A METHOD AND APPARATUS USED IN THE MANU¬

FACTURING OF LAYERED PRODUCTS [001] This invention relates to a method and an apparatus used in the manufacture of highly viscous products that solidify afterwards, in particular soaps with multiple colored layers having features such as additives and fragrance and a product man¬ ufactured thereby. [002] Prior art [003] In conventional soap production, soap pasta passes through the presses after it is converted to soap mass and fragrance and dyes are added and then packed. Thus, a homogenous and uniformly colored soap bar is produced. Conventional soap bars are packed one by one or packed with two, three, four or more bars together. [004] Present invention allows to produce striped and fragranced soap bars having two or more colors at the same time. [005] Conventional soap production method or the so-called Marseille method is comprised of fourt stages : saponifying, washing, baking and drying. [006] Saponifying stage is based on the reaction with sodium hydroxide. In the washing stage, gylcerol which is an important side product in soap production is removed. [007] In baking stage saponifying is realized and in drying stage the soap bar takes the final form. [008] These stages are well known in soap manufacturing and the modern soap industry is based on the continuous and automatic application of these stages. After these stages the soap bars are formed in the stages called finishing which consists of the drying, kneading, moulding, marking and finally packing processes. [009] During kneading, additives or fillers such as fragrances, dyes, binders, deodorants are added to the soap mass. The types and amounts of such additives may vary according to the end use of the soap namely as toilet soap, bath soap, antibacterial soap etc. [010] However, these monochrome soaps fail to satisfy the desire of the customers so as to provide a variety of products. Therefore, various methods and apparatus have been developed to produce striped soap bars in the prior art. [011] In prior art, US 3 884 605 discloses a method of producing a multicolored and striped soap bars by mixing the different colored soap pastes emerging from two helical tubes positioned parallel on top of each other by means of an injector having parallel tubes. [012] On the other hand, US 3 890419 discloses an apparatus for producing a soap bar having colored stripes on its outer surface manufactured by introducing coloring matter into the soap mass at the extruder area. [013] Yet, in another reference, US 3 923 438 discloses an apparatus for the manufacture of a single striped soap bar. A series of tubes are provided in the extruder of this apparatus and coloring mater is injected into the soap mass while passing through these tubes. [014] In US 4094 946, two co-eccentrical and transverse helical tubes are provided. Each of the tubes are injected with a soap paste having a different color and the different colored pastes are intermingled in the extruder, thus the striped soap bar is man¬ ufactured. [015] In US 4 127 372 an apparatus used for the same purpose is disclosed in which the paste is passed via a helical tube to another and coloring matter is mixed into the paste at the end of the second helical tube from some perforations. [016] In US 4 196 163 the colored striped soap is manufactured by using a specially formed piece provided on the extruder. [017] However, all the above mentioned prior art provides soaps having stripes only on the outer surface of them. After some usage, the stripes diminish. In case the stripping extends throughout a greater depth of the bar, these stripes tend to crack or split along the lines in a short time. [018] BRIEF EXPLANATION OF THE INVENTION [019] An object of this invention is to provide a product for instance a bar of soap having two soap mass intermingled in as specific form and rate with layers of different colors, fragrances, additives. [020] Another object of this invention is to provide the intermingling of the different soap pastes having specific range of fragrance, dye and additives with each other and thus producing a visually appealing and different product. [021] Yet, another object of this invention is to provide the intermixing the soap pastes without cracking or splitting by locating the nozzle into a junction place where the different soap pastes pass through. [022] Another object of this invention is to provide an apparatus to manufacture a layered soap in an inexpensive and reasonable manner. [023] This apparatus basically comprises helical tubes to enable the passage of at let two soap paste having different features, a nozzle to provide the intermixing of the different soap pastes and characterized in that the head has a barrel inserted into the said head to divide the cross section of the head into defined areas. [024] Each soap paste passing through each helical tubes may be of different color, fragrance and additives. [025] As the billet having layers of different characteristics is carried onto the press via a conveyor and moulded at various angles and thus a soap bar is manufactured having layers on it with different appearance, fragrance, pattern etc. [026] DETAILED EXPLANATION OF THE INVENTION [027] The apparatus is illustrated in the accompanying drawings, in which [028] Figure 1 is the upper schematic view of the apparatus. [029] Figure 2 is the upper view of the barrel [030] Figure 3 is the front view of the barrel [031] Figure 4 is the side view of the barrel [032] Figure 5 is the cross sectional view of the barrel taken along the line A-A [033] Figure 6 is the cross sectional view of the soap bar manufactured by this barrel [034] Figure 7 is the upper view of the soap bar manufactured by this barrel [035] Figure 8 is the upper view of the second embodiment of the barrel [036] Figure 9 is the side view of the second embodiment of the barrel [037] Figure 10 is the front view of the second embodiment of the barrel [038] Figure 11 is the cross sectional view of the second embodiment of the barrel taken along the line B-B [039] Figure 12 is the cross sectional view of the soap bar manufactured by the second embodiment of the barrel [040] Figure 13 is the upper view of the soap manufactured by the second embodiment of the barrel [041] Figure 14 is the upper view of a third embodiment of the barrel [042] Figure 15 is the front view of the third embodiment of the barrel [043] Figure 16 is the side view of the third embodiment of the barrel [044] Figure 17 is the cross sectional view of the third embodiment of barrel taken along the line C-C [045] Figure 18 is the cross sectional view of the soap bar manufactured by the third embodiment of the barrel [046] Figure 19 is the upper view of the soap bar manufactured by the third embodiment of the barrel [047] Figure 20 is the upper view of the fourth embodiment of the barrel. [048] Figure 21 is the front view of the fourth embodiment of the barrel [049] Figure 22 is the side view of the fourth embodiment of the barrel [050] Figure 23 is the cross sectional view of the fourth embodiment of the barrel taken along the line D-D [051] Figure 24 is the cross sectional view of the soap bar manufactured by the fourth embodiment of the barrel [052] Figure 25 is the upper view of the soap manufactured by the fourth embodiment of the barrel [053] Figure 26 is the front view of the barrel lid [054] Figure 27 is the cross sectional view of the lid [055] Figure 28 is the upper view of the press and billet [056] Figure 29 is the perspective view of the soap. [057] Parts of the apparatus are numbered as follows: 1. Apparatus 2. Plodder 3. Nozzle 4. Barrel 5. Inlet 6. Chamber 7. Outlet 8. Press 9. Conveyor 10. Separator 11. Soap 12. Layer 13. Lid 14. Housing 15. Wall [058] The term "layered product" is used in this description to indicate a product in the form of a bar comprising of several layers (12) in the same product having various features such as color, fragrance, additive, pattern. When the product is in its highly viscous state, it is in paste form, after moulded and dried it is solidified. While this product may be a food stuff, cleaning product or the like, it is preferably a soap bar and comprises of soap bars known as striped soap. The soap is called "striped" as it comprises of several stripes or lines of various designs and colors on the bar. [059] The apparatus according to this invention comprises of at least one plodder (2) into which the soap paste flows. The helical tubes (not shown) rotates axially and provides the mixing of the soap paste. A head is provided at the junction end of the plodder to provide the intermixing of the different soap pastes. The apparatus according to this invention is characterized in that a barrel (4) is provided in the head (3) to pass separated soap pastes entering through different inlets (5) via different chambers (6) and pressing out by intermingling them as one paste through one outlet (7). The soap paste (10) leaving the barrel (4) is in the form of a billet having several layers and carried onto the press (8) by means of the conveyor (9) where it is moulded to be ready for packaging. [060] Each chamber (6) opens to a separate inlet (5) and then is connected to a common outlet (7). The chambers (6) have the cross section of the soap bar (2) to be man¬ ufactured. [061] Another embodiment of the invention is shown in Figures 2 to 5 where it is shown that the barrel (4) has the shape of a cylinder with a circular, rectangular or elliptical base. This cylinder has two inlets one on the base and the other on the side wall. The shapes of the inlets are preferably circular to facilitate the flowing of the soap paste. Each of these inlets (5 a and 5b) open to a separate chamber (6a and 6b) in the cylinder. These chambers are separated via a wall (15) starting from the inner side of the side wall and ending just before the outlet. The area of the wall close to the inlets are sloped to facilitate the flowing in X and Y directions. The soap paste is forced to obtain the shape of a rectangle, elliptical or the like while flowing through the chambers. Due to the continuous flow through the plodder, paste within the barrel is oriented from the inlet (5) towards the outlet (7). [062] Soap (11) manufactured according to this embodiment is shown in Figure 6 and 7. This soap comprises two layers having different features and placed on top of each other. The borderline connecting the layers is at the center of the cross section of the soap. [063] Yet another embodiment of the invention is shown in Figure 8 to 11. In this embodiment barrel (4) is preferably in the form of a cylinder having a rectangular base. Internal volume of the cylinder is divided into four chambers (6a, 6b,6c,6d) by means of a vertical (15a) and two horizontal walls (15b and 15c).Two of the chambers (6a and 6b) open to the inlets located in the cylinder base. Other two chambers (6c and 6d) open to the two separate inlets (5c and 5d) at the side wall of the cylinder. In the preferred embodiment of the invention to the first two chambers, soap base from a plodder having a specific feature flows and a different soap base flows from a second plodder. [064] Thus, a soap bar is manufactured having a cross sectional view like a "+" [065] (See Figure 12 and 13). [066] In figure 14 to 17, another embodiment of the apparatus is shown where the barrel (4) is preferably in the form of a cylinder having a rectangular base. The internal volume of this cylinder has three separate chambers (6a, 6b, 6c) opening to three separate inlets (5a, 5b, 5c). Two of the chambers (6b and 6 c) open to the inlets (5b and 5c) on the side wall. The other chamber (6a) opens to the inlet (5a) located on the base of the cylinder. Two of the chambers (6b and 6c) protrudes into the chamber (6c) on the inlet (5a) and thus the chamber has the cross section in the form of the letter "H". The soap (2) manufactured in accordance with this embodiment has separate layers (12b and 12c) on and under the middle layer (12a). The top and bottom layers (12b and 12c) can be of the same width as the middle layer (12a) or different. [067] In another embodiment as shown in Figure 20 and 21, the barrel (4) is preferably in the form of a cylinder having a rectangular base. The inner volume of the cylinder comprises of a main chamber (6a) opening to an inlet (5 a) located on the base of the cylinder. The main chamber is surrounded with chambers (6b, 6c,6d,6e,6f, 6g,6h,6i) opening to the inlets (5b,5c,5d,5e,5f,5g,5h,5i) located in the side walls of the cylinder. The chambers (6b,6c,6d,6e,6f,6g,6h, 6i) opening to the side walls protrudes into the main chamber like the teeth of a comb. [068] The soap (11) manufactured in accordance with this embodiment has separate layers of different colors (12b and 12i) on and under the middle layer (12a). (Figure 24, 25) [069] The outlet (7) is covered via a lid (13) having a housing (14) on it in order to form a billet from the paste leaving the barrel. The billet formed like that has the same cross section of the housing (14). (Figure 26 and 27) [070] In a preferred embodiment of the invention, a separator (10) in the form of a wedge located outside the wall of the barrel in order to orient the paste leaving the same plodder (2) to separate inlets. This separator (10) preferably has the cross section of a equilateral triangle. When the paste reaches the peak of the triangle, it flows upwards and downwards equally towards the chamber inlets (5). [071] Soap leaving the barrel (4) as a billet having various layers is carried under the press by means of a conveyor to be cut as pre-formed bars to be ready for packaging. Here, the angle («) of axis of the billet (T9 and angle of the axis of the press (P) can be changed so as to create various visual effects on the soap bar by various angles of the soap layers to the soap axis. For instance, an angle of 0-89° between the axis of the billet and the axis of the press provides a diagonal layer on the soap bar. In case this angle is 90°, layers have the same angle to the soap axis. (Figure 28) [072] In another embodiment, the bars may be pressed twice or more after having rotated at an angle (Ml or M2 direction) following the first pressing step. Thus, more complicated layers can be produced. (Figure 29) [073] Soap pastes flowing from separate plodders may have the same or different features like humidity, fatty acid saturation and others. [074] Although the apparatus according to this invention has been described by specific reference to soaps, it may be used for other products as described herein. [075] The components of the apparatus may be uniformly or separately produced. [076] Susceptibility into Industry [077] Soap base is in liquid phase having a humidity of 30-32 % and at a temperature of 80-85 0C. After the neutralization stage, some additives are added to the soap and the acidity (pH) is adjusted. Afterwards, soap paste is pressed to stock tanks and then to the drying unit. [078] At the drying unit, the toilet soaps are dried to a humidity of 15-16% and the bath soaps to 24-25%. Soap is then subjected to stripping and extruded from a drying plodder. [079] While passing through the screen of the drying plodder the soap takes the form of a soap pasta as the knife in the form of a rotating fan. Then, this soap pasta is taken into the tanks and then poured to the helical upper conductor of the MC apparatus. The sensor of the system prevents the spills and excess amount. [080] In the upper helical tube of the MC apparatus, soap moves under the pressure formed because of the rotation of helical tube and kneaded during which stage coloring matter, fragrance and other additives are added. Soap paste flows out of the screen at the end of the helical tube by pressure after passing through the MC apparatus. [081] A knife in the form of a fan in front of this screen splits and cuts the paste and the soap paste is formed as sticks having specific size. During those stages fragrance, dye and other additives are added and intermixed thoroughly. Soap paste in the form of sticks become more homogenous and suitable as the process advances. [082] The soap paste passes through the two nozzles respectively is poured over to the carrying conveyor at the outlet of the MC apparatus and carried to the upper nozzle of the apparatus called the plodder (2). [083] Here, it is kneaded in a similar manner via the drive and rotational forces of the helical tubes and gains a homogenous structure. It passes through the screen at the end of the upper nozzle and cut by means of the knife having the form of a fan at the end of the screen and for the third time, soap paste in the form of sticks having the same size is obtained. This paste is poured to the lower nozzle of the plodder (2) which is under vacuum. [084] This vacuum effect at this stage of the process is very important as air entrapped in the soap paste is taken out by vacuum and bubbling, cracks, splits and collapses due to entrapped air are thus prevented. Still in the same manner, soap is kneaded via the drive and rotational forces of the helical tubes and proceeds. At this stage screen and knife lie a fan are not present. Soap paste passes through upper and lower nozzles of the MC apparatus and upper and lower nozzles of the plodder. [085] At the last stage namely at the outlet of the lower nozzle of the plodder (2) there is a oily heater. This heater heats the soap paste to a temperature of 70-8O0C. Soap paste including fragrances, coloring matters and additives flows into to the barrel located at the outlet via the temperature and vacuum caused by the continuous working of the system. [086] The same process as described above are repeated in a different MC apparatus and plodder (2) the same manner for the second soap paste having different fragrance, coloring matter and additives other than that of the first soap paste. [087] This second MC apparatus and plodder are located with an angle of 900C to the first MC apparatus and plodder. Just at the junction point of the line a barrel (2) is located at an angle of 900C through which soap pastes having different fragrance, dye and additives are intermingled. [088] Two soap pastes having separate coloring matter and fragrance pass through separate plodder nozzles (3) and meet at a special barrel and this barrel thanks to its unique design intermingles the soap pastes and thus a soap billet is obtained having stripes of different colors and of specific designs. [089] Soap paste coming from the drying tanks to the MC apparatus at direction "X" and passing to the plodder intermingles with the other soap paste coming from direction "Y" at the junction point "XY". [090] For intermingling, one of the soap pastes which is heated to a temperature of 60-80° C and proceeds under vacuum with the pressure of helical tubes in the X direction enters into the barrel (5a) and fills into one of the chambers (6a) and flows fast under vacuum to a direction of x. [091] Soap paste having different coloring matter, fragrance and additives flows from the inlets at the upper and lower walls of the barrel into the chambers (6b-6i) protruding into the main chamber (6a). [092] Soap flowing in the direction of "X" hits the walls of the chambers (6b-6i) which are closed to the soap paste coming from the X direction but open to the other side. Therefore, as the soap paste hits these chambers, cavities are formed in the soap base volume of which is equal to the chamber. In to these cavities, other soap paste coming from the other plodder and side chambers (6b-6i) fills in. Thanks to the heaters on the nozzles of the plodder the soap base that has already been heated up to 60-800C are in¬ termingled because of the vacuum in the chambers. [093] As the system is continuous, soap proceeds under a constant flow rate mixes at the outlet (7) under vacuum and leaves the outlet as color stripped soap billet. [094] The distance between the chambers opening to the side walls of the barrel hor¬ izontally and vertically is very important as it affects the thickness of the soap layers and may cause formation of cracks and splits at the junction point of the layers. [095] In case the vertically extending chambers are combined, the layers split as the layers coming from the X direction will loose contact with each other. Preferably the distance between the chambers horizontally and vertically are 0.1 to 5 cm. [096] The striped soap may combine cream soap and fragranced soap at the same time and the user may benefit from the softening and nourishing effect of the soap and enjoys the fragrance as well. During use, namely when the soap is lathered with water, all the intermingled layers (2) lather and melts equally. [097] The striped soap has the very same effects of a conventional soap as far as cleaning, removing dirt are concerned and it is not detrimental to skin. [098] The user benefits from the visual effect of the striped soap as well. [099] No additive, binder or intermediate layer whatsoever is used to intermingle the separate colored soap layers to each other.