INTRUMENTATION AND PROCESS 1

CONTROL
IN
SOAP MAKING INDUSTRY
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QUAID-E-AWAM UNIVERSITY OF ENGINEERING, SCIENCE &
TECHNOLOGY NAWABSHAH, SINDH PAKISTAN

In the respect of
SIR HIRA LAL SONI

By:

Ihsan Ali Wassan

Chemical Engineering Department

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Presentation Outlines

 Process Control & Instrumentation?

 Why do we need Process Control?

 Process Variables and sensors ?

 Soap?

 Soap Production Flow Chart

 Equipments used in Soap Making Industry

 Why Automation is needed in Soap Manufacturing Industries?

 Automation In Soap Manufacturing

 Conclusion
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Process Control
&
Instrumentation ?
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Process Control?

 The technology of controlling a series of events to transform a material into a desired end product
is called process control.

 Industrial process control was originally performed manually by operators. Their sensors were their
sense of sight, feel, and sound, making the process totally operator-dependent.

 Instrumentation and control slowly evolved over the years, as industry found a need for better,
more accurate, and more consistent measurements for tighter process control.
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Process Control? (cont.…)

 The first real push to develop new instruments and control systems came with the Industrial Revolution,
and World Wars I and II.

 Industrial process control is now highly refined with computerized controls, automation, and accurate
semiconductor sensors.
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Process Control? (cont.…)

Process control can take two forms:

Sequential Control,
which is an event-based process in which one event follows another until a process sequence is
complete.

Continuous Control,
which requires continuous monitoring and adjustment of the process variables.
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Process Control? (cont.…)

 These variables can vary from temperature, flow, level, and pressure, to time and distance, all of
which can be interdependent variables in a single process requiring complex microprocessor
systems for total control.

 Due to the rapid advances in technology, instruments in use today may be obsolete tomorrow.

 These changes are being driven by the need for higher accuracy, quality, precision, and
performance
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Instrumentation?

 The operator’s control function has been replaced by instruments and sensors that give very
accurate measurements and indications, making the control function totally operator-independent.

 The processes can be fully automated. Instrumentation and sensors are an integral part of process
control.

 The subtle difference between an instrument and a sensor is that an instrument is a device that
measures and displays the magnitude of a physical variable, whereas

 a sensor is a device that measures the amplitude of a physical variable, but does not give a direct
indication of the value.
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Why do we need Control Process?

 Effective process control is required to maintain safe operations, quality products and business
viability.

 Safety

 Quality

 Profit
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Process Variables and

Sensors
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Process Variables

A process variable is a condition of the process fluid (a liquid or gas) that can change the
manufacturing process in some way. Common process variables include:
 Pressure
 Flow
 Level
 Temperature
 Density
 PH (acidity or alkalinity)
 Liquid interface
 Mass
 Conductivity
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SENSORS

Sensors are the some kind of instruments used to measure changes in the process and
reporting a process variable measurement. Primary Examples:
 Pressure sensing diaphragms, strain gauges, capacitance cells
 Resistance temperature detectors (RTDs)
 Thermocouples
 Orifice plates

 Pitot tubes & Venturi tubes

 Magnetic flow tubes
 Radar emitters and receivers

 Ultrasonic emitters and receivers

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Soap

Background

 Manufacture of soap began in England around the end of the 12th century.

 Early soap manufacturers simply boiled a solution of wood ash and animal fat. A foam substance
formed at the top of the pot. When cooled, it hardened into soap.
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Soap

Introduction ?
 Soap is a combination of animal fat or plant oil and caustic soda. When dissolved in water, it breaks
dirt away from surfaces.

 Through the ages soap has been used to cleanse, to cure skin sores, to dye hair, and as a salve or
skin ointment.

 But today we generally use soap as a cleanser or perfume.

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Soap

Examples of Soaps:

 Sodium stearate (Chemical formula: C17H35COO-Na+)

 Sodium palmitate (Chemical formula: C15H31COO-Na+)
 Sodium oleate (Chemical formula: C17H33COO-Na+)
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Soap Production Flow Chart
 Equipments Used In Soap 18
Making
Oil Vacuum Soap Finishing
Treatment Saponification System Line

1. Carburetion Tank
9. Saponification cauldron 11. Ingredients Mixer Tank
20. Mixing Agitator
2. Alkali reaction Tank
10. Soap Base Storage Tank 12. Heat Exchanger
21. Three Roll Grinding Mill
3. De-color Tank
13. Vacuum Spray Dryer
22. Vacuum Plodder
4. Mist Eliminator
14. Fine Separator
23. Soap Cutting Machine
5. Filter
15. Barometric Condenser
24. Soap Stamping Machine
6. Barometric Condenser
16. Eliminator
7. Water Pool
17. Stage Vacuum Pump
8. Storage Tank for Refined Oil
18. Pelletizer
19. Soap Noodle Tank
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Why Automation is needed in Soap Making Industries?

 Earlier soap was made by cutting into pieces from whole soap block with the help of Knife. That
gave soap an irregular shape and size.

 As evolution started various machines were developed which could be used to cut every piece of
soap in proper shape and size.

 AUTOMATED SOAP MANUFACTURING MACHINE were needed.

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Automation In Soap Manufacturing

STANDARD COMPONENTS USED IN THE SOAP MAKING MACHINES

 VIRGO process automation valves

 METLOR/VISHAY load cell and control modules
 FESTO/SMC pneumatic components
 BONFIGLIOLI geared motors
 BANNER/P&F sensors
 Allen Bradley/OMRON PLCs, HMIs
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a) Raw Material:

 In soap manufacturing, the required raw material with proportionate content is mixed in soap
mixer in order to gain fine powder.

 The raw materials may be different as the soap having various properties like soap having the
high market value for their fragrance.

 Raw material should be cheap and good material strength.

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c) Pouring And Soaking:

 Then after proper mixing of raw material, this mixture is poured into the tray and allowed to
soak for required soaking time.

 Soaking is important for the removal of moisture.

 As the moisture content removes, there is negligible possibility of breakage of soap during the
time of pressing and stamping.
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b) Mixture:

Agitator Variables
 The proportionate content of raw materials are
mixed in soap mixer or agitator.
 Temperatures

 The raw materials are introduced into the mixer  Pressures

through hopper.
 Shape of the
 The mixer machine is driven by electric motor ingredient
externally in which blades are fixed on the
shaft.  Density of ingredient

 Agitator speed
 As the shaft rotate, blades revolves.
 Particle size
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d) Pressing And Stamping:

 After soaking, these trays are allowed to treat with stamping machine.

 For pressing and stamping process plunger is used. In which, plunger strikes the soap on the
upper side of soap to emboss.

 The plunger provided with the dies supported by plate which is having vertical movement.

 The dies can be changed as per the requirement of the soap size and shape or as per the
customer’s specifications.
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STAMPING MACHINE

 The look of soap depends on the stamping and punching operation as it give shape and proper look
to the soap. So we have selected this operation of stamping and punching to be automated as it
maintains consistency and gloss look to the soap.

 Stamping machine is very important in order to increase the market value of the soap.

 Stamping machine consist of plunger, table and die in which plunger having vertical movement.

 The die is fixed on the plunger which is supported by plate.

 The die can be changed as per the requirement of size and shape of soap.
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Stamping Machine
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Stamping Machine Basic Classification
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Soap Cutting Machine

 The automatic soap cutting Machine is used to cut

soap bar from the plodder at equal lengths.

 The cutting system works based on the position of

the sensor.

 The bars are sensed automatically and pushed

forward for secondary bar cutting.

 All the pneumatic components are FESTO / SMC

make.
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Soap Cutting Machine
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e) Packing:

 Packing is one of the most important process in soap manufacturing as the high percentage of
people are attracted towards attractive look of soap.

 Many of the customers go through the external appearance.

 Therefore soap manufacturing industries mainly focused on the packing of soap

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e) Packing by Wrap Machines

 Horizontal flow wrap machines designed to wrap soap

bars.

 Basic machine with PIV drive enables easy adjustments of

product

 PID (Proportional, Integral, Derivative) controllers ensure

temperature accuracy for effective sealing performance

 Fully plc ( public limited company) controlled

 Speed upto 100 pcs/min

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Horizontal Wrap Machine Standard Model

Model HFM-120
Speed (Pcs/Min) Up to 120 *
Pouch Size (LxW) in mm 200 x 150
Auto product infeed Optional
Power Required in KW 4.00
Dimension (LxBxH) 3793 x 750 x 1529MM
Weight (Approx.) 800 kgs.
Online batch coding Optional
* Depends upon product shape, packing material,
etc.
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Soap Packaging Machine

 Features:
 Rejection automatically if no products.

 Stop automatically if incorrect position of products

into carton.

 Protecting automatically for overloading

 Automatically displaying device for speed and

finished products counting.
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Conclusion

 In the designing of the stamping and punching machine, we have focused on the economically
cheap, readily available and having good strength of materials in fabricating of machine in order to
make available in low cost for set up of cottage industry in rural areas.

 Soap is integral to our society today. For generation its use has increased and its manufacture has
become an industry essential to the comfort and health of civilized human beings. Therefore we
can say that Soaps and detergents occupy a vital place in modern chemical science.
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Thank
You