SOAP STAMPING SYSTEM

FIELD OF DISCLOSURE

The present disclosure generally relates to systems and methods used for manufacturing soaps.

Particularly, the present disclosure relates to systems and methods used for manufacturing toilet soaps.

BACKGROUND

Generally, toilet soapsare manufactured in a set of equipment (generally called a toiletsoap finishing line) which allows making toilet soaps of a variety of shapes, size,weight and qualities.

Toilet soap manufacturing normally involvesthe following process steps: mixing dry soap base (mostly received in pellets or short 'noodles' form) with colour, perfume and other minor solid and liquid ingredients;

. refining the mixed material into a uniform and homogeneous mass; extruding the homogeneous mass as a continuous bar having a cross- sectionsuitable to stamp out finished product (i.e. stamped soap); cutting the continuous bar into individual cut bars having length as requiredby the stamping machine (soap press); stamping the cut bars into stamped soaps having a specified shape and weight; and packingthe stamped soaps as required.

The continuous bar is plastic/ pliable and takes the shape of a die when it ispressed between a matching set of die-cavities to produce stamped soaps. To meet capacity requirements, a die-set having two matching halves with one ormore die-cavities is used. To ensure the complete fill-up of each die-cavity, the die-setis fed with excess material.

Generally, stamping operation includes: afeed suction cup arrangement for picking-up a cut bar from anin-feed conveyor and positioning it on top of the bottom half of the die-set. In machines where the bottom half of the die-set rotates by 180 degrees, the cut bar is pushed into the bottom half of the die-set by the top half of the die-set; bringing the top half of the die-set in near-contact with the bottom half ofthe die-set; this squeezes the cut bar between the bottom half and the top half of the die-set, which results in the mass filling up the cavities in the two halves ofthe die-set and taking the shape of the die-cavity / die-cavities; and the excess mass being squeezed out as flashing. Presently, there are two methodologies used for stamping the cut bars into stamped soap,which are briefly discussed below:

Option 1 :

Step (i) By controlling the temperatures of the bottom half and the tophalf of thedie set, it is ensured that the stamped soap along with the flashing

(which remains attached to the stamped soap as a web) are retained onthe bottom half of the die set;

Step (ii) Moving the tophalf of the die set away from the bottom half;

Step (iii) Rotating the bottom half of the die-set by 60 to 180 degrees;

Step (iv) Moving adischarge suction cup arrangement, which gets attached to thestamped soap (with the attached flashing); and

Step (v) Moving the discharge suction cup arrangement with the stamped, soap

(with the attached flashing) away from bottom half of the die-set through a fixed de-flashingplate.

It is to be noted here that the de-flashingplate has a cut-out with the dimensions and orprofiles as per the cross-section of the stamped soaps. Thisresult in the flashingbeing shaved-off the stamped soaps.The stamped soapsare then discharged by the discharge suction cup arrangement on to adischarge conveyor. The flashing drops onto a recycle chute / conveyor.The bottom half of the die-set rotates back (by 60 to 180 Degrees).The next cycle starts subsequently.

However, the present method (Option l)has certain disadvantages. For example, the present methodrequires the bottom half of the die stamp to be rotated by 60 to 180 degrees.Thisrotational motion is intermittent with long dwells resulting in jerks. Further, this rotationalmotion requires extra power to configure rotational motion of the drives of the bottom half of the die set.Further, this rotational motion requires higher maintenance of the stamping machine.Also, such arrangement is more costly.

Option 2:

Step (i) The flashing is captured by thespecially designed and costly bottom half the of the die-set and is squeezed out at each cycle anddropped onto a recycle chute / conveyor,

Step (ii) Controlling the temperatures of the bottom half and the tophalf of the die-sets, to ensure that the stamped soap is retained on the bottom half ofthe die-set,

Step (iii) Moving the top half of the die-set away from the bottom half,

Step (iv) Moving the discharge suction cup arrangement, which gets attached tothe stamped soap,

Step (v) Discharging the stamped soap by the discharge suction cup

arrangementon to a discharge conveyor, and

Step (vi) Dropping the flashings onto a recycle chute / conveyor.

The next cycle starts subsequently.

However, the present method (Option 2) has certain disadvantages. For example, the present method requires costly bottomhalf of the die-set. This increases the cost of the stamping machine. Also, flow of the excess mass to the flashing capture arrangement of thebottom half of the die-set results in flow lines on the stamped soaps.

OBJECTS:

Some of the objects of the present disclosure, which at least one embodiment herein satisfies are as follows:

It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.

An object of the present disclosure is to provide a soap stamping machine/ systemor a soap press to manufacture stamped soaps from a cut bar.

Another object of the present disclosure is to provide a soap stampingmachine/ systemfor manufacturing stamped soaps of specified shape and weight;

Yet another object of the disclosure is to provide a method ofmanufacturing stamped toilet soaps in a continuous operation at higher speeds.

Still another object of the present disclosure is to provide a method formanufacturing stamped toilet soaps, which reduces maintenance costs.

Another object of the present disclosure is to provide a method formanufacturing stamped toilet soaps, which reduces power consumption.

Other objects and advantages of the present disclosure will be more apparent from the following description when read in conjunction with the accompanying figure, which are not intended to limit the scope of the present disclosure. SUMMARY

In accordance with an embodiment of the present disclosure, there is provided a soap stamping system. The soap stamping system includesa die assembly, a pick up unit and a de-flashing plate. The die assembly includes a bottom die and a top die. The bottom dieincludes a plurality of die cavities configured thereon. The top dieincludes a plurality of die cavities configured thereon. The bottom die and thetop die are adapted to stamp out plurality of soaps along with flashing, and, wherein temperature inside the bottom die and the top die is controlled in a way such that the plurality of soaps is retained on the bottom die. The pick-up unit movesthe plurality of soaps along with the flashing from the bottom die. The de- flashing plate has a plurality of slots configured thereon for removing the flashing of the plurality of soaps.

Typically, the top die is a movable die.

In one embodiment, the pick-up unit is a discharge suction cup holder.

The soap stamping systemmay include a discharge conveyor for discharging said plurality of de-flashed soaps.

Also, the soap stamping system, may further includea recycle conveyor / chute for facilitating recycling of the flashing removed from said plurality of soaps.

In accordance withanother embodiment of the present disclosure, there is provided a method for manufacturing soaps. The method includes the steps of: stamping a soap slab to form a plurality of soaps along with flashing by a bottom die and a top die of a die set, wherein temperature inside the bottom die and said top die is controlled so that the plurality of soaps being retained on the bottom die; moving the top die away from the bottom die; picking the plurality of stamped soaps along with the flashing; and de-flashing the picked plurality of stamped soaps by moving the picked plurality of stamped soaps through a slotted de-flashing plate for removing the flashing of the plurality of stamped soaps.

The method for manufacturing soapsmay further include a step of discharging the plurality of de-flashed soaps on a discharge conveyor.

Also, themethod may further, include a step of dropping the flashing removed from the plurality of soaps on a recycle conveyor.

BRIEF DESCRIPTION OF ACCOMPANYING DRAWING

The soap stamping system and method of the present disclosure will now be described in relation to the accompanying drawings, in which:

Figure 1 illustrates a perspective view of asoap stamping system/machine or soap press, inaccordance with one embodiment of the present disclosure;

Figure 2 illustrates a perspective view of a discharge suction holder of the soap stamping machine shown in Figure 1, wherein the discharge suction holder is being brought in alignment with the stampedsoap pieces;

FIGURE 3 illustrates a perspective view of the discharge suction holder, afterthe de-flashing plate is brought in alignment with the dies or moulds having

soapcavities; FIGURE 4illustratesa perspective view of the discharge suction holder and thede- flashing plate, wherein thedischarge suction holder is being attached tothe stamped soap pieces;

FIGURE 5 shows a perspective view of the discharge suction holder and the de- flashing plate, wherein the soaps are being lifted above the de-flashing plate after completion of de-flashing activity;

FIGURES 6a to 6cillustratevarious views of the de-flashing platehaving a plurality of rectangular slotsconfigured thereon;

FIGURES 7a to 7cillustrate various views of the de-flashing platehaving a plurality of circularslotsconfigured thereon;

FIGURES 8a to 8cillustrate various views of the de-flashing platehaving a plurality of ellipticalslotsconfigured thereon;

FIGURES 9a to 9cillustrate various views of the de-flashing platehaving a plurality of drum-shapedslotsconfigured thereon; and

FIGURES 10a to lOcillustrate various views of the de-flashing platehaving a plurality of irregularslotsconfigured thereon. DETAILED DESCRIPTION

Asoap stamping system and method of the present disclosure will now be described with reference to the embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.The embodiment herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

FIGURE 1 shows a detailed perspective view of the various sub-assemblies of thesoap stamping machine/system or soap press 100 in accordance with one embodiment of the present disclosure. The soap stamping system 100 includesan in-feed conveyor 1 on which an extruded soap bar or slug 2 in a plastic orpliable state is fed. This soap slug 2 is cut in suitable lengths and fed in the directionof the arrow 3. A ram 4 is fitted with a reciprocating upper die or mould 5 having aplurality of die cavities (not shown). These cavities correspond to the upper halvesof the desired shape and/or weight of the soap pieces to be stamped on this machine.

The in-feed suction cup holder 6 is provided with fingers 13 for keeping thesoap slug 2 attached to it during stamping operation. The ram 4 is suitablypositioned over the soap slug 2 to be subsequently aligned with the lower die or mould7, similarly having the die cavities 8 for the lower halves corresponding to the desiredshape and/or weight of the soap pieces to be produced.

A discharge suction holder 9 is also provided for attaching itself with the finallystamped and soap pieces with attached flashings and moving it away from the bottomhalf of the die-set through the fixed slots 14 provided on each of the soap profile onthe de-flashing plate 11. By means of suitable driving and control system, the upper die5 and lower die 7 are brought together in alignment with the soap slug 2 disposed inbetween, and the soap slug 2 is pressed between these dies to obtain the soap pieces ofdesired shape, size and/or weight.

In order to avoid any air pockets in the soap pieces so formed, i.e. to ensure completefill-up of each die cavity, the die-sets are sized to ensure an excess mass, so thaton pressing between these dies, the soap mass is compacted and there is excessmaterial flowing out as flash pieces attached to the stamped soap pieces.

Subsequently, these soap pieces with flashed out material are passed through thede-flashing plate 1 1 having edges 15 to remove this excess material to produce finishedsoap pieces 12 of the desired shape, size and/or weight, which now have no flow lines,thereby imparting a better aesthetic value to the soap pieces. These soap pieces arenow discharged by the discharge suction cup holder 9 on the dischargeconveyor 10 to be packaged on packaging machines provided do wnstream of this soapstamping machine.

FIGURE 2 illustrates a perspective view the discharge suction holder 9 of the soap stamping machine 100, wherein the discharge suction holder 9 is being brought in alignment with the stampedsoap pieces. Also, wherein the upper die 5 and lower die 7 and the de-flashing plate 1 1 having lateral slots 14 are shown in alignment at the start of the de-flashing operation. FIGURE 3 illustrates the discharge suction holder 9 is shown as in alignment with the stampedsoap pieces via the slot 14 provided in the de-flashing plate 11 for attaching soappieces to discharge suction holder 9 for shaving-off the flashed excess material.

FIGURE 4 illustrates the discharge suction holder 9 is being attached to stamped soap pieces forshaving-off the flashed excess material by means of the de-flashing plate 1 1.

FIGURE 5 illustrates the soap stamping machine 9 with the finishedsoaps 12, wherein the finishedsoaps 12 being removed from the slots of the de-flashing plate 11 and excess material of flash beingshaved-off by means of the edges 15 of thede- flashing plate 1 1 by raising the dischargesuction holder 9 holding the stamped soap piecestherethrough.

FIGURES 6a to 6cillustrate various views of the de-flashing plate 11 having a plurality of rectangular slotsconfigured thereon.

FIGURES 7a to 7cillustrate various views of the de-flashing plate 11 having a plurality of circularslotsconfigured thereon.

FIGURES 8a to 8cillustrate various views of the de-flashing plate 11 having a plurality of ellipticalslotsconfigured thereon.

FIGURES 9a to 9cillustrate various views of the de-flashing plate 11 having a plurality of drum-shaped slotsconfigured thereon.

FIGURES 10a to lOcillustrate various views of the de- flashing platehaving a plurality of irregular slotsconfigured thereon.

PROCESS OF TOILET SOAP MANUFACTURE:

In accordance with the present disclosure, the toilet soap is manufactured in a set of processsteps as given below: (i) Mixing the dry soap base (mostly received in pellets or short noodles form)with colour, perfume and other minor solid and liquidingredients;

(ii) Refining the mixed material into a uniform and homogeneous mass;

(iii) Extruding the homogeneous mass as a continuous bar having a cross-section suitable to stamp out the finished product, i.e., stamped soap;

(iv) Cutting the continuous bar into individual cut bars or slugs having length asrequired by the stamping machine soap press;

(v) Stamping the cut bars or slugs 2 into stamped soap pieces having a desiredand specified shape and weight. The actual stamping operation consists of thefollowing steps:

(a) a feed suction cup arrangement 6 picking-up a cut bar or slug2 fromthe in-feed Conveyor 1 and positioning it on top of thebottom half 7 of thedie- set;

(c) Bringing the top half 5 of the die-Set in near-contact withthe bottom half 7 of the die-Set;

(d) This 'squeezes' the cut bar 2between the bottom half7and the tophalf 5 of the die-Set, which results in the massfilling up the cavities in the two halves of the Die-Set and takingthe shape of the Die-Cavity / Die-Cavities; and

(e) The excess mass is squeezed out as Flashing, which is laterremoved as , shaving-offs by means of the edges 15 of thede-flashing plate 11. (vi) Controlling the temperatures of the bottom half7 and the top half 5 of the die- set,to ensure that the stamped soap along with the flashing (which remainsattached to the Stamped Soap as a web) are retained on the bottom half 7 of thedie-set;

(vii) Top half5 of the die Set is moved away from the bottom half;

(viii) Discharge Suction Cup Arrangement9 moves and attaches it to the stamped soaps (with the attached flashings);

(ix) The discharge suction cup arrangement 9 with the stamped soaps (with theattached flashings) moves away from bottom half 7 of the die-set through fixed slots 14 of the de-flashing Plate 11;

(x) The de-flashing plate 11 has a cut-out with dimensions/profile as per the crosssectionof the Stamped Soap and slots to allow for the entry of the suction cupholders;

(xi) This results in flashings being 'shaved-off the stamped soap pieces;

(xii) The stamped soap pieces are then discharged by the discharge suction cup arrangement 9 on to a discharge conveyor 10;

(xiii) The shaved-off flashings drop onto a recycle chute/conveyor; and

(xiv) Subsequently, the finished stamped soap pieces are packaged on the packagingmachines (not part of this invention), as required.

In one embodiment, the technical details of the stamping process described above in step (v) are asfollows:

- Toilet soapsare produced at up to 600 stamped soap pieces per minute.

- Stamping machine or soap press is configured to operate at 60 stamping cycles per minute.

- Die-Sets with up to 10 die cavities for soap stampings are used. - However, to increase the efficiency, die-Sets with up to 14 die cavities canalso be provided.

TECHNICAL ADVANCEMENTS

The soap stamping system and methodin accordance with the present disclosure has several technical advantages including but not limited to the realization of:

• a soap stamping machine/ system or soap press to manufacture stamped soaps from a cut bar;

• a soap stamping machine/ system for manufacturing stamped soaps of specified shape and weight;

• a method ofmanufacturing stamped toilet soaps in a continuous operation at higher speeds;

• a method formanufacturing stamped toilet soaps, which reduces maintenance costs; and

• a method formanufacturing stamped toilet soaps, which reduces power consumption.

Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

The use of the expression "at least" or "at least one" suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results. Wherever a range of values is specified, a value up to 10% below and above the lowest and highest numerical value respectively, of the specified range, is included in the scope of the disclosure.

The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.