1) PRE-MIXTURING OF THE COMPONENTS
All the liquid components are placed in a stainless steel container, eventually added with solid components (previously at bain-marie liquefied), to moderate and combine them.
2) BASE UPLOAD
90/120 Kilos of soap base are uploaded, through the conveyor belt, in the steel bladed mixer. At the same time the premixed components (point 1) are added slowly and thinly. The addition must be done slowly in order to allow the perfect amalgamation of all the components.
3) DOUBLE-HELIX DRAWING
Once come out from the mixer, the product is conveyed into a double cochleas machinery, where is further mixed and subjected to a first compaction. Come out from the cochleas, the product is extruded by a “spaghetti” mesh, and cut immediately with a rotating star-shaped knife.
4) DOUBLE-STAGE DRAWING
The product obtained at the previous point is conveyed, through the conveyor belt, into a single cochlea wire drawing machinery, where is further compacted. Once come out, the product is cut and the material looks like a chip.
The obtained chip is mechanically forced in a vacuum-sealed room and extruded in a single bar, to ensure a stable final weight.
5) FINAL BAR CUTTING
The product is conveyed to the rotating cutter, calibrated to make the soap rough, whose weight is slightly more than the final ones.
6) FINAL PRESSING
The rough soaps are carried to the printer, where takes place the final shaping. The machinery provides to the lettering printing, in both sides of the soap, if required. The soaps must have weight equal to the declared ones, and without spots or imperfections. An operator controls the weight and removes the eventual scraps.
IN- MANUFACTURING STAGE CONTROLS
During each stage of the manufacturing, the product must be marked and recognizable with a board with the number of preparation and the name of the product impressed, for having a right stock rotation.
The soaps must be homogeneous, without spots, extraneous material, scraping or damage, and having a typical odor. The lettering engraved must be readable and tidy. If required, it could be done cracking test, according to the contractual modalities.
SOAPS WEIGHT CHECK
None soap can weigh less than the declared weight, however it mustn’t exceed the limits provided for by law. The weight control is made immediately after the final pressing stage, with 10 minutes pause.
This check is carried out with a specific electronic scale, equipped with a printer, that calculates average, minimum, and maximum production weight. These results are maintained in archive provided for by law.
IN MANUFACTURING STAGE QUALITY CONTROLS
1) pH control
2) WASH Test
3) Weight control, according to regulations
4) Product humidity control, if required
5) Production’s batch counter sample, archived for 3 years.
6) All production lines are equipped with metal detector
FINAL PRODUCT QUALITY CHECKS
The checks are realized according to Deskin protocol for product quality, or according to client’s operating manual.
1) Identification with code and batch number, on final packaging box.
2) Pallet checking: pallet labeling and numbering, for stock rotation purpose.
– Different payload scales
– Stainless steel laminators
– Stainless steel mixers, with cochleas upload
– Double-helix stainless steel drawing machine
– Double-stage stainless steel drawing machine equipped with conveyor belt, cochlea and vacuum-sealed room
– Rotating cutter
– Continuous printers
– Wrap machine
– Automatic boxing machine