CLIAMS:1. A method for manufacturing soaps by extruding a plurality of soap materials, the method comprising:
mixing a viscous base soap material with a viscous colored soap material in a mixer to obtain a mixed soap material, wherein the mixed soap material is of a predefined pattern, and wherein the predefined pattern includes stripes of the viscous base soap material and stripes of the viscous colored soap material;
extruding the mixed soap material through the die, wherein the extrusion generates the soap waste;
extracting the soap waste generated in the extrusion;
changing a color of the soap waste to obtain recycled viscous colored soap material, wherein the color of the recycled viscous colored soap material is changed to that of the viscous colored soap material; and
feeding the recycled viscous colored soap material along with the viscous base soap material to the mixer.
2. The method as claimed in claim 1, wherein the viscous base soap material is obtained by:
refining a base soap material to obtain a refined soap material, wherein the base soap material is refined by rolling; and
processing the refined soap material to obtain the viscous base soap material, wherein the viscous base soap material is in form of continuous soap paste, and wherein the viscous base soap material is of such a texture that the viscous base soap material can be extruded through a die.
3. The method as claimed in claim 1, wherein the changing the color of the soap waste comprises:
adding a first predetermined quantity of color additive to the soap waste for changing the color of the soap waste from a first color to a second color, the second color being the color of the viscous colored soap material, and wherein the first predetermined quantity of color additive is based on at least one of dosing pump frequency, stroke length and number of operating nozzles.
4. The method as claimed in claim 1, wherein the viscous colored soap material is obtained by:
extracting a portion of the refined soap material;
changing a color of the portion of the refined soap material to an intermediate color to obtain a viscous intermediate colored soap material, wherein the intermediate color is a lighter shade of the color of the recycled viscous colored soap material;
further changing the color of the viscous intermediate colored soap material from the intermediate color to the color of the recycled viscous colored soap material; and
processing the viscous intermediate colored soap material to obtain the viscous colored soap material, wherein the viscous colored soap material is in form of a continuous soap paste, and wherein the viscous colored soap material is of such a texture that the viscous base soap material can be extruded through a die.
5. The method as claimed in claim 4, wherein changing the color of the refined soap material includes adding a second predetermined quantity of color additive to the refined soap material based on at least one of dosing pump frequency, stroke length and number of operating nozzles.
6. The method as claimed in claim 4, wherein further changing the color of the refined soap material includes adding a third predetermined quantity of color additive to the refined soap material based on at least one of dosing pump frequency, stroke length and number of operating nozzles.
7. The method as claimed in claim 1, wherein the color of the viscous base soap material is white.
8. The method as claimed in claim 1, wherein a Liquid Solid Marbelization technique is used to change color of the soap waste to that of the viscous colored soap material.
9. The method as claimed in claim 1, wherein extracting the soap waste further comprises extracting soap waste from a soap stamping unit.
10. A soap extrusion system (100) for manufacturing soaps by extruding a plurality of soap materials, the soap extrusion system (100) comprising:
a triple roll mill (106) to refine a base soap material to obtain a refined soap material,
a base plodder (108) comprising least one plodder, coupled to the triple roll mill (106), to receive a portion of the refined soap material, wherein the base plodder (108) is to process the refined soap material to obtain a viscous base soap material; and
a recycle plodder (118) comprising least one plodder, coupled to the triple roll mill (106), to receive a remaining portion of the refined soap material, wherein the recycle plodder (118) is to process the refined soap material to obtain a viscous intermediate colored soap material;
a color plodder (110), coupled to the recycle plodder (118), to process the viscous intermediate colored soap material and soap waste to obtain a viscous colored soap material and wherein the viscous colored soap material is in form of continuous soap paste, wherein the color plodder (110) is to change a color of the viscous intermediate colored soap material and the soap waste to that of a color of the viscous colored soap material; and
a mixer (112) comprising a mixer inlet and a mixer outlet, wherein the mixer inlet is to receive the viscous base soap material and the viscous colored soap material for extrusion, wherein the mixer (112) is to mix the viscous base soap material and the viscous colored soap material to obtain a mixed soap material of a predefined pattern, wherein the mixer outlet is to extrude the mixed soap material, and wherein the extrusion generates the soap waste.
11. The soap extrusion system (100) as claimed in claim 10, wherein the recycle plodder (118) further comprises one or more dosing pumps to add color additives to the remaining portion of the refined soap material to obtain the viscous intermediate colored soap material, the viscous intermediate colored soap material being of a lighter shade of the viscous colored soap material, and wherein the dosing pumps add a predetermined quantity of the based on at least one of predetermined dosing pump frequency, stroke length and number of operating nozzles of the one or more dosing pumps.
12. The soap extrusion system (100) as claimed in claim 10, wherein the triple roll (106) mill comprises three rolls, wherein the three rolls include a feed roll, a center roll and an apron roll.
13. The soap extrusion system (100) as claimed in claim 10, wherein the base plodder (108) comprises two plodders.
14. The soap extrusion system (100) as claimed in claim 10, wherein the color plodder (110) comprises a drill plate, wherein the drill plate is to change the color of the refined soap material to the color of the viscous colored soap material.
15. The soap extrusion system (100) as claimed in claim 10, further comprising a marbelization unit (120), wherein the marbelization unit (120) comprises multiple dosing pumps to change the color of a viscous intermediate colored soap material.
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