Training on Mixer

8/3/2019 Training on Mixer

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Contributed by:Abdullah Al Mahmud

Industrial & Production EngineerProduction Shift Officer

Soap Finishing DepartmentUnilever Bangladesh Limited

Training on Mixer


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PROCESS FLOW DIAGRAMTOILET SOAP FINISHING (LINE# 1, 2 ,3, 5, 6)

2.

DRYING

3.

NOODLE

STORAGE

5.

MILLING

4.

MIXING

6.

PLODDING

7.

BAR CUTTING

8.

STAMPING

10.

TAX STAMPING 11.

CARTONING

9. WRAPPING

COLORADDITIVES

PERFUME

1.

NEAT SOAP

STORAGE


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Why Mixer?

Mix chemical with the noodle

Mixer Z blade


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Mixer Type Distributive mixers

Ribbon Used when the primary aim is to simply coat

noodles with small amounts of minor ingredients

The blades generate minimal shear and socannot be used to break down the noodles in

anyway For this type of operation require only a minimal

residence time, allowing for a high throughput

Generally low cost and available from many localsuppliers

noodles leave the mixer and they tend to beslippy

if extended mixing occurs, the temperature willincrease which can have detrimental impact onperfume.


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Mixer Type Distributive mixers

Z Blade Can use for minor additives but greater care

required to minimise excess heat generation

Used when needing to add higher percentages ofliquids and solids

Will break noodles into smaller chunks

Will generate shear which can be exploited tomodify the phase structure of the soaps -translucent

Sufficient shear is available to enable reactions tooccur

Higher cost than ribbon blade type mixer butgreater flexibility although low cost supply optionsnow available


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Ingredients Perfume Acts very like free fatty acids ie quickly

softens soap, Brand Identity, Attracts customer Color Brand Identity, Beauty. TiO2 Opaque, helps to sustain the colour of the soap EDTA , ADPA Preservative, which protects soap from

disintegrating and increase its validity, make the soapfree from bacteria. Lauric Free stable fatty acid. react to form sodium

laurate, which is a foaming agent Frisis acts as a filler material which makes soap hard

and helps to increase its weight. Glycerine / Glycol Up to 1% will soft and above will

hard NaCl More NaCl Harder soap

Tinopal - used in White Lux to increase its brightness


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Mixer StepsMass of Soap noodles is measured in the

weighing scale through load cell andmanually discharged in the mixer byclosing the mixer outlet and openingweighing scale gate.

Then different ingredients, additives,preservatives, colour pigments, perfume is

discharged in the mixer manually by exactmeasurement.Then mixer is switched on and two Zshaped blades rotate in opposite direction.It helps to mix noodles with different

elements perfectly.

After mixing the discharge gate of themixer is switched open and soap isconveyed to Roll mill through beltconveyer.


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Other important machineries

Function of roll Mill: it provides highdegree of micro mixing and it is main routto remove grit

Function of Plodder is to complete mixing

and produce billets of homogenousconsistency

The purpose of vacuum chest is to remove

air which may otherwise trapped within thebillet which may lead to crack

The purpose of cone heater is to provide

smooth billet surface


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Roll Mill

The rpm of bottom roller is least and then middle and top,so that the top roller can transfer total amount of the soapof that carried by the middle roller though the gapbetween the top and middle roller is less than that of

bottom and middle one. This velocity gradient of the rollssurface facilitates the soap transfer from bottom to top roll.

The temperature gradient of the rolls from bottom to topfacilitates the transfer of soap from bottom to top.

The gap between middle and bottom roller is more thanthat of top and middle.


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How does particle size effect degree ofmilling & roll-mill output

A three roll mill is a machine tool that uses the shear forcecreated by three horizontally positioned rolls rotating atopposite directions and different speeds relative to eachother to mix, refine, disperse, or homogenize viscousmaterials fed into it. The particle size affects the

aforementioned operations directly. With the fineness ofthe particles the mixing, refining, dispersing andhomogenizing would be batter. The fine particle size willalso facilitate the increased output of the roll mill.


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Plodder

The plodder works like screw pump. There are two wormsinside the chest of the plodder. When the worms rotateson their axis in the direction to each other the materialflows towards forward direction through the gap in

between the two worms. In case of pre-plodder after theworms push the material through a cutter and producesnoodles and in final plodder the worms push the materialto the eye plate through a cone. The time when thematerial passes eye plate; it gets the shape of bar / roller

depending on the eye plate hole


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How does the worm carry soaps to theforward direction

The tow worms are set in such away that they create some gapsin between them.

When they rotate on their axis

to the direction of each other(like shown in figure above),then the gaps move towards theforward direction. If the rotational

direction reversed then thedirection of flow also reversedmeans backward direction.


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Factors that results in good soap

Soap temperature is 38-42 deg Celsius Excessive mixing time causes

temperature high and volatile perfume islost

Soap TFM is around 71% Soap bar should be accurate in weight Check the soap color shed Check the soap perfume effect PV should be around 30 Grit should be around 8


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Factors that results in good soap

Low temperature give more cracking More glycerin = lubricates soap and lessen

stickiness into dies Higher water = More liquid phase = softer

soap, more plastic soap = less crack Higher water = More liquid phase = more

viscous soap and it needs more force inplodder

Hard soap = more cracking More perfume = more cracking


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Other factors in mixer Preparation

Check chilling, vacuum at shift start Use proper PPE, i.e. hand gloves, mask,

goggles etc Use mixer logsheet to avoid any mistake Communicate with each other for better

soap batch preparation Weigh the perfume and ADPA at shift end


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Thank You

Training on Mixer

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