INTRODUCTION

OVERVIEW
Fabric softener or also known as fabric conditioner is a chemical
compound that prevents static cling and confers many other desirable properties that
has been machine-washed. They are available as solutions and solids. Fabric
softeners work by coating the surfaced of washed fabric with a thin layer of chemical
compounds that are electrically conductive, thus preventing buildup of static charge
and improving their feel. Besides, other functions are improvements of iron glide
during ironing, increased stain resistance, and reduction of wrinkling and piling. They
also reduce the drying time for clothes, saving energy.

Our project is softener production plant which will produce softener as end
product by using heating and mixing process. Raw materials that use in this
production are water, vegetable oil, aloe vera, dye, fragrance and acusol. The PID
control is use as a control strategy, our project will make the softener production
easier as the machine is automated and can be monitor.

OBJECTIVE

The main objectives of this final year project are to apply and enhance
whatever we have acquired during our classes during the past semester. In this
project the plant is designed for mixing and heating process. Furthermore, the
invention relates to a new approach in making of the softener production plant in
semi automation to improve traditional method. It also can help us to gain new
knowledge and ideas on how to produces this project.

Besides that, the other objectives are to design, construct and implement
the system according to the needs of the project. We can also apply the theory and
practical knowledge that we gained in German-Malaysian Institute (GMI). When the
project is completed, we are able to gain further knowledge. While doing the project,
we can learn on how to overcome problem, troubleshoot, and to counter measure
problems. Each one of us has our own responsibilities to finish up the project
according to the plan and schedule. We can generate teamwork through the project.

2.PROJECT DESCRIPTION
Softener Production Plant
This process consist of several major element that need to be control in
order to produce the desired quality product.
Heating Process
Use continuos control to make sure the temperature reach the set point 60C which
is conducted in jacketed tank.
Mixing Process
Make sure all the raw materials which are aloe vera, vegetable oil, dye, fragrance,
and water mix well.
Table 1 : Project Specification
Project title

Softener Production Plant

Main process

Heating process and mixing process

Power supply

415 VAC

Type of process

Batch process

Control method

Automatic

Raw input

Vegetable oil
Aloe vera
Dye
Fragrance
Acusol
Water

Output

Softener

Production rate

10 litres per run

Dimension

1680mm x 1200mm x 60mm

Purpose and Importance of product

Project Main Features
The system consist of several major part that are core element in order to
produce good quality products. Below are the features of some parts and
instruments that are being applied in most process plant.
Elements in project features :
1. Instrumentation / Control Features
2. Mechanical Features
3. Eletrical Features

Main features :
1. Continuos heating process
2. Continuos mixing process

Few standard feature are to be set when executing this project. The concept is to
ensure that whole system shall be up to industrial standard and will able to be
utilized in a particular industry without any red tapes.

Pictures of product
Project Design
This is our plant design. The figures below show the front view, side view and real
view.

PROJECT DESIGN

FRONT VIEW

RIGHT VIEW

TOP VIEW

3. SWOT Analysis
a) Introduction to SWOT analysis
SWOT analysis provides a structure for analysing either your own strength and
weaknesses, and the oppoetunites and threats you face, or in a work context for
analysing the strengths, weakness, oppoetunities and threats a business or event
faces . Ideally it is one step in process which helps you to:
1. Appreciate the strength of a situation and you may then decides to build on
these:
2. Define the weaknesses, which you might choose tominimise:
3. Make the most of the opportunities that present themselves
4. Recognize the possible threats and them in a planned and organized way.
Strength
Special services and goods

Develop one product every year

Give the best product in market price
One of large service in Malaysia

Weakenness
High price

The price of the tank is very expensive

Target to the high class market

High operating cost

Use high quality supply

Lack of skill in using the machine

Opportunities

Easier for entrepreneur to open up markets outside the country

To make sure this product will be on market

Threats

Many softener product has been opened

Compete with others

There are bigger more proficient teams producing apps already.

Conclusion
This Final Year Project on Maintenance of Softnener Production Plant gave
students the opportunities to redesign, implement and reconstruct a process
based on the knowledge and skills acquired. We managed to construct and
automated softener plantand achieved our target which is to produce softener.
Furthermore, we able to program the project using Programmable Logic
Controller (PLC) and to control the heating temperature at 60 C during mixing
process in jacketed tank by using PID controller. Lastly, we able to provide
verified maintenance manual for the plant.