Detergent Powder Plant

DETERGENT POWDER MEANS: -

Defining, detergent  powder is in the form of a powder that is used to wash clothes, utensils, floors and fabrics etc. It is also known as washing powder or laundry powder.

Detergent powder is one of the most traditional washing agent, with two main advantages: cheaper and power against heavy stains.

MANUFACTURING PROCESS: -

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(A)  DRY MIXING: -

Soda Ash and Sodium Carbonate in required proportions are mixed inside a mixer usually in Plough Share Mixer (PSM) for 2-5 minutes. After that Acid Slurry commonly known as LABSA (Linear Alkyl Benzene Sulphonic Acid) is added slowly through spray nozzles in required quantity and duration. The neutralization of soda ash and acid slurry starts and as a result of exothermic reaction temperature of the mixture increases and its colour becomes brownish. The agglomeration or granulation takes place inside the mixer due to its shape and rotation of ploughs.

Plough Share Mixer consists of a stationary horizontal shell with rotating shaft. Ploughs and scrapper are fitted with the shaft at different orientations. The shape and speed of ploughs are determined based on proper mixing and agglomeration of the powder should take place. High speed Choppers are fitted with the shell at a proper angle so that the lumps formed during mixing can be cut and reduced in size. For charging and discharging materials suitable size of nozzles and door is provided. For liquid injection nozzles with header pipes and spray nozzles are fitted.

The drive unit consisting of Motor and Gear Box with suitable reduction ratio are fitted with the shaft.                                                            

Some other additives are also added in the mixer to enhance the different properties of the detergent powder like-

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Builders and Fillers-

Some builders like sodium silicate are added to increase the efficiency of surfactants as well as to prevent corrosion inside the washing machine. Soluble salts which neutralizes acids are combined with surfactants to make a base of laundry detergent suitable for stain removal.  STPP (sodium tripolyphosphate) is also used as a builder. Sodium hypochlorite solution used as a bleaching agent are also added, which helps in making the product whiter and brighter.    

Surfactants-

Surfactants expedites the cleaning action of the detergent powder. It is used to create foams  which helps dirt particles to keep suspended and can be thrown out of the cloth with the help of water jet. LABSA is commonly used as surfactant. Some other surfactants are SLES (Sodium Lauryl Ether Sulphate), Alpha Olefin Sulfonate (AOS).

Enzymes- It strengthens the power of detergent powder against soil, dirt. It reduces washing time and gives better result at room temperature.

Silica- Anhydrous silica fumes are used to increase the flow ability or in other words it helps in making the detergent powder “free- flowing”.

The proportions of these ingredients depend on the final product and brand name.

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(B)  Sieving: -

After the mix powder comes out of the mixer, it is stored for some time in big silos for cooling. This powder is hygroscopic in nature. It is important that it should be prevented from absorbing moisture from atmosphere. For transportation bucket elevators or conveyor belts are commonly used.

A Vibro Siever is an equipment which segregates the powder size wise. It is equipped with different size of mesh decks used as filters, stacked one over another. A mesh size of 8-30 nos. are commonly used. Material is poured on the top of the deck and it moves towards nozzles due to its vibratory motion. During the travel it gets filtered and separated according to different wise.  

 The cooled powder is fed to the vibro sievers   where oversized particles are separated. Almost 10-20% of the total powder separated (oversized) are sent to cage mill for size reduction.

The best detergent powders are lightweight and have good free-flowing properties. Their average bulk density ranges between 0.8 – 0.9 gm/cc, comprising hollow particles with dimensions of 0.2 - 2.5mm. This detergent powder is sent to Rotary Blender for further process.

( C )  Size Reduction :-

 A Cage Mill is the equipment meant to break the oversized particles or lumps which are formed during mixing process in the PSM. After sieving, the oversized or lumps in the detergent powder is separated and passed through the cage mill. The powder is charged from top and discharged from bottom.  Inside the Cage Mill there is a rotating part which breaks the lumps into small particles.