Hindustan Unilever Limited

Factory Layout
 Oil PSM Noodler
Root Blower/RAV

Noodle Bin
Blend Oil

(Distilled Fatty acid) Perfume/ Colour

DFA Mixer
(glycerine, residue,
volatile)

(Plough Shear Mixture)

PSM Noodler
(DFA,caustic,salt,EHD2P
EDTA) (82-85 °C)

Multi-screw
conveyor
Roll Mill
Chilled Drum
Pre Plodder WRA

Metal
Final Plodder
Detector

Banding
Bar cutter
Machine

Metal
Case Packer
Detector

BSM
 Tank Farm
• All the different types of oils containing trigylceroid (gylcerine) is imported and
collected here in different tanks. The oils which are mainly used here are given
below:-
• 1. HPFAD
• 2. PFAD
• 3. CPS
• 4. RPS

• These oils are taken in different ratios and mixed together (mainly through
agitator) in the tank to prepare Blend Oil.
• Eg. HPFAD(40%) + PFAD(60%) = Blend Oil

• After mixing, sample is taken and various chemical tests are performed and if it
passes the required tests then transfers to DFA Plant for the preparation of DFA.
 DFA Plant
•In DFA Plant,
•Blend Oil and DM Water
is mixed through
hydrolysis process on the
application of steam(55-
60Kg/cm2) at 255-260C
in Splitting Tank which
gives the product of CSFA
and Sweet Water
(glycerine)
DFA Plant
After obtaining these products , distillation of CSFA is
performed at 755 mmHg pressure which gives us
DFA(C14,C16,C18), Volatile material (C8,C10) and
Residue(C18.1,C18.2,C18.3)
 DFA Plant
• Distillation is mainly performed at cylendrical tanks known as
Candles. These candles are in groups of seven and two known as Main
Still and Backened Still respectively.
• Candles' temperatures are maintained at profile i.e. different candle
have different temperature.
• Temperature of different candles are given below:-
• Candle 1 and 2 - 195-200 C.
• Candle 3,4 and 5 - 215-220 C.
• Candle 6 and 7 - 228-230 C.
• Candle 8 and 9 - 245-246 C.
• CSFA when passed through different condensors, gives different
products.
 DFA Plant

• Volatile products are exported to different factories where they are

required while the obtained residue is further used as fuel for boilers.
 PSM (Plough Shear Mixer)
• After obtaining DFA, it is transferred to PSM where other necessary
materials of soaps are mixed together in a definite ratio.
• 9.5 kg of salt uis taken into PSM, then 90.6 kg of DFA is mixed with it
and then Caustic(340.8kg) with 26 kg of water is mixed. After that
Glycerine (24 kg), EHDP(2kg) and EDTA(1.4kg) is mixed.
• The temperature of soap mixture is about 82-90 C.
• When the mixture(batch) is completey prepared, it still contains
moisture more than the required amount so it is controlled by the ID
fans.
• After preparing this, the mixture is transferred to Chilled drum
through Multiscrew conveyer(4 screw conveyer).
 Chilled Drum
• In Chilled-drum, soap mixture is cooled down through cold water. the
temp. of water at e try and exit is 10 C and 15C respectively.
• In Chilled drums, there are cutters present on their outer surfaces to
prevent the soap mixture from sticking on their surfaces.
• After that it goes into the Noodler via Noodle Hopper.
• From PSM Noodler, when the noodles are prepared then with the help
of Root Blower & RAV they are transferred to Noodle Bin at high
pressure. After this , they are taken to Mixer
 Mixer and Roll Mill
• At Mixer noodles are mixed together with other important ingredients
of soaps like colour, glycerine, fryses and perfume.
• Firstly Noodles(600kg) is put into the mixer where they breaken down
into small shapes and further mixed together, for 5 minutes.Then we
add colour(7.5kg),then Fryses(23kg), Glycerine(13 kg) and in last
perfume(5.5kg) is mixed.
• When the mixing is complete, this batch is transferred to Noodler
where again the noodles are prepared
• Theses noodles then comes into the Roll Mills where a three rolls roll-
mill mixes and refine the batch(mixture) into vey thin layers
• The batch is then transferred to Pre-Plodder and Final Plodder.
 Pre Plodder and Final Plodder
• The main objective of these plodders is the mixing of batch(mixture)
and reducing its temperature and IN Pre-Plodder, vacuum is used to
remove the air bubbles from the batch.
• After passing through Final plodder it goes through an orifice dye from
which two bars are obtained which are cutted through cutters, known
as Bar Cutters.
• These Bars are passed through Metal detectors to check it they
contains any sort of metallic material or not and if not passed then
they are stopped from futher processes and taken for reusage and
removal of these harmful metallic materials and when passed then
goes further into BSM.
BSM (Binacchi Stamping Machine)
• It is one the important stoppage in the process of soap making
because the design, size and shape of a soap acquired right here.
• After passing the metal detector test, these bars are transferred to
BSM where there are two rotary dyes and one reciprocal dye.
• When soap bars enter the BSM then lifter lifts them and placed infront
of the dyes while the reciprocating dye applies force on it hence results
in the desired shape of the soap.
• These soaps are then picked up by the pickup assembley and place
them on the moving conveyer belt through soap cases so that the
proper finishing is obtained.
• From these moving belts, these soaps enter the WRA.
 WRA(Wrapping Machine)
• The wrapping of a soap is done here.
• When the soap enters the WRA through band conveyer and Infield
belt. It is then picked-up by the Pickup assembly and placed in the
soap pockets of pocket belt, which is runned by the driven/drive gear.
• There is a overflow limit switch is placed in the path of pocket belt
which detects and gives output in case of any overflow of soaps.
 WRA
• Top elevator picks up the soap while bottom elevator pushes it in
upward direction where paper-card (used to conserve the moisture
and perfume of soap) and Poly-paper Wrapper Wraps around it.
• {Soap paper and paper card are cutted into accurate size through
cutters before wrapping}
• After that Soap plough picks up the soap and it moves in forward
direction for Banding machine.
• *A WRA can wrap upto 145-150 soaps per minute.
• After passing through WRA, the wrapped soaps again passed through
Metal Detectors for a formal check of any metallic particle in a soap.
• On passing the test it goes into the Banding Machine
 Banding Machine
• Banding Machine is mainly a kind of packing machine where soaps are
packed in the groups of four.
• Soaps enters the Banding Machine then they are collected inside in
the packs/bundles of four and moves forward.
• While moving forward glue tape is applied which is cutted by cutters
at the next point and then moves forward.
• {Various size brushes are used to maintain the balance of soaps and
applyin glue tape properly n the pack.}
• After passing the Banding Machine it goes through the sensors which
check whether the packing of soaps is done in right manner or not like
whether the manufacturing date and batch no. and other important
details are completely visible or not.
• When the packs passed the tests then moves forward for the Case
Packer.
 Case Packer

• At the end of every line there is always a Case Packer, a machine that
places individual soaps or multipack bundles into cartons or CLDs.
• Soap bundles enters the Case Packer and pickedup by the Star-wheel
and placed them in vertical position(standing position) and through
conveyer belts they moves fowrard in the group of six bundles and
placed infront of the pusher.
• Pusher pushes the soaps' bundles into the C-Plane.
 Case Packer
• Now, Vertical lifts the soap when three group of six bundles of soaps
are placed in the C-Plane, with the help of Pickups and placed them
into the CFCs.
• When the CFCs are completely filled then it moves forward where it is
packed by the employees and moves forward for the one final
inspection and if all is clear then for the exportation.
• CFCs are placed into the magazine which are automatically pickedup
by the Erector.
• {
• *A magazine have the capacity of about 85 CLDs at once
 Case Packer
• *A Case Packer can pack 400 CLDs per hour, if no errors occured}
• Different Errors and Problems occured in Case Packer:-
• *Door Number Open
• Sol. Check the respective door and close it properly
• *Case Extraction Error
• Sol. Check if the CLD case is properly tight in the magazine and if not
then tighten it.
• *No Safety Relay Feedback
• Sol. Check if all the doors are properly closed(check infeed gaurd) and
if not then close it properly.
 Its Error and Solution
• *Flap Reed Relay Not Detected
• Sol. Check if all the four sides of CLD are properly opened and if not
do it so.
• *Vacuum Pump Stop
• Sol. If machine is stopped for more than 30 minutes then we have to
manually start the vacuum pump.
• *Case broken
• Sol. Check if CLD is damaged or broken near Erector and remove it.
• *CFC Placing Error
• Sol. Erector not picking CLD three times from the magazine/sensor or
not able to detect as CLD is not properly placed in magazine, Tighten
the magazine.
• *Pusher Servo Drive not ready
 Errors and their Solution
• Sol. Check if there is any extra layer of soap on C-Plane and remove it.
• *Pickup Error Low Vacuum
• Sol. Place overturned soap tablet properly or insert more layers to
count it to three on C-Plane
• *C-Plane and Vertical Over Travel Error occured when they extends
more than their fixed travel paths.
• *Some bundles of soaps contains soft soaps due to some defect then
these soaps becomes a kind of hindrance in the smooth continuous
functioning of the machine as they oftenly get damaged and loose
shape on the application of very small force.
 Error and their Solution
• *Error due to mismatch in the packing speed of Star-Wheel and no. of
incoming bundles .
• Sol. All the applied vacuums and pressure are kept in check.
• Strict checking on the quality of soaps should be done before its entry
in the Case packer