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SOAP CHILL ROLLS / DRUM FLAKER
Chill Rolls, also known as Soap Drum Flakers, are used in soap manufacturing to rapidly cool and solidify neat soap. These machines produce soap flakes directly from hot liquid soap, providing an efficient cooling solution for soap manufacturing.
Chill Rolls – Drum Flakers for Soap Manufacturing
Chill Rolls, also known as Soap Drum Flakers, are machines used in soap manufacturing to cool and solidify soap coming from the saponification plant. Before the introduction of the Soap Vacuum Drying Plant, Chill Rolls were used mainly for producing laundry soap bars with low TFM (Total Fatty Matter). A Chill Roll cannot adjust the moisture content of the soap; its function is specifically to cool and solidify the soap coming from the saponification process. For this reason, before the development of the JET Saponification Plant, Chill Rolls could not be used to produce toilet soap with high TFM.
Chill Rolls and JET Saponification
The introduction of the JET Saponification Plant changed the possible applications of Chill Rolls. JET technology makes it possible to produce concentrated neat soap containing the required moisture level. Because the soap already has the required concentration, it does not need to pass through a Vacuum Drying Plant for further moisture removal. The soap only needs to be solidified, making Chill Rolls a suitable solution for cooling the concentrated soap produced by the JET saponification process. For this reason, several soap factories have adopted Chill Rolls instead of Vacuum Drying Plants in applications where the JET process produces soap with the required moisture content.
Soap Drum Flaker Construction
The Soap Drum Flaker consists of two special counter-rotating stainless-steel drums, each equipped with an internal cooling jacket. Cold water circulates inside the drums in a spiral pattern along the internal surface. This arrangement provides uniform heat transfer throughout the drum. The drums are equipped with rotary joints that allow proper water distribution and continuous water recycling in a closed circuit when a water chiller is used. Each drum is driven by an independent motor-reducer. The product discharge conveyor also has its own drive. The independent drives simplify maintenance and provide greater flexibility during operation.
Soap Cooling and Flaking
The neat soap is pumped on the two counter-rotating rolls, which distribute the product evenly between their surfaces. The soap forms a thin layer approximately 0.5 mm thick. This layer is rapidly cooled and solidified as it comes into contact with the cooled rolls. The blades scrape the solidified soap from the drum surfaces. The soap falls onto the discharge conveyor belt in the form of flakes. The Chill Rolls are suitable for producing soap flakes from neat soap at approximately 90°C.
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