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Manufacture of Multicolored and MulticomponentSoaps 0 363

Primary Base
Feed Hopper
Primary Base
Refining/Pelletizing
Stage

Secondary Base
Feed Hopper

Primary Base
Extrusion
Stage

Duplex
Vacuum
Plodder

Marbleized
Slugs

Secondary Base
Co Extruder
Plodder

Primary Base
Extrusion
Stage

Secondary
Base
Injection
Worm
Head
support

Tube
Bundle
Cylinder

Tube
Bundle

Extrusion
Head
Drilled
plate Rotor

p*%??,.

0 Gp
O%

Fig. 12.1 0. Solid-Solid Co-Extrusion System for Marbleized Soaps.

364

L spitz

Primary Base
Feed Hopper
Primaw Base
Refining/Pe//etizing
Stage

Secondary Base
Feed Hopper

Primary Base
Extrusion
Stage

Duplex
Vacuum
Plodder

Striped
Slugs

Secondary Base
Co-Extruder
Plodder
Primary Base
Extrusion
Stage

Secondary
Base
Injection
Head
Worm
support

Tube
Bundle
Cylinder

Tube
Bundle

Fig. 12.1 1, Solid-Solid Co-ExtrusionSystem for Striped Soaps.

Extrusion
Head

Manufacture of Multicolored and Multicomponent Soaps 0 365

Primary Base
Feed Hopper
Primary Base
Refining/Pelletizing
Stage
Secondary Base
Feed Hopper

Primary Base
Extrusion
Stage

Duplex
Vacuum
Plodder
Primary
Base
Extrusion
Stage

Rotor
Drive Group

Striped &
Marbleized
Slugs

Secondary Base
Simplex
Co-Extruder
Plodder

Worm
support
Secondary
Base
Injection
Head

Rotor
Drive
Connecting
Cylinder

Rotor
Drive
Group
Tube
Bundle

Tube

Fig. 12.12. Solid-Solid Co-Extrusion System with Rotor Drive Group for Striped and Marbleized Soaps.

366 0 L. spitz

Fig. 12.1 3. Solid-Solid Co-Extrusion Assembly for Striping.

Fig. 12.14. Solid-LiquidCo-ExtrusionSystem Assembly with Rotor Drive Group for Striping and Marbleizing.

Manufacture of Multicolored and Multicomponent Soaps 0 367

Primary Base
Feed Hopper
Primarv Base
Refining/Pelletizing
Stage

Secondary Base
Feed Hopper

Primary
Base
Extrusion
Stage

Duplex
Vacuum
Plodder
Rotor
Drive
Group
Primary Base
Extrusion
Stage

Rotor
Drive
Group

Worm
Support

Striped &
Marbleized
Slugs

Secondarv
Base
Co- Extruder
Plodder

Color
Injection
Pump
Group

Secondary
Base
Injection
Head

Tube
Bundle
Tube
Drilled Rotor
Bundle
Plate
Cylinder Sc
Extrusion
%,b
Head
Q/

%-%$I
OQ Gp

O%

Fig. 12.1 5. Solid-Solid-Liquid Combination MultipurposeSystem for Striped and Marbleized Soaps,

368 0 L. Spitz
Secondary Base
Feed Hopper

Primary Base
Feed Hopper

Tangential
Twin- Worm
Plodder

Two-Tone
Striped
Slug

Secondary Base
Single- Worm
Co-Extruder
Plodder

Primary Base
Extrusion Stage
Worm
support

Connection
Cone Group

plate Coupling
Soap
Pattern
Forming
Device

Extrusion
Head

Fig. 12.16. Solid-Solid Co-Extrusion Systen for Two-Tone Striped Soaps with a Tangential Twin-Worm
Plodder and a Single-Worm Co-Extruder.

Manufacture of Multicolored and Multicomponent Soaps 0 369

Solid-Solid Co-ExtrusionAssembly for Two-ToneStriped Soaps (Fig. 72.7 7.)

Fig. 12.1 7. Solid-Solid Co-extruder System Assembly for Two-Tone Striped Soaps.

Recycling Methods
To maintain the constancy of multicolored and multicomponent effects, an essential action is to control
the recycling of these key variables:
Flashing: the excess soap formed as the dies come together when the flashstamping system is used
for stamping bandless shaped bars;
Excess slugs: the result from extrusion, cutting, and stamping rate synchronization;
Rejected stamped bars: the result from the press and packaging unit speed synchronization operation
and the stamped bar inspection; and
Shavings: (in case) a thin surface removed from the surface of the extruded slugs to expose a better
defined inner pattern.

Recycling Method for Solid-Liquid Systems

The simplest method is to recycle everything into the first stage of the Duplex Vacuum Plodder. But in
this case, no control exists over the total amount recycled, and therefore no control is possible over the
final marbleized pattern of the extruded soaps (Fig. 12.18).

Recycling Methods for Solid-Solid Co-ExtrusionSystems

All items to be recycled are recolored and repelletized in an additional Simplex Pelletizing Plodder and
fed into the Secondary Base Co-extruder. Two Versions are illustrated in Fig. 12.19 and 12.20.

w
0

Group
Fig. 12.18. Recycle Method for Solid-LiquidSystems.

Soap P r e s s V

Primary Base
Feed Hopper
Secondary Base
Co-Extruder

RnmlnrnA
Dallatc
bI C..,c.CJ

..kCV.V,

Conveyor to
Co-Extruder

Blade;
and
Grinding
Group

Cutter

&w
+..

Soap Flow
Regulating

Dosing

cFlashing and
Ground Shavings
Recycle Conveyor

3
Q
0)

3
Q

e.

8
3

Soap Press

0
n
3

2
0

Fig. 12.19. Recycle Method for Solid-Solid Co-Extruding Systems -Version 1.

372 0 L. Spit2

Fig. 12.20. Recycle Method for Solid-Solid Co-Extrusion System -Version 2.

Manufacture of Multicolored and Multicomponent Soaps 0 373

Stamping Options
Standard and Angled Bar Soap Stamping Modes
Fig. 12.21 illustrates the difference between the straight (standard) and the special angled (bias) stamping
modes. Stamping with the dies positioned from 20 to 30 degree angle, enhances the appearance of
multicolored soaps.

Fig. 12.21. Standard and Angular Bar Soap Stamping Methods.

374 L. Spitz

Mottled Laundry Soap Manufacturing System

Mottled laundry bar soaps for laundering purposes are still widely used in many developing countries.
Fig.12.22. illustrates a complete Mazzoni LB plant for the continuous production of blue mottled
laundry soaps. ?he finished laundry bars are extruded from dryer's last stage plodder and are cut with a
cutter provided with engraving rolls (see Chapter 11).

Fig. 12.22. Mottled Laundry Soap Manufacturing System.

Manufacture of Multicolored and MulticomponentSoaps 0 375

Acknowledgment
The assistance of Mazzoni LB, SPA for the preparation of the manufacturing system diagrams is very
much appreciated.

Reference
Spitz, L. (Ed.) SODEOPEC;AOCS Press: Champaign, Illinois, 2004; pp. 212-237.

Patents
The following is a selected list of the most important and interesting patents relating to multicolored
and multicomponent soap formulation and processing.

Miscellaneous Patents
Bernard, A. Apparatus for Making Composite Product. Savonnerie Clair Bernard. U.S. Patent 3,779,676 (1973).
Homing, H. Soap Bar and Process for Its Manufacture. Blendax-Werke. U.S. Patent 4,311,604 (1982).
Kaniecki, T. Method and Apparatus for Producing Striped Soap Bar. Armour-Dial Inc. U.S. Patent 3,890,419 (1975).
Meye, RW.; G. nor. Process for the Continuous Manufacture of Marbleized Soap Bars. Henkel GmbH. U.S. Patent
3,663,671 (1972).
Patterson, C. Method for Soap Bars Having Marble-like Decoration. Purex Corp. U.S.Patent 3,676,538 (1972).
Tanaka, Y. Marbleized Soap Plodder. Ideal Soap Co. U.S. Patent 4,077,753 (1978).

Colgate-Palmolive Patents
Compa, RE. Process for Making Variegated Soap. US.Patent 3,485,905 (1967).
DArcangeli, A. Method and Equipment for the Manufacture of Variegated Detergent Bars. U.S. Patent 3,940,220
(1 976).
Fischer, C.R Soap Plodder Nozzle Plate. US.Patent 3,868,208 (1975).
Fischer, C.R. Apparatus for Making a Striated Soap Bar. U.S. Patent 3,891,365 (1975).
Fischer, E;D.P. Joshi. Continuous Process for Making Variegated Soap. US.Patent 4,141,947 (1979).
Joshi, D.P. Method for Producing Multicolored Variegated Soap. U.S. Patent 4,156,707 (1979).
Joshi, H.H. Process of Making Variegated Soap. US.Patent 4,017,573 (1979).
Marchesani, C. Apparatus tbr Making Soap with Orifice Plate and Trimmer Plate. U.S. Patent 4,738,609 (1988).
Perla, G. Apparatus for Making a Variegated Soap Base. U.S. Patent 3,923,438 (1 975).
Perla, G.; A. DArcangeli. Apparatus for Manufacturing Marbled and Striped Soaps. U.S. Patent 4,127,372 (1978).
Perla, G.; A. DArcangeli. Method for Making Soap Bars. U.S.Patent 4,201,743 (1989).
Pickin, 1.; H.H. Joshi. Marbled Detergent Bar. US.Patent 4,011,170 (1977).
Ran, R.M. Variegated Soap Apparatus. U.S. Patent 3,857,662 (1974).
Sanabria, J.A. Plodder Outlet Assembly. U.S. Patent 4,459,094 (1984).

Lever Patents
Alderson, D.A.; R.C. Scott. Manufacture of Multicolored Detergent Bars. U.S. Patent 4,304,745 (1981).
Aronson, M.P. and six others. Process for Making Extruded Multiphase Bars Exhibiting Artisan Crafted Appearance.
US.Patent 6,723,690 (2004).
Coyle, L.A. and five others. Personal Washing Bar Having Adjacent Emollient Rich and Emollient Poor Phases. U.S.
Patent 6,383,999 (2002).

376 L. spitz
Kelley, W.A.; RJ. Petix. Method for Making Variegated Soap. U.S. Patent 3,398,219 (1968).
Marchesani, C. Apparatus for Striated Soap Bars of comparable Aesthetic Quality on Both Inner and Outer Log Faces
for Soap Bars Produced in a Dual Extrusion Process. U.S. Patent 5,246,361 (1993).
Matthei, R.G. Method for the Manufacture of Marbleized Soap Bars. U.S. Patent 3,673,294 (1972).
Schonig, E.; H. Briickel. Manufacture of Detergent Bars. U.S. Patent 4,720,365 (1988).

Procter & Gamble Patents

Borcher, T.A.; J.R. Knochell. Apparatus for Making Variegated Soap Bars or Cakes. U.S. Patent 4,077,754 (1978).
Lewis, W.I? Apparatus and Process for Manufacture of Variegated Soap Bars. U.S. Patent 4,092.388 (1982).
Murray, G.D. Process for Manufacturing Color-Striped Stamped Detergent Bars. U.S. Patent 3,899.566 (1 975).