Soap is one of the most commonly used products in each household beautiful aromas and colors and various forms and textures transform washing of a body into a pleasant ritual. It nourishes and moisturizes our skin but its main function is to remove dirt and microbes during the pandemic .
It has become an essential commodity have you ever wondered how it’s manufactured today.
In this blog we will tell you how liquid soap is manufactured in factory scale. Let’s see how soap is manufactured the entire process. It starts at the Formula department where the formulation is developed and prototype samples are prepared the laboratory develops a formulation with ingredients. Including water surfactants responsible for example a soap forming and active ingredients like extracts vitamins or essential oils.
When the formulation is developed application tests must be performed with a panel of testers as well as tests on relevant equipment. only after their successful completion can the product be launched into the market. The large scale production begins raw materials required for production are delivered to the plant by tankers and the entire unloading dosing and weighting system is automatic.
Raw materials are unloaded to relevant tanks located in a designated zone in the warehouse . Then they are automatically weighed and dosed to a mixer. Those used in smaller quantities such as pigments or extracts are dosed using buckets the system is controlled with a data scanner to avoid mistakes.one of the key ingredients used in the production is water bodies determine technology water distributed in the mixing department.
Continuously circulates preventing development of microorganisms its parameters similarly as of other raw materials are continuously monitored a sample of the products prepared in the mixer. It is delivered to the quality control department where its parameters are verified against the specification their viscosity density PH, color or aroma are verified. when all test results are positive the product is released from the mixer and supplied to a storage tank . Pipelines are equipped with a system of cleaning pistons that thoroughly push all soap to the product tank this way no soap is wasted and much less water is used to clean the entire system . when the cosmetic mass ready it’s time to pack it at the cerapol cosmetics products section are packed on several dozen production lines installed at two plants pouring lines can be classified . According to a packaging type first it will see how popular doy packs are filled. A printed film from a roll passes through a system of tensioners then is automatically folded and sealed at its edges then a cap is sealed. This way a sachet is formed which is later filled with liquid.
Finally the top edge is sealed and the finished product is placed on a belt conveyor several dozen millions pieces of products leave these lines every year.
Now it will see how soap is poured into bottles packaging is also manufactured on site in the plant pet HDPE and recycled R pet granules are used. when material is plasticized a preform is molded which is then blown a robot collects a bottle and places it on a transport line.
At the next station soap is poured into bottles as three different types of soap can be poured simultaneously then the bottle is closed with a cap . With a pump and then a label is applied before the soap leaves the line the finished product. Inspection is performed an employee of the quality control department verifies the product against a specification at random intervals. Then the cartons with soap are packed on pallets. This packed soap transported to the finished product warehouse. Obviously cosmetics produces soaps manufactured at the plant can be found on shelves of the most recognized retailers in World.