SAS Mariani
SOAP AUTOMATIC STAMPERS - SINCE 1934
FLEXI PLODDERS
The FLEXI Plodders optimized translucent soap production by enabling high processing pressures, improving homogenization, refining capability, and providing precise temperature control.
The primary mission of the FLEXI project (formerly known as Transavon) was to optimize process control in translucent soap finishing by converting opaque soap noodles into translucent soap and producing translucent soap bars from translucent noodles.
After successfully applying translucent soap technology and extensively testing various products, Flexi Plodders proved effective for regular toilet soaps, synthetic formulations, and combination products. We focused on the following key characteristics:
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Enabling high soap processing pressures
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Allowing in-line soap pressure adjustment
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Enhancing refining capability
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Improving soap homogenization
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Providing powerful and precise temperature control
COMBO-SCREW DESIGN
The novel “combo-screw” design with two different diameters optimizes the two main functions of a plodder screw: the large-diameter infeed section ensures optimal soap intake, while, the small-diameter, long compressing section maximizes soap homogenization and compression.
LONG & NARROW BARREL FOR BEST HEAT EXCHANGE
Efficient dissipation of heat generated in the barrel is crucial for optimal soap processing. Heat exchange efficiency is determined by the ratio of the barrel's internal surface area to the enclosed soap volume. The calculated efficiency ratio for FLEXI is 70% to 80% higher than that of conventional soap plodders. Additionally, the soap temperature can be effectively reduced during the FLEXI stage.
SHEARING PLATE
The “ Shearing Plates” group consists of a fixed plate and an adjustable (movable) plate embedded inside the fixed plate. The combined position of the two plates determines the quantity of soap passage hence the level of the working pressure and the degree of refining.
The operator can choose the proper setting depending on the required soap quality and formulation. During production, the tool can be successfully used to adjust the process parameters such as soap temperature and, in the case of translucent soap, level of translucency.
FLEXI PLODDER REFINING PROCESS
This new concept was born by combining the special features of the SAS «combo-screw» worm and 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 doubles the refining process of 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».
