easy and intuitive
weight) of the tablets are defined by the volume of mode, allows for control of all opera-
the cavities when the di es are totall y closed: the tional paramet ers.
upper half-die is mounted under a slide with a de-
fined stroke and is driven by an hydraulic actuator;
the lower half-die is install ed onto the mandrel of
Good electronics that are specifically
the machine.
designed for this application are
During stamping exceeding soap is squeezed out of
used for a total control of the ma-
the dies in form of “flashing” (hence “flash stamp-
chine.
ing”) that is trimmed off by a passage through the
de flashing plate.
MFS stampers produce both bandless and banded
bars for toilet, laundry or hotel formats using only a
set of two half-dies that allows a remarkable eco- Hydraulic force is used in stamping
nomical saving for die-sets. processes pneumatic commands are
Sensors are continuously connected to the software used for the conveyors and all the
on board and this allows for a working cycle only most actual softwares are used to
when it’s necessary and there are soap bars on the control their interactions.
in-feed conveyor. Also its logic unit can control the
recycle mode of the previous cutter.
In-feed motion is created by a cam
Machine body is a rigid, heavy duty, welded carbon and an actuator. All suction cups
steel machined to guarant ee precise alignment of all supports are provided with springs
the elements composing the machine itself. to help the picking of the soap bars.
Hydraulic liquid tank is also created inside the ma-
chine and the fluid is used to creat e the stamping
force of the upper die and the rotation of the man-
drel. 60° mandrel rotation is giv en by an
hydraulic actuator. Hydraulic force is
All auxiliary circuits such as compressed air and used to stop the mandrel during
cooling are pre-mounted and ready to be connected stamping process.
to the local supply.

MULTI FLASH STAMP ER

DIES MAX CONVEYORS Discharge motion is produced by
MAX STROKE another cam and actuator. Suction
TYPE NUMBER SPEED
SOAP DISCHAR-
OF IN-FEED pad spring loaded for gentle
LENGTH GE
CAVITIES Stroke/min. stamped tablet transfer.
mm
2 161
3 105 SINGLE SINGLE
MFS-HY 20
4 77 LINE LINE
5 60
Flashing of the dies falls on the flat
belt and is taken out of the machine
INSTALLED POWER through the back wall. Machine can
HYDRAU-
MAIN IN-FEED DISCHARGE FLASHING
LIC be equipped with a “flashing cutting
TYPE MOTOR CONVEYOR CONVEYOR CONVEYOR
PUMP device”.
kW kW kW kW
Lt/min
MFS-HY 4 0,25 0,25 0,25 35

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 79

“Pilot”
SOAP FINISHING LINE

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“Pilot”
SOAP FINISHING LINE

This line has been designed on two differ- 3) Duplex Vacuum Plodder with two
ent versions: screws or a simplex refiner plodder with
one screw (for the laboratory line). They
PILOT line: used to produce samples of are equipped with drill ed plate and extru-
toilet soap until 80 gr.; sion cone so they can produce both soap
pellets and soap bars. The speed of these
LABORATO RY line: used to produce smaller machines is governed by a RPM knob and
soaps for testing scents, additives and the temp erature of the extrusion cone
analysis. can be regulated and monitored by act-
ing on push buttons. The maximum in-
All machines are separately driven and all stalled power is 1.5 kW.
the main paramet ers such as temperatures
and working pressures are monitored by a
set of instruments on a main display panel. 4) Manual blade cutter. The soap bar can
This set up allows the production of high be cut into billets of the required length
quality soap tablets. using the manual blade cutter. The de-
sired length can be set on a graduated
scale.
Both lines can be composed of the follow-
ing machines mounted on a work bench:
5) Semi-automatic hydraulic press SP-
1) Open-sigma blades mixer to process till 1000P can stamp any used size of soap. It
10 kg. of soap noodles per batch or an is equipped with a cooled die complete
amalgamator (for the laboratory line) to with a movable insert and 2 rows of num-
process till 5 kg. of soap. Upon finishing the bers for marking the samples. Ejector can
cycle the mix er is tilt ed by a hand wheel for be moved independently and the die
discharging. The maxi mum installed power change procedure is easy and fast. The
is 0.55 kW. installed power is 0.75 kW.

2) Water cooled Three Roll Mill with inlet 6) These lines can be also equipped with
and outlet temperatures control. Soap film instrumentation package for close con-
thickness can be adjusted and it’s removed trol and monitoring of important working
by a flaker knife. To increase homogeneity paramet ers.
of the soap, is also possible to pass it All the parts in touch with the product
through the roll mill more than once. The are mad e of AISI 304 stainless steel.
maximum installed power is 1.1 kW.

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Phone: +39-0331-852312 Fax: +39-0331-677792 E-mail: [email protected] M
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web site: www.s o apt ec .b iz
 81

“Pilot”
SIGMA MIXER DASM-10P

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“Pilot”
SIGMA MIXER DASM-10P
In the soap industry a correct definition and meas- Electrical Control Panel supplied by
urement criteri a for the mixing do not exist. power side and push button is sepa-
rated from the machine.
Solid additives mixing with the base soap pell ets in a
standard mixer is called macro-mix.

During macro-mixing, the additives only cover the

pellets surface.

When the pell ets are crushed it is possible to obtain The double-sigma mixing arms are
a micro mix, or an intensive mixing in order to pre- made in an AISI 316 stainless steel
sent larger surface to the additives and allo ws the casting, then polished and ma-
same to pass through inside the soap pellet. chined.

Ref: Spitz L., ed. Soaps and Detergents

A theoretical and pratical review,
AOCS press, Champaign, Illinoi, 1996, pp. 243.

DASM-10 is a mixer provided with t wo double sigma Product discharge is performed by

arms performed to small productions or dedicated means of the tank tilting, obtained
samples production. by rotating a hand wheel rotation
which acts on the small endless
The double housing tank, completely manufactured screw reducer.
in AISI 304 stainless steel, has a 30 lt. capacity and
on request, can be built with cooling jacket.

The arm rotating driv e is performed by ‘Rossi’ or-

thogonal axes gearbox with load capacity according
UNI, DIN, AFNOR, AGMA and ISO standards, and by
a couple of gears connected on the arms. The tank cover is provided with in-
spection sight glass and with two
Arms rotate counter clockwise between them at plugs to add the additives during the
fixed speed. mixing phase.

Rotating speed of the primary arm is about the dou-

ble of the secondary arm.

On request, the mixer motor can be driven by in-

verter to obtain vari ations on arms rotation speeds.

Drive motor has 0,75 kW power. Special cover design allows easy
soap feeding. Security switch stops
The double housing of the tank is machined in order the arms rotation when the door is
to guarantee a right tolerance with the mixing arms open.
which are special profiled. Close tolerance between
tank housing and the arms is most important thing
to achieve a correct pellets crushing.

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Phone: +39-0331-852312 Fax: +39-0331-677792 E-mail: [email protected] A
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web site: www.s o apt ec .b iz
 83

“Pilot”
ROLL MILL M-100P

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“Pilot”
ROLL MILL M-100P
“The refining is the work made on the soap thanks Electrical control panel with power
to a combination of actions of pressure and cutting button and control push buttons is
compression. separated from the machine.

The refining has a triple purpose:

• To produce homogeneous and uniform soap.
• To improve th e soap bar quality, removing the
dry spots. Rolls are manufactured in carbon
• To increase th e foaming power, the solubility steel, chromed and rectifi ed on the
and solidity obtained from the change the crys- surface. All parts in contact with
talline structure. soap are built in AISI 304 stainless
steel.
The refining is made by the plodder, by the roll mill
or by the combination of both machines.”

Ref: Spitz L., ed. Soaps and Detergents

A theoretical and pratical review,
Rolls are supplied jacketed with cool-
AOCS press, Champaign, IllinoiS, 1996, pp. 243.
ing coils. Inlet and outlet of the wa-
ter is done by rotating joints in ev ery
Specific function of the roll mill is refining the soap
single roll.
obtaining the above indicated benefits.

The M-100 three-roll mill is a machine dedicated to

small productions or sample productions.
The gap bet ween the rolls can be
regulated by means of hand wheels
Three rolls have a diameter of 100 mm and a l ength
and endless screws/wheels couples.
of 300 mm.

Rotation drive performed by a ‘Rossi’ orthogonal

axes gearbox with load capacity verified according
UNI, DIN, AFNOR, AGMA and ISO.
Scraping blade can be manually
locked or unlocked upon the outlet
On request drive motor can be controlled by an
roll by means of a hand wheel.
inverter to vary the r.p.m of the rolls.

The three rolls are installed on ecc entric flanges and

can be manually adjusted by means of hand wheels
and endless screws.
In feed hopper is built in AISI 304
stainless steel with fixed protection
grid.

Water circuit is pre-assembled and

completed with adjusting manual
valves. There’s an outlet wat er tem-
perature digital indicator for ev ery
single roll and one single inlet digital
indicator for all three of them.

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 85

“Pilot”
PLODDER DVs-100P

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“Pilot”
PLODDER DVs-100P
DVs-100P is a Duplex Vacuum Plodder with a single Electrical control panel with the
100 mm diameter screw dedicated to small and power side and th e push-buttons is
samples productions. separated from the machine. Drive
motor is driven by inverter to vary
Soaptec proposes the SRs-100P Simplex Refinerand the worm r.p.m.
DVs-100P Duplex Vacuum Plodder for refining
work.
The worm drive is performed by
Simplex Refiner can be fitted with both Drilled Plat e ‘Rossi’ orthogonal axes gearboxes.
(for pellets production) or Nose Cone extrusion Load capacity verified according
group (for soap continuous bar production). UNI, DIN, AFNOR, AGMA and ISO
standards.
Duplex Vacuum Plodder L oriented version is
equipped with extrusion group for pellets on pre-
liminary stage and extrusion group for continuous
bar on final stage.
Cylinder is provided with jacket and
Preliminary stage is, in fact, a refiner plodder with cooling insulation, completely manu-
drilled plate, pel lets knife and refining screen. factured in AISI 304 stainless steel.

Refined soap pellets are compacted and extruded in

a continuous bar in the final stage. The vacuum
chamber is the connection between the preliminary
and final stage. Worms completely machined in
aluminium alloy, on request in NI-
The conical head , heat ed with diathermic oil Resist or AISI 304 stainless steel.
through electrical heat er and thermostat at the
selected temperature, extrudes the bar.

The cylinder l ength/diameter ratio is 4. All parts in

contact with soap are manufactured in AISI 304
stainless steel. Vacuum chamber with pre-
assembled circuit complete with
vacuum pump. It is provided with
transparent inspection door for an
easy inspection.

Standard pre-assembled wat er cir-

cuit with solenoid valve and digital
inlet water t emperature indicator
from the cylinder.

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Vi a San Luc io 69 21050 Lonate Ceppino Varese Italy IN
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Phone: +39-0331-852312 Fax: +39-0331-677792 E-mail: [email protected] M
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 87

“Pilot”
SOAP PRESS SP-2000

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“Pilot”
SOAP PRESS SP-2000

Hydraulic press SP-2000 is a soap press dedicated to The upper die is activated by the
small or samples productions manufactured accord- operator by pushing simultaneously
ing to the prevailing safety standards. the two start push-buttons with
both hands.
Soap bar feeding and stamped soap discharge are
manually done by the operator. Printing is done by
means of an hydraulic cylinder controlled by an
hydraulic unit.
Hydraulic unit, which drives the cyl-
The use of hydraulics in th e press SP-2000 allows to inder for soap stamping and ejec-
obtain 2000 kg of force at 160 bar pressure, thus tion, is installed inside the base with
allowing to stamp up to two 100 gr soap at a time. a 0,75 kW power pump.

The operator, after positioning the soap bar on the

lower die, pushes simultaneously two start push- Hydraulic cylinder stroke for the
buttons that activate the movement of the upper stamping is 100 mm while stroke of
die. for the ejection is 10 mm.

Once the stamping is done, the upper di e goes up

automatically.

The ejector, which is hydraulically driv en, pushes The working base of the press and
out the soap from the lower die allowing the opera- the upper die-holder are in AISI 304,
tor to pick up the bar easily. supplied with a T c avity for fitting
the dies with different dimensions.
The SP-2000 press supplied with a supporting table.

Electrical control panel and hydraulic unit are in-

stalled inside the table itself.
Dies can be built with one or more
cavities. Upper and lower dies pro-
vided with groves for cooling chan-
nels.

The upper and lower dies are sup-

plied with interchangeable engraving
inserts. For soap samples produc-
tion, dies are equipped with inter-
changeable alphanumerical inserts

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MANUAL PLEAT WRAPPER

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MANUAL PLEAT WRAPPER

Pleat wrapping has been considerably growing in Main components of the machine are:
importance and popularity.
• Upper folder
It offers good protection from outside elements • Lower folder
and enhances the final look of the tablet by giving
a professional and elegant look to it. • Diaphragm closing
• Pusher and Ejector

Pleat wrapper is a manual wrapping device suit-

able for rounded and oval soap shapes. Upper and lower folders are manufactured
based on the soap shape to be wrapped.

With pleat wrapper is possible to wrap soaps with

maximum diamet er of 90 mm and maximum thick- The paper sheet with rounded shape is in-
ness of 35 mm. serted between the upper and the lower
folder.

Being a manually operated machine, its perform-

ance is related to the capability of the operator,
however, it is possible to wrap an average of 10
soaps per minute. Soap to be wrapped is placed inside the hole
of the upper folder and pushed by means of
the pusher through the two folders.
To obtain a good wrap it is necessary to select a
good paper or transparent film.

Pushed soap forces the passage of the paper

The paper must neither t ear nor deform and must through the folders thus forming wrinkles on
keep its original surface after th e wrapping. the paper.

The reduced dimensions of the machine allow an

easy positioning on every working plane.
When soap reaches the lowest position, the
diaphragm gets closed and the soap is
wrapped.

The diaphragm is opened as needed in order

to allow the positioning of the closing adhe-
sive with Customer’s logo.

After opening completely the diaphragm,

the ejector al lows to easily pick up the
wrapped soap.

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Vi a San Luc io 69 21050 Lonate Ceppino Varese Italy IT
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Phone: +39-0331-852312 Fax: +39-0331-677792 E-mail: [email protected] A
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web site: www.s o apt ec .b iz
 91

MARBLED SOAP SYSTEM

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MARBLED SOAP SYSTEM

There are different systems to produce marbled or Base soap coming from the duplex vacuum plodder is
stripped soap. Some versatile components are needed extruded inside the tube system while coloured soap
in order to obtain soap with different colours and draw- injection takes place through the co-extruder plodder
ings. The most used systems are: which feeds the tubes system.
Soap base and coloured soap come in contact inside the
• SOLID-LIQUID SYSTEM drilled plate placed after the tubes system causing the
• SOLID-SOLID SYSTEM stripped drawing on the soap.
• SOLID-SOLID-LIQUID SYSTEM Marbled drawing is obtained using a rotor driven by Du-
plex Vacuum Plodder screw or by its own drive group.

SOLID-LIQUID SYSTEM SOLID-SOLID SYSTEM is composed by:

It consists of one or two coloured liquid injection into the
base soap coming from the duplex vacuum plodder. • Co-extruder
• Tubes system holder connection
ROTOR DRIVE GROUP
DRILLED PLATE, NOZZLES
• Tubes system
COLORDOSING GROUP • Drilled plate
ROTOR
• Rotor drive group
• Rotor

SOLID-SOLID LIQUID SYSTEM

Consisting in the injection of coloured liquid and/or soap
into the soap base coming from Duplex Vacuum Plodder.

CO-EXTRUDER
Coloured liquid injection goes forward inside colour dos- ROTOR DRIVE GROUP
ing group, drilled plate and nozzles. CONNECTION
The color distribution and so the marbled drawing on th e TUBES SYSTEM

soap is obtained by the rotor which can be driven by the

duplex vacuum plodder screw or by its own drive group.

SOLID-LIQUID SYSTEM is composed by:

DRILLED PLATE
• Colour dosing group ROTOR
• Drilled plate with nozzles
• Rotor drive group COLORDOSING GROUP
• Rotor
SOLID-SOLID LIQUID System is the combination of solid-
SOLID-SOLID SYSTEM liquid and solid-solid systems. It is the most versatile de-
Consisting in the injection of coloured soap inside soap vice, since it allows the colour addition to the base soap
base coming from the Duplex Vacuum Plodder. with coloured liquids, coloured soap or both varying soap
drawing.
CO-EXTRUDER
ROTOR DRIVE GROUP SOLID-SOLID LIQUID SYSTEM is composed by:
CONNECTION

• Co– extruder
• Tubes system holder connection
• Tubes system
• Drilled plate
TUBES SYSTEM • Rotor drive group
DRILLED PLATE
ROTOR • Rotor
• Colour dosing group

s o a p t e c
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Vi a San Luc io 69 21050 Lonate Ceppino Varese Italy IT
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Phone: +39-0331-852312 Fax: +39-0331-677792 E-mail: [email protected] A
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web site: www.s o apt ec .b iz
 93

STRIPPED SOAP SYSTEM

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STRIPPED SOAP SYSTEM

By observing extrusion technologies used in electric A new former is needed in case a

cables industry Soaptec has created an extrusion new soap bar section design would
system for stripped soap production. be required.

This innovative and advanced technology permits to

extrude the soap by designing sections on the soap
bar.
T joint and former are int egral ly built
The system consist in two plodders, L positioned,
in AISI 304 stainless steel so are all
which extrude two different coloured soaps inside
parts in contact with the product.
the same nose cone.

Nose cone comprises a T connection and a former.

T connection is the most important outside element

of the nose cone because it permits the correct To facilitate soap flow T joint is pro-
coupling of the two plodders that will allow the two vided with a diathermic al oil heating
coloured soap transport towards the former. jacket, an electric resistance and a
thermostat.
Former is the principal element inside the extrusion
nose cone. Its function is to shape the design of
soap bar section.
Nose cone is supplied with die plate,
Former permits a so well defined distinction be-
die plate holder, electric resistance,
tween different colours that a small text can be
thermostat and all necessary fittings.
engraved on soap bars.

After some technical verifications

and information-sharing with client
is possible to apply the extrusion
nose cone in old plodders.

This technology can also be used for

producing two different perfume
soap.

By means of the former a piece of

soap with A perfume is carried to the
central part of the bar, and a B per-
fumed piece of soap is carried at the
same time to the outside part of the
bar. The result is a bar of soap with
two different kinds of perfume for
both internal and external parts.

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 95

s o a p t e c
Vi a San Luc io 69 21050 Lonate Ceppino Varese Italy
Phone: +39-0331-852312 Fax: +39-0331-677792 E-mail: [email protected]
web site: www.s o apt ec .b iz