Field of the Invention
The present invention relates to a modified cooling-ejection system for obtaining soap cast
products. More particularly the present invention relates to a modified cooling-ejection system
for obtaining soap cast products with flexible cross-section by provisioning the cavity module as
change-part.
Background and the Prior art
The soap manufacturing process traditionally has been carried out by Cast-and-Stamp route,
cooling-ejection system i.e. by extrusion or by casting routes.
The soap manufacturing process via cast and stamp route entails pouring of soap melt into a
cuboidal tank. The base of tank comprises of an array of movable pistons which moves down to
allow entry of soap melt into tubular cavities with oval or any fixed cross section. The vertical
tubes (moulds) are submerged into a cuboidal shell provided with inlet and outlet ports for a
suitable coolant (glycol water solution) to ensure rapid cooling of soap in the moulds. The
vertical tubes are welded to the base plate with array of desired cross-section at the two ends of
cuboidal shell and also supported at the center with a similar base plate.
Coolant flows through the cuboidal shell in two sections (separated by the middle base plate).
Post sufficient solidification time, the pistons (provided with a flexible rubber gasket) move
upwards and in the process eject the solidified soap bars (called as candles); which are then
transferred to the downstream finishing operations.
US 2011/0278429 relates to a system and a process for continuous casting of melt cast
compositions such as soaps, detergent tablets and the like, and in particular to a system and
method for continuous casting of such melt cast compositions involving solidification and

shaping of the melt composition during traverse of the melt through a mould. This would favor
continuous and effective mould filling and release, and also flexibility in generating a wide range
of such cast products, i) a substantially vertically disposable mould unit to favour
solidification/casting of the melt cast product during an upstream motion through the mould unit;
ii) the mould unit operatively connected at its lower end to a supply source of the melt-cast
product; iii) means for controlling the temperature of a melt in the mould unit to achieve the
desired solidification and shaping during traverse of the melt from the bottom of the mould
towards the top thereof, which is adapted to eject the formed cast product; and iv) wherein the
fatty acid soap melt-cast product cannot be readily stamped and shaped into tablets or bars
following extrusion.
US 2006/0151748 provide a process to prepare a multi-phase cast solid detergent log capable of
being cut into plurality of bars comprising:
i. positioning a rigid insert into a rigid elongate mould wherein the insert is substantially co-
extensive with the mould, to define a cavity in the elongate mould;
ii. filling melt of first detergent composition into the cavity;
iii. cooling the detergent composition to promote solidification of the melt;
iv. ejecting the insert to define a cavity;
v. filling melt of second detergent composition into the cavity;
vi. cooling the melt to promote solidification; and
vii. ejecting the solid detergent log from the elongate mould.
A process to prepare multi-phase cast solid detergent log which is capable of being cut into a
plurality of bars in a rigid elongate mould is provided. Cross-section of the mould is chosen
based on the desired shape of the detergent bar. Although any shape may be used, the most
preferred cross-sectional shapes of the rigid elongate mould are rectangular, square, circular and
oval. The rigid elongate mould is capable of being cooled to ensure that the molten detergent
composition filled therein can be efficiently cooled and solidified. Preferred cooling arrangement

is jacketing the mould, and cooling is enabled by circulating cooling water through the jacket. A
preferred arrangement of the mould is the Schicht cooler.
US5589130 relates to a preform injection-molded in the injection molding station is cooled by
the injection cavity mold and injection core mold, and thereafter the preform is released only
from the injection cavity mold. Thereafter the preform is transferred by means of the injection
core mold to the cooling and ejection station. Both during the transfer and in the cooling and
ejection station, the preform is cooled by the injection core mold, and thereafter the preform is
ejected.
US4363769 (herein referred to as '769) teaches a method of manufacturing a thin ribbon wafer
of semiconductor material having a fine microscopic structure of high density in a high speed, by
melting semiconductor material, ejecting the melt of semiconductor material through a nozzle
and quickly cooling said melt on "a surface of a moving or rotating cooling substrate.
The cooling ejection system of consists of a heat resisting tube, a nozzle, a heater, a
thermocouple, moving or rotating cooling substrate. The melt is rushes through the nozzle into
the tube.
In the above candle cooling ejection system, separate coolers to obtain candles of varying cross
section are required. Flexibility with the shape of the soap is required to cater change in needs.
Continuous process has been mentioned in prior art wherein the soap tube ejection happens due
to traverse motion of the soap mass due to pressure difference upstream and downstream.
However there is a need to develop a batch process of solidification and ejection of soap candles
with varying cross-sections obtainable via replacement of cavity tubes in the same cooler system
that provides flexibility of operation with a single cooler system and change-part as boltable
tubes. Another unique feature of the present invention is the idea of using a common coolant
jacket space between the Neck Mould (fixed larger cross-section tube) and the changing Cavity
Moulds (desired cross-section tubes) which are appended together using bolt-plates. This way
the same outer shell for cooling material in tubes of different cross-sections can be maintained.

Object of the Invention
It is an object of the present invention to overcome the drawbacks of the prior art.
It is an object of the present invention to provide a modified cooling-ejection system for
obtaining soap cast products with flexible cross-section by provisioning the cavity module as
change-part.
It is yet another object of the present invention to provide a method of producing soap by
solidification and ejection of soap candles from varying cross-sections obtainable via
replacement of cavity tubes in the same cooler system that provides flexibility of operation with
a single cooler system in a modified cooling-ejection system.
It is a further object of the present invention to impart flexibility in terms of cross-sectional shape
of solidified candles. Change-parts with different cross-sections are envisaged in the form of
easy-to-change modular sections.
Summary of the Invention
The present invention relates to a soap casting System comprising of:
a. Circular jacketed pipes with inlet and outlet connections for coolant flow;
b. Vertical cavities, residing within the circular tube bolted at the top with the circular
jacketed pipe;
c. Hydraulic Cylinder attached to a piston ejection assembly which comprises of piston rods
with replaceable teflon heads;
wherein said system provides soap products with flexible cross section and said vertical cavities
are provided as change-part.
It is another aspect of the present invention to provide method of producing soap in a casting
system, comprising following steps of:

a) Moving the piston to the top of vertical cavities;
b) Pouring Soap Melt into the reservoir tank at a pre determined temperature and
lowering pistons to minimize foam generation;
c) Cooling water in the cuboidal shell, pouring over the melt;

d) Moving pistons upwards using the hydraulic system to produce a predetermined
pressure;
e) Ejection of the different candles from the differently profiled tubes.
Brief description of Accompanying Drawings
Fig 1: Candle Cooling-Ejection Set-up for solidification of Soap mass in vertical cavities
illustrating (1) material poured in vertical cavities at the top of reservoir (2) Hydraulic cylinder
assembly for ejecting out solidified candles (3) manual withdrawal of solid candles from the top.
Fig 2: Schematic of proposed Cooling- Ejection System illustrating (4) piston guide assembly (5)
hydraulic cylinder clamping screw (6) hydraulic cylinder (7) melt reservoir at the top (8)
weldment structure (9) piston-rod ejection assembly.
Fig 3: Top view of the upper Base plate showing two different cross-sectional tubes illustrating
(10) screw bolting on the base plate (11) round piston (12) inner circular tube cavity assembly
(13) inner rectangular tube cavity assembly (14) piston screw over piston rod (12) rectangular
piston.
Fig 3.A Product made by using two different cross sectional tubes
Fig 4: Cylindrical Jacketed Assembly for a Rectangular vertical cavity illustrating (16) bottom
plate (17) cylindrical jacketed tube (18) inlet for the coolant (19) outlook connection of the
coolent.
Fig 5: Inner Vertical Cavity Assembly illustrating (20) flange connection to the inner rectangular
cavity tube (21) guide support plate acting as fin for turbulence generation.

Fig 6. Flowchart explaining the method of production.
Detailed description of the invention
The present invention discloses a modified cooling-ejection system for obtaining soap cast
products with flexible cross-section by provisioning the cavity module as change-part. The
cavity module consist of
• Vertical tube with a desired cross section (oval circular, rectangular, square or any other 2
dimensional profile)
• Flange at the upper end with a common profile so as to bolt the tube with the upper base
plate
• Bottom portion of the tubes are profiled to settle perfectly on the rubber seal at the
bottom base plate
Piston arrangement with modular heads provided with rubber gasket for ejection of candles with
variety of cross sections.
Cooling- Ejection System is illustrated in figures where (4) piston guide assembly (5) hydraulic
cylinder clamping screw (6) hydraulic cylinder (7) melt reservoir at the top (8) weldment
structure (9) piston-rod ejection assembly (10) screw bolting on the base plate (11) round piston
(12) inner circular tube cavity assembly (13) inner rectangular tube cavity assembly (14) piston
screw over piston rod (12) rectangular piston (16) bottom plate (17) cylindrical jacketed tube
(18) inlet for the coolant (19) outlook connection of the coolent (20) flange connection to the
inner rectangular cavity tube (21) guide support plate acting as fin for turbulence generation are
depicted.
The inventive feature of the present patent resides in the shape flexibility that can be obtained by
changing the cooler tube unit instead of a separate cooler for separate shape and hence faster
response to market change. According to the present invention it is surprisingly found that using
a common cooler infrastructure and employing different cross-section tubes with bolt-plates and
piston heads allows flexibility of shapes of the final product without changing the whole

infrastructure. Also, a multiple tubes all with different cross-section can be cooled into a single
cooler and ejected out post solidification using a hydraulic cylinder and corresponding piston
arrangement with modular heads.
Basic premise is to design the cooler system for imparting flexibility in terms of cross-sectional
shape of solidified candles. Change-parts with different cross-sections are envisaged in the form
of easy-to-change modular sections.
The present invention specifically relates to a soap casting system comprising of:
a) Circular jacketed pipes with inlet and outlet connections for coolant flow;
b) Vertical cavities, residing within the circular tube bolted at the top with the circular
jacketed pipe;
c) Hydraulic Cylinder attached to a piston ejection assembly which comprises of piston
rods with replaceable teflon heads.
The said machine consists of a reservoir tank. The base of the tank comprises of an array of
movable pistons which moves down to allow entry of soap melt into tubular cavities with any 2-
D cross-section. The vertical tubes (moulds) are submerged into a cuboidal shell provided with
inlet and outlet ports for a suitable coolant to ensure rapid cooling of the soap in the vertical
cavities. Flanges are provided at the upper end of the tubes (which can be of different cross-
sections) with a common profile so as to bolt the tube with the upper base-plate. Bottom portion
of the tubes are profiled to settle perfectly on the rubber seal at the bottom base-plate.
Piston arrangement with modular heads (profiled as per the tube cross-section) is provided with
rubber gasket for ejection of candles with variety of cross-sections. Piston module could be
replaced from the top by removing the head by the help of screws when the piston is at its
uppermost position.
Figure 1 shows Candle Cooling-Ejection Set-up for solidification of Soap mass in vertical
cavities illustrating (1) material poured in vertical cavities at the top of reservoir (2) Hydraulic
cylinder assembly for ejecting out solidified candles (3) manual withdrawal of solid candles from
the top.

The pipe-in-pipe type of arrangement of the present invention with a singular coolant system
provides uniformity and avoids any dead zones in the system.
Coolant flows through the cuboidal shell in two sections (separated by the middle base plate).
Post sufficient solidification time, the pistons (provided with a flexible rubber gasket) move
upwards and in the process eject the solidified soap bars (called as candles); which are then
transferred to the downstream finishing operations.
Unique feature of the present invention is the use of a common coolant jacket space between the
Neck Mould (fixed larger cross-section tube) and the changing Cavity Moulds (desired cross-
section tubes) which are appended together using bolt-plates.
Present invention offers advantages in terms of:
• Manufacture of candles with any desired 2-dimensional cross-section in a common
Cooling-Ejection System with replacement of the centre cavities and corresponding
piston heads. Hence, flexibility of production can be achieved.
• Minimal changeover time with the replacement of
o cavities which are bolted at the top flange on the base plate of rectangular
reservoir
o piston heads, which are screwed on piston rods, can be moved all the way to the
top position
• Uniform cooling of the candles in the pipe-in-pipe type of arrangement
o Guide support plate provides additional turbulence to the flow of coolant in jacket
and avoid any dead zones in the system
o Better control over the temperature difference, to which the melt in vertical
cavities is subjected, by modulating coolant inlet temperature and flow-rate
The present invention is now illustrated by way of non limiting examples.

Example 1:
Soap Melt is poured into the reservoir tank at 85°C and pistons are lowered slowly to minimize
foam generation due to the motion. Cooling water in the cuboidal shell enters at 8°C and leaves
at 10°C. Post 50 minutes of residence time, the melt is cooled upto 27°C and pistons are moved
upwards using the hydraulic system. Pressure is applied at 400 psi resulting in smooth ejection of
the different candles from the differently profiled tubes such as circular tubes (diameter 60mm),
rectangular tubes (50mm x 80mm) and an irregular shape (Shell-like profile) bolted on the base
plate along with suitable piston head designs.

WE CLAIM:
1. A soap casting system comprising of:
a) circular jacketed pipes with inlet and outlet connections for coolant flow;
b) vertical cavities, residing within the circular tube bolted at the top with the circular
jacketed pipe;
c) hydraulic Cylinder attached to a piston ejection assembly which comprises of piston
rods with replaceable teflon heads;
wherein said system provides soap products with flexible cross section and said vertical
cavities are provided as change-part.
2. The soap casting system as claimed in claim 1, wherein the teflon head is designed as per
the 2-D profile of the vertical cavity.
3. The soap casting system as claimed in claim 1, wherein the teflon heads which can be
tightened onto the piston rod via screw mechanism.
4. The soap casting system as claimed in claim 1, wherein flexibility in terms of cross-
sectional shape of solidified candles is obtained by easy-to-change modular sections.
5. The soap casting system as claimed in claim 1, wherein pipe-in-pipe type of arrangement
provides uniformity and avoids any dead zones in the system.
6. A method of producing soap in a casting system of claim 1, comprising the steps of:

a) Moving the piston to the top of vertical cavities;
b) Pouring Soap Melt into the reservoir tank at a pre determined temperature and
lowering pistons to minimize foam generation;
c) Cooling water in the cuboidal shell, pouring over the melt;

d) Moving pistons upwards using the hydraulic system to produce a predetermined
pressure;
e) Ejection of the different candles from the differently profiled tubes.

7. The method of producing soap in a casting system as claimed in claim 6, wherein the said
predetermined temperature in step (a) is in a range of 70°C to 90°C
8. The method of producing soap in a casting system as claimed in claim 6, wherein the said
predetermined pressure in step (c) is in a range of 300 psi to 600 psi.

ABSTRACT

The present invention relates to a soap casting system comprising of:
a) circular jacketed pipes with inlet and outlet connections for coolant flow;
b) vertical cavities, residing within the circular tube bolted at the top with the circular
jacketed pipe;
c) hydraulic Cylinder attached to a piston ejection assembly which comprises of piston
rods with replaceable teflon heads;
wherein said system provides soap products with flexible cross section and said vertical cavities
are provided as change-part.
The present invention further provides a method of producing soap in a casting system,
comprising the steps of:
a) Moving the piston to the top of vertical cavities;
b) Pouring Soap Melt into the reservoir tank at a pre determined temperature and
lowering pistons to minimize foam generation;
c) Cooling water in the cuboidal shell, pouring over the melt;
d) Moving pistons upwards using the hydraulic system to produce a predetermined
pressure;
e) Ejection of the different candles from the differently profiled tubes.