instrumentation and process control in soap making industry

INTRUMENTATION AND PROCESS CONTROL

IN SOAP MAKING INDUSTRY

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By:

Ihsan Ali WassanChemical Engineering Department

In the respect of SIR HIRA LAL SONI

QUAID-E-AWAM UNIVERSITY OF ENGINEERING, SCIENCE & TECHNOLOGY NAWABSHAH, SINDH PAKISTAN

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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

Presentation Outlines

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Process Control&

Instrumentation ?

5Process 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.

6Process 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.


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.


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

9Instrumentation?

The operator’s control function has been replaced by instruments and sensors that give very accurate measurements and indications, making the control function totally operator-independent.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

10Why 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

12Process 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

13SENSORS

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

14Soap

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.

15Soap

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.

16Soap

Examples of Soaps:

Sodium stearate (Chemical formula: C17H35COO-Na+) Sodium palmitate (Chemical formula: C15H31COO-Na+) Sodium oleate (Chemical formula: C17H33COO-Na+)

17Soap Production Flow Chart

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Oil Treatment

1. Carburetion Tank 2. Alkali reaction Tank 3. De-color Tank4. Mist Eliminator 5. Filter 6. Barometric Condenser 7. Water Pool 8. Storage Tank for Refined Oil

Saponification

9. Saponification cauldron10. Soap Base Storage Tank

Vacuum System

11. Ingredients Mixer Tank 12. Heat Exchanger13. Vacuum Spray Dryer 14. Fine Separator 15. Barometric Condenser 16. Eliminator 17. Stage Vacuum Pump 18. Pelletizer 19. Soap Noodle Tank

Soap Finishing Line

20. Mixing Agitator 21. Three Roll Grinding Mill22. Vacuum Plodder 23. Soap Cutting Machine 24. Soap Stamping Machine

Equipments Used In Soap Making

19Why 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.

20Automation 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

21a) 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.

22c) 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.

23b) Mixture:

The proportionate content of raw materials are mixed in soap mixer or agitator.

The raw materials are introduced into the mixer through hopper.

The mixer machine is driven by electric motor externally in which blades are fixed on the shaft.

As the shaft rotate, blades revolves.

Agitator Variables

Temperatures

Pressures

Shape of the ingredient

Density of ingredient

Agitator speed

Particle size

24d) 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.

25STAMPING 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.

26Stamping Machine

27Stamping Machine Basic Classification

28Soap 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.

29Soap Cutting Machine

30e) 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

31e) 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

32Horizontal Wrap Machine Standard Model

Model HFM-120Speed (Pcs/Min) Up to 120 *Pouch Size (LxW) in mm 200 x 150

Auto product infeed OptionalPower Required in KW 4.00Dimension (LxBxH) 3793 x 750 x 1529MMWeight (Approx.) 800 kgs.Online batch coding Optional* Depends upon product shape, packing material, etc.

33Soap 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.

34Conclusion

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