A NEW APPROACH TO TOILET SOAP FINISHING
First mission of the FLEXI (before called Transavon) project was the efficient process control for translucent soap finishing:
- Conversion of opaque soap noodles into translucent soap.
- Production of translucent soap bars using translucent noodles.
After the success in translucent soap applications and extensive testing of various products, the Flexi Plodders proved to be applicable for regular toilet soaps, synthetic and “combo” products. We focused on the following characteristics:
- To allow high soap processing pressures
- To allow in-line soap pressure adjustment
- To increase refining capability
- To increase soap homogenization
- To allow powerful soap temperature control
- To allow fine soap temperature control
The novel “combo-screw” design with two different diameters optimizes the two main functions of a plodder screw:
The large diameter infeed section assures an optimal soap infeed.
Small diameter and long compressing section assures maximum soap homogenization and soap compression.
LONG & NARROW BARREL FOR BEST HEAT EXCHANGE
Dissipation of generated heat in the barrel is a critical issue.
Heat Exchange Efficiency = Barrel Internal Surface / Enclosed Soap Volume.
Calculated FLEXI efficiency ratio is 70% to 80% higher than a conventional soap plodder.
Soap temperature can be decreased in a FLEXI stage. Minimum soap thickness = minimum temperature gradient.
SHEARING PLATE (MILLING VALVE)
The name «FLEXI» recalls the fact that the first of the two drilled plates, the «Adjustable Shearing Plate» is a special combination of two plates: the inner plate is adjustable within the containing plate and this determines more or less soap passage thus more or less working pressures and refining. With a simple, in-line adjustment this special tool allows an «energy-saving»: each formulated soap need more or less refining and the Adjustable Shaering Plate allows the immediate fine-tuning of the amount of refining that is needed.
FLEXI PLODDER REFINING PROCESS
This new concept was born by a combination of the special features of the SAS «combo-screw» worm, and the idea of applying two soap refining sections in one stage.
The intimate refining of soap happens when the same passes through a fine screen, hence the presence of two fine screens per stage practically double the refining process to the formulated soap. The unique features of the «combo-screw» i.e. long L/D ratio (8:1) and the conical section allow the soap to reach extremely high working pressures (up to 100 bars in the last part of the barrel) therefore it is possible to combine two drilled plates with refining screens by simply applying an extension of the barrel, the «Recompacting Section».