
Industry: Soap
Material Handled: Process Soap flakes, Soap Recycled materials, Scrap soap, Noodles, Flashings, Reject soaps
Product Category: Belt, Screw, Bucket Elevator
Activity to be Mechanized/Automated:
- To collect any scrap soap generated from the packing lines and return it to the plodder.
- To return the soap scrap from the Stamper, bar cutter, and cone discharge to run through the plodder again as recycled soap.
- To connect the flaker, roll mill, and plodder with inclined conveyors.
The Recycle Soap Conveying System is designed to efficiently handle and recycle soap scraps from various stages of production, ensuring minimal wastage and contamination. By incorporating specialized conveyors such as enclosed cleated belts, screw, and bucket conveyors, the system addresses challenges like steep inclinations, spillage, and power loss while optimizing recycling efficiency, energy savings, and overall productivity. This solution provides a cost-effective and low-maintenance approach for continuous, 24/7 operation in soap manufacturing.
Challenges vs Solutions
Challenges | Solutions |
---|---|
The inclination turns out to be steep, and materials can fall back. |
Enclosed Cleated Belt Conveyors: These belts are enclosed from all sides except where the materials need to be fed in. |
A lot of spillages are possible that need to be avoided. |
Goose Neck Inclined Belt Conveyors: The inclination allows for a horizontal portion at the end to facilitate effective transfer. |
The recycle percentage needs to be controlled, which increases the load on the plodder. |
Cleated Heavy Duty Spill-Proof Belt Conveyors: Tall cleated belt conveyors with sidewalls, goose necks, and spill-proof feeding areas improve efficiency. |
Loss of power in stamping and re-stamping is a cost factor. |
Screw Conveyors: The screw mechanism allows for mixing, homogenizing, and transferring recycle materials where contamination isn’t a concern. |
Prevention of contamination and ensuring operator safety are paramount. |
Bucket Conveyors: These carry soap recycles flashings and granular materials in a steep angle. Bucket Elevators: Ideal for transporting soap noodle materials in bulk. |
Results / Benefits:
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Cost Effective: Lowest cost of ownership with a minimum of 1-year ROI.
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Increased Efficiency: The special design of the belts reduces spillages and minimizes material transfer outside the conveyor’s extremities, increasing efficiency.
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Energy Saving: IE 3+ motor with energy-efficient transmission systems.
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Low Capital Investment: Utilizes proven technology and components, making it one of the lowest capital-intensive systems.
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24x7x365 Running Capacity: Maintenance-friendly systems ensure very low unplanned downtime.
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High Productivity: Basic technology ensures reliability and maximized capacity utilization for higher productivity.