DESIGN AND DEVELOPMENT OF A SOAP STAMPING AND TABLETING MACHINE FOR SMALL SCALE SOAP MANUFACTURING

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DESIGN AND DEVELOPMENT OF A SOAP STAMPING AND

TABLETING MACHINE FOR SMALL SCALE SOAP MANUFACTURING

CHAPTER ONE

INTRODUCTION

BACKGROUND OF THE STUDY

Soap is a salt of a fatty acid used in textile spinning, lubricants production and mainly as surfactant in conjunction with water for washing, bathing and cleaning [1, 2, 3]. Thus, it is a vital product for good hygiene of man and his environment. Soaps for cleansing are usually obtained by treating vegetable or animal oils and fats such as palm oil, coconut oil, olive oil and laurel oil with strong alkaline solution [4, 5]. Wikepedia [6], attributed the cleaning action of soap/water mixture to the action of micelles, tiny spheres coated on the outside with polar hydrophilic (water loving) groups, encasing a lipophilic (fat loving) pocket that can surround the grease particles, causing them to disperse in water. In other words, whereas normally oil and water do not mix, the addition of soap allows oils to disperse in water and be rinsed away [6]. According to refs [7], [8], [9] and [10], soap production is a lucrative business which every business-minded person can invest on because the raw materials for the production are readily available in all part of Nigeria. Zillion [7], further said that the amount of soap consumed daily in Nigeria is staggering and the huge market presents a golden opportunity for investors and opportunity seekers who may decide to go into soap making. LEAP [11], also indicated that the simplicity of soap making process has led to its worldwide practice as a small business operation. Soap making falls into two distinct scales;small and industrial production [6]. The industrial production of soap involves a continuous process that requires constant addition of fat and removal of products. Smaller scale production involves the traditional batch processes with three major variations: the coldprocess, wherein the reaction takes place substantially at room temperature, the semi-boiled or hot-process, wherein the reaction takes place at near-boiling point, and the fully boiled process, wherein the reactants are boiled at least once and the glycerol recovered [2]. The cold and hot processes (semi-boiled bath process) are the simplest and typically used by small scale soap producers, artisans and hobbyists [6]. The sequential steps involved in use of these two processes for soap production by these categories of producers as described in [2], [6] and [7] are shown in Figure 1.

Soaps are produced in different shapes, sizes, colours and qualities/grades depending on their specific uses and manufacturer. However, soaps produced by different manufacturers may have identical shapes and sizes especially when the shape is not part of the manufacturers trade mark. Hence, it is always difficult to differentiate soaps of the same features produced by different manufacturers.

Abstract

A soap stamping and tableting machine comprising a printing die/pattern inscriptioner, cutting blade, conveyor belt, and two electric motors was developed and tested. Performance test analysis conducted showed that the machine operated with an optimal stamping/tableting capacity of 10205 soap tablets per hour with an efficiency of 98.8% when its conveying and stamping/tableting units were powered with 2HP and 4HP electric motors respectively. All materials used in the fabrication of this machine were sourced locally, and the estimated cost for producing one unit of the machine is ninety five thousand six hundred and fifty naira (N95,650). The machine reduced drudgery and tedium in small scale soap making and also enhanced mass production and profit.

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