6 Semi-Boiled and Integrated

Saponification and Drying Systems

Luis Spitz
L. Spitz, Inc., Highland Park, Illinois, USA

Introduction
There are two major soap processing systems based on not-extracted and extracted
glycerine:
■ Not-extracted glycerine processes: Soap With Included Glycerine (SWING)
■ Integrated saponification and drying

■ Semi-boiled

■ Extracted glycerine processes: Soap After Glycerine Extraction (SAGE)

■ Continuous saponification

■ Full boiled

Semi-boiled saponification is the oldest SWING type process, and it is still widely used
for laundry soap and economy-grade multipurpose soaps. In this process, the glycerine
contained in the fats and oils produced by the saponification reaction remains in the base
soap (Figure 6.1).
As glycerine prices dropped over the last decade, it became unprofitable for soap pro-
ducers to recover glycerine. As a result, the soap industry has been adopting the SWING
technology for toilet and laundry soap production worldwide.
This chapter will cover the not-extracted glycerine SWING processes.

Saponification Reaction
for Soap With INside Glycerine
(SWING)

Fats/Oils + Caustic Soda

Soap + Glycerine
(SWING Soap)

Figure 6.1 Saponification reaction.

117
118 ■ Chapter 6

Traditional and Current Technology

Traditional Technology: Two Independent Plants

Saponification plant Drying plant

Base soap Dry soap pellets

28–32% water 10–15% water

Current Technology: One Integrated Plant

Integrated saponification
and drying plant

Dry soap pellets

10–15% water

Figure 6.2 Traditional and integrated soap processing systems.

Traditional and Current Technology Yield Comparison

1000 Kg of Fats and Oils

Traditional process Semi-boiled process

Yield: 1,200 Kg Yield: 1,350 Kg

dry soap pellets dry soap pellets

Composition

70–72% TFM 78–80% TFM

13–15% Water 13–15% Water
0.5–0% Glycerine 7–8% Glycerine
0.04–0.06% NaOH 0.04–0.06 % NaOH
0.6–0.6% NaCl 0.6–0.6% NaCl

Figure 6.3 Traditional and current process yield comparison.

 Semi-Boiled and Integrated Saponification and Drying Systems ■ 119

Total Fatty Matter (TFM) and Water Content

Total fatty matter (TFM) and water content analysis are very important for quality control
purposes. TFM analysis requires laboratory equipment and skill. Water content (mois-
ture) is determined with a simple moisture analyzer used in the laboratory and alternately
can be easily used on the manufacturing floor by an operator. Water content determina-
tion is the preferred method used by most producers.
Table 6.1 summarizes the data for base soap (neat soap) and dry toilet soap pellets
with glycerine and without glycerine. (For more information on TFM, refer to Chapters
7 and 12.)
Saponification plants produce 28–32% water content liquid base soap (also called
neat soap). Vacuum spray drying plants convert the liquid-base soap into dry soap pellets
containing 10–15% water. These two plants can operate separately from each other or
combine into a single integrated system for the production of SWING soap.

Table 6.1 TFM and Water Content

Base Soap Dry Soap Pellets
% TFM % TFM % TFM % TFM
% Water (SWING) (DFA) % Water (SWING) (DFA)
Standard 28–32 58–54 66–62 19–23 66–63 74–71
Semi-concentrated 22–28 64–58 72–66 13–19 72–66 80–74
Concentrated 18–22 67–64 75–72 9–13 75–72 83–80
Notes:
TFM (SWING): Value obtained by saponifying fats and oils, generating 8% glycerine.
TFM (DFA): Value based on neutralization of distilled fatty acid mixtures without generating
glycerine.
The data assumes that the dry toilet soap pellets contain: 8% glycerine, 0.04% NaOH
and 0.4% NaCl.

Integrated Saponification and Drying Processing Plants

for SWING Soap Production
Binacchi & Co., Mazzoni LB, SpA, SAS, and Soaptec Srl are the most widely used
SWING soap processing plants. The different reactor designs by each manufacturer and
the detailed processes will be described.
There are many advantages in installing and operating integrated plants:
■ Low capital cost compared to other systems
■ Reduced manufacturing cost
■ 7–8% of glycerine remains in the neat soap
■ No washing, no neat soap and spent lye separation
■ No glycerine treatment, evaporation, and refining plants
■ No need for neat soap holding tanks
■ Wide range of raw materials usage
120 ■ Chapter 6

■ No final alkalinity adjustment

■ Zero steam consumption
■ Savings in electric energy and cooling water
■ Compact layout
■ Simple and flexible operation
■ Fast and easy formula changeover
■ Lower operator skill level requirements
■ Simple quality control requirements
■ No byproducts, resulting in lower environmental impact
■ Reduced soap fines formation and cooling water entrainment

Binacchi MPSD Integrated Saponification and Drying Plant

The Binacchi MPSD integrated plant consists of two plants integrated into a single com-
bine (Figure 6.4). The saponification section is designed for the continuous saponification
and neutralization of fats and oils and fatty acids, or admixtures of both.
The plant is designed to saponify neutral fats-oils (tallow, palm oil, coconut oil, palm
kernel oil, palm stearin, etc.), and neutralize fatty acids alone or any fats and oils and fatty
acid mixture. The semi-concentrated soap base (neat soap) is dried into soap pellets in the
vacuum spray dryer.

Saponification Section
■ Filtered water, caustic soda, fats and oils, and fatty acids are fed from storage tank
dosing pumps.
■ Two different dosing lines of fats and oils and fatty acids allow for easy changes to the
soap composition.
■ Multihead additive pump doses brine, chelants, and other minor additives.
■ A water addition system is included to allow for the use of commercial 50% caustic
soda solution.
The dosing pumps are controlled by frequency inverters that receive signals from flow
meters, ensuring a very precise amount of dosed raw materials.
Before the reaction, the raw materials are mixed with static mixers, heated in preheat-
ers and emulsified in the first turbo mixer. The reaction takes place inside a rotating multi-
blade reactor with internal agitator (Figure 6.5, p. 122).
Continuous soap recirculation ensures a very effective catalyst and intensive mixing in
the reactor, and soap recirculation guarantees complete saponification.

Drying Plant
Liquid neat soap is sent directly to the drying section to produce dry soap pellets. The neat
soap storage tank, feed tank, vapor separator, and heat exchanger are no longer required
because the liquid soap is fed at low moisture (semi-concentrated liquid neat soap); thus,
the evaporation under vacuum can reach any required final soap pellet moisture. For de-
tails on drying, see Chapter 7.
 SAPONIFICATION PLANT DRYING PLANT

Additives Cooling
pump water

Reactor Barometric
condenser

Preheater
Strainers
Water
Recycle
pump

Caustic Single
soda cyclone

Spray
Preheater First chamber
Fats and turbo
oils mixer
Second
turbo
Scrap mixer
Fatty soap
scids Flow meters Soap fines
extruder Plodder Vacuum
pump
Dosing pumps Control panel Pump Hotwell
Dry soap pellets

Figure 6.4 Binacchi MPSD integrated plant.

Source: Binacchi & Co.
121
122 ■ Chapter 6

Base
soap

Recycle
loop

Rotating
multiblade
reactor

Recycle
pump

Caustic
soda
Fats and oils Emulsion

Turbo
mixer

Figure 6.5 Binacchi multiblade reactor.

Source: Binacchi & Co.

Binacchi Multiblade Reactor

The vertical jacketed reactor with a rotating multiblade agitator is fed with the emulsion
formed in the turbomixer. The intensive mixing by the multiblade combined with a high
volume recycle of the soap, guarantees complete saponification of all types of raw materi-
als. Fully saponified wet base soap is discharged from the top of the reactor.

Mazzoni LB Integrated Toilet Soap Pellets Production Plant

An integrated plant for the production of 10–15% water content dry toilet soap pellets is
illustrated in Figure 6.6. The plant consists of: raw materials feed groups, saponification
loop, vacuum spray drying plant, and optional additive group. Fats and oils are preheated
in a plate heat exchanger with low pressure steam. Caustic soda diluted with process water
in an in-line static mixer is also preheated. Brine and chelant solution are dosed by pis-
ton dosing pumps at room temperature. All the materials are fed into the turbodispenser
and the reactor of the saponification loop. A recycle pump completes the loop. The base
soap from the reactor is sent directly to the “no spray” vacuum chamber. The flow sheet
shows that this plant can be used for the neutralization of fatty acids. Refer to Chapter 7
for details.
 RAW MATERIALS FEED GROUPS SAPONIFICATION/NEUTRALIZATION DRYING

C austic Fats/oils
Chelants Brine Water Cooling
soda fatty acids
water
Barometric
Tubular condenser
Strainers
reactor

Preheaters

In-line Recycle
mixers
pump

Dosing loops Trim pump

ADDITIVE GROUP (OPTIONAL) Single

Turbodisperser
Superfat Glycerine cyclone

In-line
Strainers mixer
No spray
vacuum
chamber
Fines
extruder Hotwell
Vacuum
Plodder Dry soap pellets pump
Dosing pumps

Figure 6.6 Mazzoni integrated plant for toilet soaps.

Source: Mazzoni LB SpA.
123
124 ■ Chapter 6

Mazzoni LB Tubular Reactor and Saponification Loops

Tubular Reactor
The tubular reactor (Figure 6.7) is a static jacketed reactor without any moving parts. The
operating conditions in the reactor are: 2–3 barg pressure and 115–120 °C temperature.
Depending on the raw materials, the residence time varies from 10 to 20 minutes.

Tubular
reactor

Base soap
to drying

Fats and Oils

Caustic soda,
brine, and water
Turbodisperser Recycle pump

Figure 6.7 Mazzoni LB tubular reactor.

Source: Mazzoni LB SpA.

Saponification Loops
The reactor uses two saponification loop configurations according to base soap water con-
tent requirement for toilet and laundry soaps (Figure 6.8).

Saponification Loop for 20–24% Water Content Base Soap

The saponification loop consists of a positive displacement (PD) type recycle pump with
a recycle loop, a high shear turbodispenser, and a tubular reactor. Soap from the reactor
is sent directly to the vacuum chamber for all type of soaps. This loop is used for laundry
soap production.

Saponification Loop for 28–32% Water Content Base Soap

This saponification loop consists of an open-impeller centrifugal type recycle pump, a tu-
bular reactor, and a recycle loop. Base soap from the reactor is fed directly to the vacuum
chamber for toilet soap production.
 RAW MATERIAL FEEDING SYSTEM SAPONIFICATION LOOPS
Process Causc Fats & 20–24% water content base soap 28–32% water content base soap
Chelant Brine water soda Oils Blend

Strainers Tubular Tubular

reactor reactor

Preheaters
In-line
mixers
Recycle Recycle
loop loop

Flow meters

Dosing pumps
Turbodisperser
p p
P.D. recycle e soa r e soa r
s e s e
pump Ba dry Ba dry
to Centrifugal to
recycle
pump
125

Figure 6.8 Mazzoni LB Tubular Reactor Applications.

Source: Mazzoni LB, SpA.
126

Fats
and Caustic Vapor
oils soda chimney
blend solution Water Steam

JET
reactor
Three-
stage
reactor 70–74% TFM
Strainers concentrated soap
Soap
to chill roll
filter
Homegenizing worm

66–70% TFM
semi-concentrated
soap to dryer
Feed pumps for
Control board viscous base soap
Feed pumps for
raw materials

Figure 6.9 SAS saponification plant with JET reactor and 3-stage reactor.
Source: SAS.
 Semi-Boiled and Integrated Saponification and Drying Systems ■ 127

SAS Saponification Plant with JET and Three-Stage Reactors

All the raw materials and steam are fed into the JET reactor, which feeds the formed emul-
sion into the first stage of the atmospheric three-stage reactor. A mechanical homogeniz-
ing screw feeds the second stage. The three-stage reactor completes the saponification in
the second and third stages while the mass is mixed with a homogenizing worm and live
steam. If more homogenization is needed, the soap can be recycled (Figure 6.10). The fin-
ished base soap is fed from the bottom of the third stage, and cooled down on a chill roll
or dried on a vacuum spray dryer.
Steam Vapors
Fats and Causc
oils soda Recycle
JET
reactor Recycle

Recycle

Emulsion
3-stage
reactor 1st stage
2nd stage Recycle

3rd stage

Homogenizing
feed screw
Recycle
Base soap
Pump Pump
to drying

Figure 6.10 SAS JET and three-stage saponification reactors.

Source: SAS

JET reactor

Three-stage reactor

Figure 6.11 SAS JET and three-stage saponification reactors.

Source: SAS
128 ■ Chapter 6

SAS JET Reactor

The JET reactor initiates the saponification reaction between a small volume of fats
and oils, caustic soap, and steam (Figure 6.12). The advantages of using a JET reactor
are: reduction of saponification time, steam usage, and process water for production of
standard, semi-concentrated, and concentrated base soaps. The JET reactor is easy to
apply to all soapmaking systems

Steam
Fats and oils

Caustic
soda

Emulsion

Figure 6.12 SAS JET reactor.

Source: SAS.
 Semi-Boiled and Integrated Saponification and Drying Systems ■ 129

Soaptec Integrated Saponification and Drying Plant

Filtered raw materials are dosed in correct proportions into the reactor. Oils are kept at
temperature in storage tanks, and caustic soda heats up during dilution with process water
inside static mixers. Heat exchangers are provided to control the temperature of the fats
and oils and caustic soda and the rest of the raw material. Minor ingredients are dosed at
room temperature.
The reactor is divided into four sections with specially designed baffles fed with all the
materials. Soap is formed quickly. Reaction is induced by the fact that the relatively small
quantity of raw materials is injected into the stream of already-formed soap. A recycle loop
ensures vigorous flow and good homogenization of all the ingredients.
The base soap (neat soap), using the reactor’s pressure, goes to the spray chamber of
the vacuum spray drying section of the plant. Moisture is removed from the base soap in
pellet form and is extruded from a twin-worm plodder.

Vapors to
condensing
system

Single
cyclone

Spray
chamber
Recycle
loop
Reactor

Raw es
material Soap fin or
Base re w c o nvey
inlet sc
soap

Recycle Twin-worm
pump plodder

Dry soap pellets

ap pe

Figure 6.13 Soaptec integrated plant.

Source: Courtesy of Soaptec Srl.
130 ■ Chapter 6

Soaptec Reactor
The Soaptec reactor is divided into four sections with specially designed internal baffles
for vigorous mixing of all of the ingredients. A recycle pump assists homogenization and
completes the saponification of all types of fats and oils blends over a temperature range
from 90 to 140 °C. The reactor has no moving parts.

Recycle
Reactor

Raw
material
Recycle inlets
pump
Base soap

Figure 6.14 Soaptec reactor.

Source: Courtesy of Soaptec Srl.

Semi-Boiled Saponification Plant with Crutchers

Figure 6.15 illustrates a system with two saponification crutchers operating in tandem and
an optional post-addition crutcher for minor liquid and solid additives. When the first
one is fed with the raw materials, the second completes the saponification and discharges
the semi-boiled SWING soap in a post-addition crutcher for final formulation with liquid
and/or solid ingredients. The formulated base soap is ready to be dried. Plants with only
one or two crutchers are available for producing economical soaps.
 Liquid additives
tanks with mixers

Flow
meter
Caustic
soda

Filter
Dry additives
feeder
Pump

Flow
meter Saponification Saponification Post-addition
Fats and oils crutcher crutcher crutcher
blend

Filter

Base Soap
Pump Pump

Figure 6.15 Semi-boiled saponification plant with three crutchers.

131

Source: SAS.
132 ■ Chapter 6

Crutchers
Crutchers are powerful, versatile mixers used for saponification of all types of raw materi-
als (Figure 6.16). They are also used to incorporate liquid and solid additives into the soap.
The key component of a crutcher is a vertical helical screw rotating inside a draft tube. The
screw moves the product up inside the tube and moves it down outside the tube, provid-
ing vigorous mixing. Crutchers can operate under atmospheric or low pressure conditions.

View port Inlet

ports

Mandoor

Helical
mixing
screw in
a draft
tube

Draft
tube

Base
soap
Sweeper
discharge
blades

Figure 6.16 Crutcher.

Source: Soaptec Srl.

Acknowledgments
I appreciate the information and illustrations provided by Binacchi & Co., Mazzoni LB,
SAS, and Soaptec Srl. Their assistance made this chapter possible.

References
Spitz, L. (Ed.) 2009. Soap Manufacturing Technology. AOCS Press, Urbana, Illinois; pp. 249–265.
Owen, R. V. 1947. Continuous Saponification of Fats. U.S. Patent 2,566,359.
J. Crossfield & Sons. 1935. Steam Jet Saponification.