1. DETERGENT CAKE PLANT
 

The Basic process comprises of all the raw materials being added into a mixer as per the sequence of the formulation and mixed till the reaction is complete. The mass is then extruded into bar or cake depending on the shape and size using plodder. Our capacity is from 100 kgs/hr to 10,000 kgs/hr

The equipment needed for a detergent cake are as follows:

1. Sigma Mixer : Double `U' shaped trough, suitably designed `Z' arm blades - 2 Nos, moving in opposite direction at different rpm. For thorough and homogenized mixing of Detergent Powder and additives. Complete with drive and having manually operated bottom discharge. 

2. Lump Breaker: Multi screw conveyor with geared motor directly coupled to the one screw .The other screw are driven by gears. 

Material of construction: S.S.304 contact parts

3. Belt Conveyer: The Belt will be cleated belt with cleats molded to belt. The belt will be moving in a SS 304 channel with roller support at the bottom of the conveyor. The belt conveyor will be fitted with a feed hopper and discharge chute will be fitted both will be made of SS 304 material..The drive will be through chain fitted directly to the geared motor of reputed make with chain guard. The stand will be made of hollow pipe and fitted with castor wheel/ or fixed type depending on the conveyor requirement.

4. Plodder: 

• SINGLE WORM SINGLE PLODDER: Single worm single plodder having jacketed barrel with suitably designed S.S.304 worm to ensure proper compression. Rotary blade device and extrusion noodle plate complete with drive. 
• TWIN WORM SINGLE PLODDER : Twin worm single plodder having jacketed barrel with suitably designed S.S.304 worms to ensure proper compression. Extrusion noodle plate complete with drive. 
• SINGLE WORM DOUBLE VACUUM PLODDER : Vacuum comprising of single worm plodder consisting of a jacketed barrel and a suitably designed S.S 304 worm to ensure proper compression. Preliminary Plodder consisting of rotary blades and extrusion noodle plate, interconnected by a vacuum chamber to the final plodder having a mouth cone with heating arrangement. Complete with drive.  
• TWIN WORM DOUBLE VACUUM PLODDER : Comprising of twin preliminary and final plodders each consisting of a jacketed barrel and a suitably designed S.S.304 worms to ensure proper compression. Preliminary plodder consisting of rotary blades and extrusion noodle plate, interconnected by a vacuum chamber to the final plodder having a mouth cone with heating arrangement. Complete with drive. 

5. Cutting with Embossing Machines:

• SB-S-CUTTER EMBOSSER(DUPLEX/SIMPLEX): Made of two set of Single Blade Cutter with Servo motor connected to the Blade. The servo motor is controlled by the PLC. Soap from plodder is cut into bars by single blade. The length of the soap is adjusted by the HMI which send the signal to the PLC to adjust the blade. Also two individual Embossing attachment are fitted in front of the cutting machine in case Embossing is required for the soap. In Embossing mode the is given by the roller fitted to move the blade to cut the soap. Material : S.S.304 contact parts.
• CUTTING CUM EMBOSSING MACHINE: Semi automatic type machine with movable flat. This flat has a forward and backward motion. The forward and backward motion is given by a eccentric cam fitted on the reduction gear box and driven by a electric motor. The cam also drives the embossing shaft which in turns embossed the brand name on the detergent cake before cutting. The cutting frame is an aluminum frame easily removable and fitted with the cutting blade of exact size. Material of construction : S.S. 304 contact parts
• AUTO CUTTING EMBOSSING MACHINE The cutting machine with have a pneumatic cylinder to move the flat forward and backward. There is another cylinder to move the embossing plate. The embossing plate will embossed the brand name on the detergent cake before cutting . The cutting frame is an aluminum frame easily removable and filled with cutting blade of exact size.                                              

2.1 DRY MIX DETERGENT POWDER PLANT

The dry mix process is recommended when a medium bulk density powder detergent is required. The Basic process comprises of all the raw materials being added into a mixer as per the sequence of the formulation. The mixer used depends on the characteristics and moisture of the final product. The advantage of this process to produce detergent powder, compared to the more traditional spray drying process, is the almost total elimination of fuel cost for water evaporation. The powder is the taken for sieving and then packed into the require packing.

Ⅰ) The different types of Mixer used are:

1. Sigma Mixer: Double `U' shaped trough, suitably designed `Z' arm blades - 2 Nos, moving in opposite direction at different rpm. For thorough and homogenized mixing of Detergent Powder and additives. Complete with drive and having manually operated bottom discharge.

Material : S.S.304 contact parts.

2. Roto Mixer:  It consist of two conical cone welded together rotating on the central shaft. The Roto Mixer has hollow shaft from one side powder is feed through the mixer & other side liquid is spray from the Hollow shaft. It has a Central Nozzle for removing the mix material.

Material of Construction : S.S.304 Contact Parts.

3. Ribbon Blender:  A 'U' Shape trough with a specially Fabricated ribbon agitator. A Ribbon agitator consists of a set of inner & outer helical blades. It has a single nozzle at the bottom for discharge.

Material of Construction : S.S.304 Contact Parts.

4. Plough Shear Mixer : It is a circular horizontal vessel with a main stirrer, connect with plough on the shaft for mixing, It has impeller on the side depending on the capacity for intense mixing. The main shaft is driven by gearbox. 

Material : SS 304 Contact parts.

5. Pan Mixer : 

Ⅱ) For sieving a cage mill and a vibratory sieve is used:

• CAGE MILL: It is cylindrical Vessel with stirrer in the center.  In the bottom side it has a sieve to segregate the lumps from the powder. The stirrer is Rotated by the Gearbox. It is then driven by a motor through pulley & V-Belt. Material of Construction : S.S.304 Contact Parts.
• VIBRATORY SIEVE: Screen type vibratory sieve Complete with electric motor, anti vibration pads. Material of construction : S.S.304 contact parts.

2.2. SPRAY DRYING DETERGENT POWDER PLANT 

The spray drying process is used where a low bulk density powder detergent is required. The Neutralised sulphonic acid and other raw materials are thoroughly mixed in a slurry preparatory. The slurry thus formed is then filtered. The slurry is sprayed from the top of a tower, to form very thin droplets because of High pressure. As the droplets of the slurry fall from the top they come in contact with a stream of hot air. Some of the water gets evaporated and the droplet then forms a small hollow hard shells called "beads". The finished product is then stored and cooled in air lift from where it is taken to a packing machine where it is then packed into the required packing.

3. LIQUID DETERGENT PLANT

Patil Machines supply equipment to produce liquid detergents for personal care and household products.

4. PILOT PLANT 

We also give Sulphonation plant to manufacture surfactants for use in detergent Product

5.  Batch Sulphonation Plant Using Sulphuric Acid/Oleum

Sulphonation Plant : In this process organic material like LAB/DDB is Sulphonated by Using Oleum and/or sulphuric acid as sulphonating agent, sulphonation is completed in a single agitated vessel called sulphonator. This vessel also acts as a dilutor and a separator to give final sulphonic acid and spent acid, cooling coils are provided to maintain the temperature. Such plants require less investment and are ideal for small capacities.

6. Continuous Sulphonation using Sulphuric Acid/Oleum
 

In this process organic material like LAB/DDB is sulphonated by Sulphuric acid and/or oleum .The process of sulphonation is completed by using various equipments like sulphonator, Dilutor, and a separator. This is a continues process where by the raw materials are fed continuously by means of dosing pump and the final products like sulphonic acid, spent acid are also discharged continuously. Such a plant is ideal for medium as well as large capacity

7. Continuous Sulphonation by Cascade Reactor

In this sulphonation is carried out by using a mixture of SO3 and dry air. The SO3 gas can be obtained either by Oleum stripping or vaporization of liquid SO3 or by sulphur burning. Main equipments like Cascade reactor, Air generator, Air drier, Scrubber system, Electronic precipitators (ESP) and equipment for SO3 generation are used for this process. Additional equipments like Heat exchanger and vaporizer are required for oleum stripping/liquid furnace, SO2 cooler, SO2- SO3 convertor, SO3 cooler and SO3 filter are used. This process is ideal for medium to large capacities and requires fairly high investment. Moreover the quality of sulphonic acid produced by this method is better than the above two process.

8. Continuous Sulphonation using Sulphur Burning

The basic process of sulphonation is similar to that of cascade reactor. This is a continuous process and sulphonation is carried out by a film reactor instead of a cascade reactor. The quality and the colour of sulphonic acid produced by this method is very much superior than any other process. Another advantage of this process is that it can sulphonate various organic material like linear Alkyl Benzene, Alpha olefin, Methylesters etc. This process is ideal for large capacities and requires a high investment.