Abstract:
Mechanical soap plodders refine, homogenize, and compact soap. Processing
pressure, screen mesh size, and L/D affect plodder capacity and soap quality. Grittiness, air
bubbles, and poor surface finish hinder soap production. This study optimised soap plodder
machine screw length, speed, and density to maximise pressure at low-temperature. Soap
plodder FEM was made with ANSYS Polyflow software. The rheological and thermal
properties of soap paste were measured with a rotational viscometer and transient hot wire.
Viscosity, thermal conductivity, and heat capacity were 900 cps, 0.0449 W/m-K, and 17.29
J/Kg-K. A L9 Taguchi DOE was used for three screw speeds (20, 35, and 50 RPM), screw
lengths (300, 550, and 800 mm), and soap product densities in FEM simulation. ANOVA and
Taguchi optimization modelling were adopted for analysis. The ANOVA showed a positive
correlation between extrudate pressure, screw length, speed, and density. Temperature was
mostly density-dependent. Ideal conditions were 800 mm screw length, 50 RPM screw speed,
and 900 kg/m3 material density. Response pressure was 4.3604 bar, temperature 315 K. The
observed responses would optimize soap plodder pressure, improving refining,
homogenization, and soap processing with small mesh screens. The low temperature
eliminates the need for a cooling jacket, reducing construction and operating costs