Industry: Soap and Detergent
Material Handled: Soap Molds, Soaps
Product Category: Belt
Activity to be Mechanized/Automated::
- Liquid soap is poured into specially designed Molds that need to be cooled to the desired temperature for soap hardening.
- The Molds travel for a specific residence time at controlled temperatures to achieve the required hardness.
- Throughput requirement: 50 Molds per minute.
- The system includes temperature zones ranging from room temperature to 12-14°C with variable airflow speeds for optimal cooling.
This innovative conveyor system ensures effective cooling, precise handling, and efficient integration of processes to meet high production demands within limited factory space.
Challenges vs Solutions
| Challenges | Solutions |
|---|---|
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Space Constraints: The available factory space for the system was limited. |
Modular Design: Equipment was designed with a compact, modular layout, maximizing efficiency in limited space. |
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Insulation & Maintenance: Cooling conveyor insulation required ease of maintenance and bottom cleaning. |
Cooling Modular Belt Conveyor: 30% open perforated belts were used for effective air circulation and cooling. |
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Automation and Handling: High throughput and delicate Mold handling were necessary to avoid disrupting the hardening proces |
Mold Pusher Infeed Conveyor: Electro-pneumatic pushers and modular belts ensured precise handling of Molds. |
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Automation and Handling: High throughput and delicate Mold handling were necessary to avoid disrupting the hardening process. |
Corrosion-Resistant Build: Stainless steel materials were used for durability and resistance against chemicals. |
Results / Benefits:
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Cost Effective: Achieved the lowest cost of ownership with ROI in 1 year.
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ncreased Efficiency: Comprehensive design and modular layout improved system performance.
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Energy Saving: IE3+ motors with energy-efficient transmission systems reduced energy consumption.
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Low Capital Investment: Leveraged proven technologies for cost-effective solutions.
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24x7x365 Running Capacity: Maintenance-friendly design ensured minimal downtime.
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High Productivity: Reliable components increased system reliability and throughput.