A journey called RogFree
Let me take you through the journey called RogFree, from the time the used soap is collected to its rebirth and new life as a RogFree soap.
- Batches of used soaps are first cleaned manually by the workers. They use a sharp blade and various brushes to remove the upper layer and dirt sticking on the outer area.
- The cleaned soaps are pressed in a crusher which uses heat to turn them into a softer mixture. This process ensures accurate balance of moisture and softness in the soap.
- The crushed soap mixture like dough is fed into a large Mixing machine called "Roll Mill" at 80-degree Celsius along with water to gain 14% moisture. The homogenized soap mixture comes out in thick ribbons after 15 minutes of processing. Hard water is never used because the unwanted substances within the water could take part in the reaction. Although the amount of water doesn't need to be exact for successful soap making, too much water can cause the soap to become soft while too little water can cause the soap to become caustic and dry.
- The thick ribbons are then added to Plodder machine where extrusion dye is added as per soap grammage and quantity needed. The machine which uses a simultaneous process of cooling and heating, processes the soap material at 60-degree Celsius and produces the soap as thick roundels called soap noodles or soap rods. The noodles from the refining plodder are compressed under considerable pressure by the action of the screw (worm) forcing the soap through a warmed conical chamber and then through a die shaped to suit the cross section of the eventual soap rod. Vacuum plodder is the main equipment for the final refining, compacting & air free extrusion of a continuous bar. It plays a major role and gives a final shape in bar form to soap mass. End of the conical compression head is heated by electrically heated oil bath chamber under the control of a temperature controller to get glossy surface on the soap bar. The roundels come out as long blocks of 15 cms each which are held straight to maintain a firm texture.
- The big roundel blocks are cut further into pieces of 2 cms each in a Wire Machine that uses a sleek metal thread for cutting them finely.
- Soap roundels are then put into a stamping machine one by one. Each piece is put into a dye mould and pressed by a large hammer to get the required shape, size and imprint.
- The round soap cakes are sent for cleaning & sorting that happens manually with blades and brushes. This process checks consistency in shape, look and cleanliness of the bars.
- Post clearance from the sorting process, the soap cake is put into 'RogFree' packaging wrapper which also mentions the ingredients of the soap. Each pack is then sealed through a heated sealing machine at 180-degree Celsius.
- The finished product is distributed to the end user