Design and Modelling of Soap Bar Making Machine

BAHIRDAR UNIVERSITY
BAHIRDAR INSTITUTE OF TECHNOLOGY

FACULTY OF MECHANICAL AND INDUSTRIAL ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
DESIGN AND MODELING OF SOAP BAR MAKING MACHINE
BY:
Name ID NO
1.Yalemsew Tebik………………………1102305
2.Abrham Haileyesus……………………1102217
3. Melkamu Dagnachew………………....1103358
Advisor:
Melak Misganaw(MSc)
A Final Year Project Submitted to the faculty of Mechanical and Industrial Engineering
at Bahirdar Institute of Technology-Bahirdar University in Partial Fulfillment of the
requirements for the Degree of Bachelor of Science in Mechanical Engineering
June 8, 2015 E.C

Bahirdar, Ethiopia
DECLARATION
We declare that this thesis project entitled Design and Modelling of Soap Bar Making
Machine is our own original work carried out under the supervisions of Melak Misganaw
(MSc). It is being submitted to the Faculty of Mechanical and Industrial Engineering for the
Degree Bachelor of Science in Mechanical Engineering. The part of this project has not been
submitted before for any degree or evaluation to other University.
Name of student Signature Date
1. Yalemsew Tebik ________________ _________________

2. Abrham Haileyesus _________________ _________________
3. Melkamu Dagnachew _________________ _________________
This thesis has been submitted for examination with our approval.
Advisor Name _______________________
Advisors Signature ___________________
i
APPROVAL
BAHIRDAR UNIVERSITY
BAHIRDAR INSTITUTE OF TECHNOLOGY
FACULTY OF MECHANICAL AND INDUSTRIAL ENGINEERING
MECHANICAL ENGINEERING PROGRAM
This is to certify that the thesis prepared by Yalemsew Tebik, Abrham Haileyesus and Melkamu
Dagnachew entitled “Design and Modelling of Soap Bar Making Machine” submitted in
fulfillment of the requirements for the degree of bachelor of science in mechanical engineering
complies with the regulation of university and meets the accepted standards with respect to
originality. Signed by examination commetee.
Name Signature Date

____________________________________________________________
Advisor:
____________________________________________________________
Examiner
____________________________________________________________
Chair person
ii
ACKNOWLEGMENT
First and foremost, we would like to thank the Almighty God for giving us the strength, ability
and courage to carry out this thesis successfully. Secondly, we would like to thank our advisor,
Melak Misganaw(MSc) for his motivation, support, advice, positive approach and his great
contribution by giving us all crucial information and continuous follow up for the success of
this paper.
Finally, we appreciate and thank our beloved families for their whole support.
iii
ABSTRACT
The soap bar making machine is a machine comprising mixer part, plodder part and manually
operated cutter part is used to produce solid soap bar. It synchronizes two functions namely
mixing and soap plodding (soap extrusion) in a single unit by using one motor for the mixer
and plodder part together. In this paper the working model of soap machine introduced. The
mixture of material used for soap is supply to the machine through hopper and it pushed forward
due to geometry of screw. As the material was pushed, it gets compressed and compacted soap
bar comes out of die. The project’s intent is to design soap bar making machine, mixer with
screw extruder that performs two operations together. This machine can be operated electrically
and it is capable of producing 140kg per hour soap bar. The scope of the project is on the detail
design and analysis of each components and draw out the part and assembly drawing. Finally
prepare working animation for the designed soap making machine. Methodology used in the
study involves collection of resources from different sources to obtain important data for the
project and having a guideline on the steps involved in the design. Among the sources of
information looked at is the internet, published books and journals. The results obtained
demonstrated that the screw conveyor has a capacity of 140Kg /hour and mixer mixes 35Kg of
soap ingredients per batch and the machine requires a motor with power rating of 10hp running
at 900rpm to operate effectively. The total cost of producing the machine before establishing
the profit is 265,210ETB. From comparison between the new and the existing machine, it was
found that when using the modified machine, the required production area and operating cost
are reduced. Finally, we conclude that the modified machine has potential to replace the
traditional machines in the soap making industry due to higher capacity and lower price of the
modified machine.
Key words: Soap bar making machine, Plodder and Extruder
iv
TABLE OF CONTENTS
DECLARATION ......................................................................................................................... i
ACKNOWLEGMENT ..............................................................................................................iii
ABSTRACT .............................................................................................................................. iv
LIST OF FIGURES .................................................................................................................viii
LIST OF TABLES..................................................................................................................... ix
LIST OF SYMBOLS .................................................................................................................. x
CHAPTER ONE ......................................................................................................................... 1
1.INTRODUCTION ................................................................................................................... 1
1.1 Background ....................................................................................................................... 1
1.1.1 The existing soap bar making machine in Ethiopia ....................................................... 2
1.2 Definitions and Types of Soap .......................................................................................... 3
1.3 Description of The New (modified) Soap Bar Making Machine ..................................... 3
1.3.1 Description of parts and its functions ............................................................................... 4
1.3.2 Working principle of the machine (our soap bar making machine) ............................. 6
1.4 Statement of The Problem ................................................................................................ 6
1.5 Objective ........................................................................................................................... 6
1.5.1 General objective ................................................................................................................ 6
1.5.2 Specific objective ................................................................................................................ 7
1.6 Significance of The Project ............................................................................................... 7
1.7 Scope of The Project ......................................................................................................... 7
CHAPTER TWO ........................................................................................................................ 8
2.LITRATURE REVIEW .......................................................................................................... 8
CHAPTER THREE .................................................................................................................. 10
3.METHODOLOGIES ............................................................................................................. 10
CHAPTER FOUR .................................................................................................................... 11
4.CONCEPTUAL DESIGN ..................................................................................................... 11
v
4.1 Needs and Requirements of the Customers .................................................................... 11
4.2 Concept Generation and Selection of Concepts.............................................................. 11
4.2.1 Solution variants and selection of variants

for the type of soap bar making machine ................................................................................ 12
4.2.2 Solution variants and selection of variants for the parts of the machine ................... 13
CHAPTER FIVE ...................................................................................................................... 19
5.COMPONENT DESIGN ....................................................................................................... 19
5.1 General Consideration of Design .................................................................................... 19
5.2 Material selection ............................................................................................................ 20
5.3 Design Analysis .............................................................................................................. 20
5.3.1 Screw conveyor ................................................................................................................. 20
5.3.2 Mixer Basin(vessel) .......................................................................................................... 23
5.3.3 Motor selection.................................................................................................................. 25
5.3.4 Pulley and belt ................................................................................................................... 26
5.3.5 Gear..................................................................................................................................... 32
5.3.6 Shaft .................................................................................................................................... 38
5.3.7 Hopper ................................................................................................................................ 46
5.3.8 Housing barrel ................................................................................................................... 47
5.3.9 Bearing selection ............................................................................................................... 47
5.3.10 The die .............................................................................................................................. 50
5.3.11 Cutter ................................................................................................................................ 50
5.3.12 Frame ................................................................................................................................ 51
CHAPTER SIX......................................................................................................................... 52
6.COST ANALYSIS ................................................................................................................ 52
CHAPTER SEVEN .................................................................................................................. 55
7.RESULT AND DISCUSSION .............................................................................................. 55
7.1 Result .............................................................................................................................. 55
7.2 Discussion ....................................................................................................................... 57
vi
CHAPTER EIGHT ................................................................................................................... 58
8.CONCLUSION AND RECOMMENDATION .................................................................... 58
8.1 Conclusion ...................................................................................................................... 58
8.2 Recommendation ............................................................................................................ 58
REFERENCE ........................................................................................................................... 59
APPENDIX 1 ........................................................................................................................... 61
LIST OF STANDARD TABLES ............................................................................................. 61
APPENDIX 2 ........................................................................................................................... 66
PART AND ASSEMBLY DRAWING .................................................................................... 66
vii
LIST OF FIGURES
Figure 1. 1 (a) Soap mixer machine and (b) Plodder machine .................................................. 2
Figure 3. 1 Sequences of design methodology……………………………………………….10
Figure 4. 1 3d view of the modified soap bar making machine………………………………18
Figure 5. 1 Mixer vessel………………………………………………………………………24
Figure 5. 2 Belt cross section ................................................................................................... 26
Figure 5. 3 Belts and Pulley...................................................................................................... 28
Figure 5. 4 Spur gear ............................................................................................................... 32
Figure 5. 5 Main shaft free body diagram ................................................................................ 39
Figure 5. 6 Vertical load diagram ............................................................................................. 40
Figure 5. 7(a) Von Misses Stress and (b) Displacements
for the main shaft of diameter 35mm ....................................................................................... 42
Figure 5. 8 Mixer shaft free body diagram ............................................................................... 43
Figure 5. 9 (a) Von Misses Stress and (b) Displacements
for the mixer shaft of diameter 40mm ...................................................................................... 45
Figure 5. 10 Hopper .................................................................................................................. 46
Figure 5. 11 Die ........................................................................................................................ 50
Figure 5. 12 Manual cutter ....................................................................................................... 51
Figure 5. 13 (a) Von Misses Stress and (b) Displacements for the frame ................................ 51
viii
LIST OF TABLES
Table 6.1 Material cost ............................................................................................................. 52
Table 6.2 Operation process cost ............................................................................................. 53
Table 6.3 Labor cost ................................................................................................................. 54
Table 7.1 Result…………………………………………………………………...………….55
Table 7 2 Comparison between the existing and the new system……………….……………57
Table A 1 Dimensions of standard v-belts according to is: 2494 – 1974 …………..………..61
Table A 2 Dimensions of standard v-grooved pulleys
according to is: 2494–1974. (all dimensions in mm) …………………………...……………61
Table A 3 Standard pitch length of v-belts according to is:2494-1974 …………………..….61
Table A 4 Minimum number of teeth on the pinion in order to avoid interference ……...…..62
Table A 5 Standard proportions of gear systems ………………………..…………………...62
Table A 6 Values of service factor ……………..……………………………………………63
Table A 7 Standard proportion of parallel, tapered and gib head keys ……………..……….63
Table A 8 Principal dimensions of radial ball bearing ………………..……………………..64
Table A 9 Values of service factor ……………………..……………………………………65
ix
LIST OF SYMBOLS
Q Capacity
P Pitch in m
∅ Loading efficiency
K Factor to take into account the inclination of the conveyor
PH Power necessary for conveying the material.
PN Driving power of the conveyor at no load
PSt Power requirement for inclination of the conveyor
CO Progress resistance coefficient (friction factor)
CS Service factor
L Length in m
r Radius
d Diameter
φ Reduced friction angle
α Screw helix angle
ρ Relative density
F Force
m Mass
g Gravity
A Area
V Velocity
D Diameter
N Revolution
B Top width
t Thickness
𝑊𝑇 Tangential tooth load
𝜎𝑂 Allowable static stress
𝐶𝑉 Velocity factor
b Face width
m Module
y Form factor
𝑊𝐷 Dynamic load
𝑊𝑆 Static load
x
𝑊𝑊 Wear load
𝑊𝑁 Normal load
𝑊𝑟 Radial load
Q Ratio factor
T Torque
M Bending moment
𝑇𝑒 Equivalent twisting moment
𝑀𝑒 Equivalent bending moment
𝜎𝑏 Bending stress,
𝜏 Shear stress
σ Stress
xi
CHAPTER ONE
1.INTRODUCTION
1.1 Background
The exact origins of soap are unknown, though Roman sources claim it dates back to at least
600 B.C, when Phoenicians prepared it from goat's tallow and wood ash. Soap was also made
by the Celts, ancient inhabitants of Britain. Mention of soap as a cleanser does not appear until
the second century A.D. By the eighth century, soap was common in France, Italy, and Spain,
but it was rarely used in the rest of Europe until as late as the 17th century. [12]
Manufacture of soap began in England around the end of the 12th century. Soap-makers had to
pay a heavy tax on all the soap they produced. The tax collector locked the lids on soap boiling
pans every night to prevent illegal soap manufacture after hours. Because of the high tax, soap
was a luxury item, and it did not come into common use in England until after the tax was
repealed in 1853. In the 19th century, soap was affordable and popular throughout Europe.
Methods of soap making improved when two scientific discoveries were made in the late
eighteenth and early nineteenth centuries. In 1790, the French chemist Nicholas Leblanc (1742-
1806) invented a process for creating caustic soda (sodium hydroxide) from common table salt
(sodium chloride). His invention made inexpensive soap manufacture possible by enabling
chemists to develop a procedure whereby natural fats and oils can react with caustic soda. The
method was further refined when another French chemist, Michel Eugene Chevreul (1786-
1889), discovered the nature of fats and oils in 1823. As soap production became less expensive
and attitudes toward cleanliness changed, soap making became an important industry.
Before the end of World War II, soap was manufactured by a “full-boiled” process. This
process required mixing fats and oils in large, open kettles, with caustic soda (NaOH) in the
presence of steam. With the addition of tons of salt, the soap was made to precipitate out and
float to the top. Here, it was skimmed off and made into flakes or bars. This process required
large amounts of energy and over six days to complete one batch.
After World War II, a continuous process of soap manufacture became popular. In the
continuous process of soap manufacture, fats and oils react directly with caustic soda. The
saponification reaction is accelerated by being run at high temperatures (248°F; 120°C) and
pressures (2atm). Glycerin is washed out of the system and soap is obtained after centrifugation
and neutralization. This process has several advantages over the “full-boiled” process. It is
more energy efficient, time efficient, allows greater control of soap composition and
concentration, and the important by-product, glycerin, is readily recovered. Both manufacturing
1
methods yield pure soap. Certain chemicals can be added to this pure soap to improve its
physical characteristics. The foam in soap is enhanced by additives such as fatty acids. Glycerin
is added to reduce the harshness of soap on the skin. Other additives include fragrances and
dyes. Several modern plodding techniques practiced today in soap making industries involves
using either press or extruder of various designs to accomplish the task of plodding, most of
which can either be manually or electrically operated.
1.1.1 The existing soap bar making machine in Ethiopia
There are various soap making machines used to soap production process. Soap making falls
into two distinct scales; -small and industrial production. The industrial production of soap
involves a continuous process that requires constant addition of fat and removal of products. It
is expensive and requires high capital but efficient and high productivity. Smaller scale
production involves the traditional batch processes. It requires minimum capital as compared
with industrial production.
a b
Figure 1. 1 (a) Soap mixer machine and (b) Plodder machine
The small scale machines in soap manufacturing use two electric motors separately for plodder
and mixer machine as shown in the figure above. In addition, the plodder and mixer machine
are installed as separate machine this requires wide space to install.
Thus, the present project is aimed at modifying the existing machine to replace by improved
soap bar making machine which synchronized two functions including mixing and soap
plodding (soap extrusion) in a single unit.
2
1.2 Definitions and Types of Soap
Soap is substances when dissolved in water possess the ability to remove dirt from surfaces
such as the human skin, textiles, and other solids. They are used as cleansing agents to remove
dirt, oil from the skin and clothes. It is very generally known that soap is made by combining a
fat or oil with a water solution of sodium hydroxide (caustic soda lye), or potassium hydroxide
(caustic soda). Sodium soaps are always harder than potassium soaps, provided the same fat or
oil is used in both cases. [1]
Soaps are produced in different shapes, sizes, colors and qualities/grades depending on their
specific uses and manufacturer. There are so many types of soaps depend on advantage and
state. For a matter of convenience, we will classify soap under four general divisions:
1. Laundry soaps
2. Toilet soaps
3. Textile soaps
4. Medicinal soaps
The most popular household soap is laundry soap. Some of laundry soaps used at home for
cleaning clothes are:
a) Solar laundry soap. Ingredients: sodium palmate, sodium kernelate, sodium chloride,
titanium dioxide, tetra sodium EDTA, optical brightener, water and color.
b) Mazaki laundry soap. Ingredients: sodium palmitate, sodium palm kernelate, aqua,
titanium dioxide, optical brightener, perfume, sodiumtripolyphosphate, silica,
magnesium carbonate, glycerin, tetra sodium EDTA and linalool.
c) Rose laundry soap. Ingredients: aqua, sodium palmitate, sodium carbonate, palm
kernelate, perfume, pigment, calcium carbonate, glycerin, builders and EDTA.
d) Diva laundry soap
e) Home laundry soap
1.3 Description of The New (modified) Soap Bar Making Machine
The machine is small scale soap bar making machine. It is cheap and affordable semi-automatic
machine for small scale industry which makes the soap with the help of extrusion process. This
machine assembles domestically in simple way so it’s price reduced drastically that is why it is
economically stable for the small scale industries.
Uniqueness of this machine is that it uses one motor for plodder and mixer, but the existing
designs uses two motors for plodder and mixer separately.
3
1.3.1 Description of parts and its functions
The soap bar making machine is made up of three main parts namely mixer, soap
plodder(extruder) and cutter.
1.The mixer
Soap mixer machines are important soap manufacturing equipment that are used to mix the
ingredients of soap used in soap making. Available in a variety of sizes, dimensions, weights
and mixing capacities. [13]
Thus, appropriate proportions of ingredients are mixed thoroughly into the mixing container.
In some operations it may take up to 10 to 15 minutes to obtain a homogenous mixture in the
mixing chamber. When this condition homogeneity of mixture of the material constituents, the
mixture is discharged through the exit and feed to hopper where it is required to extrude in the
plodder machine. [1]
The mixer machine consists of the following main parts:
a. Mixing vessel(basin)
b. Mixer Impeller (Stirrer)
c. Pulley and belt
d. Main frame
a. Mixing Basin: This part consists of centrifugal impellers (Stirrer) then mixing mechanism
is done through the rotation of shaft that hold the impellers.
b. Mixer impeller: is a device rotate inside the mixer basin used for mixing soap ingredients.
c. Pulley and belt: used for power transfer.
d. Main frame: The main frame is a rectangular shape structure which is capable for supporting
all the machine components.
2.The soap plodder(extruder)
The Soap Extruders (also called Soap Plodders) are studied to refine, homogenize and extrude
the processed soap (soap noodles + perfume + color) coming from the Mixer. The Extrusion
shaft ensures the extrusion of a compacted soap bar. The heating system of the extrusion cone
is the same of an industrials soap extruder, to produce a bar with a smooth surface. [14]
The raw material was fed to the hoppers, which convey it to screw by gravity. The material was
pushed forward due to geometry of screw. As the material was pushed, it gets compressed and
compacted soap bar comes out of die.
The extruder machine consists of the following main parts:
a. Hopper
b. The barrel
4
c. Screw extruder (shaft conveyor)
d. Gear
e. Pulley and V-belt
f. Shaft
g. The die
h. Electrical heater
i. Main frame
i. The barrel: It is a cylindrical tube in which the extrusion of soap takes place by axial force
of the screw rotating inside it.
ii. The screw shaft: The screw shaft rotating inside the barrel is the main component which
plays a great role in moving, compacting the soap, and finally taking out the final product
through the die.
iii. Pulley and belt: It is used to transmit power from motor to the screw.
iv. Gear: It is used for speed reduction.
3. Cutter:
It is used for cut a soap in to a number of bars. It is manually operated, simple and affordable
which requires little or no special skills for its operation and can be easily set up by small scale
industries even rural areas. The soap bar making machine has the following major systems:
1. The power system
2. Feeding system
3. Extrusion system
4. Heating system
5. Soap exit systems
1.The power system
This provides the driving force for all the components of the machine. This system is composed
of the motor, pulley system and belt.
2.The feeding system
Hoppers are installed to allow for a greater quantity collection. In this design we are using a
hopper for the collections of soap mixtures from the mixing vessel.
3.The extrusion system
The soap extruder is designed for to homogenize the mixture of soap noodles and to extrude to
make ready the soap to cut in to a number of bars.
5
4.Heating system
Heating system is fixed around the tip of the extrusion shaft cone. An immersion electric heater
is fitted inside the barrel (water jacket) where water is heated to make the soap smooth and
compact before it is extruded. The set point temp is usually between 60℃ and 70℃.[1]
5.Bar soap exit system
This system is composed of a die block. This makes the soap to be in the shape of the die. The
die block is firmly fitted at one end immediately after the edge of the extrusion shaft.
1.3.2 Working principle of the machine (our soap bar making machine)
The soap making machine is works with the help of 3 phase motor which work on electric
power supply. When the motor is start it provides power to the pulley and it transfer by belt to
the another pulley connected with gear box. There is gear arrangement to reduce the speed of
the motor and to transfer power to extruder. Both the mixer and extruder part of machine driven
by one motor. The mixer mixes various ingredients and chemicals of soap. Once the mixture is
homogeneous pour them into the hopper directly above the extrusion shaft. As the extrusion
shaft rotates, it pushes the soap towards the die block and the compact bar of soap comes out
from the opening with the shape of the die at the end of the chamber. There is a heater that has
a thermostat placed just before the die block to heat the water jacket and makes the soap soft
and compact. A table is placed in line below the die block. The bar soap slides on this table
where it is cut into a number of soap bars with required length by using manually operated
cutter. The size of the bar soap produced can be altered by changing the dimensions of the die
block.
1.4 Statement of The Problem
The high cost of large scale soap bar making machine prevents new entrepneurs from starting
soap making business since the machine is expensive to buy. In the other side small scale soap
machines use two electric motors separately for plodder and mixer, thus makes the cost of the
machine is high. In addition, the plodder and mixer machine installed as separate machine, as
a result a wide space is required to install. So by designing and developing a small scale soap
bar making machine which synchronized two functions namely mixing and plodding by using
one electric motor the aforementioned problem will be eliminated technically.
1.5 Objective
1.5.1 General objective
The general objective of this project is to design and modeling of soap bar making machine
which is economical, and easy to use and maintain.
6
1.5.2 Specific objective
The specific objective of the project is: -
 Selection of motor
 Material selection
 Design of each components
 Selection of standard items like bearing, bolt and nut
 Cost estimation
 Part and assembly drawing
 Prepare working animation for the designed soap bar making machine.
1.6 Significance of The Project
With the completion of this project we hope that the modified soap bar making machine will
be used widely throughout our county. Some of the benefits of the machine are;
 Improvement of the machine helps to maximize production capacity and reduce the cost
of the machine
 Generate income for us
 Satisfying the need of the customer by providing quality soap with reasonable price.
 Creation of job opportunities to start a business plan with a minimum amount of capital
requirement.
1.7 Scope of The Project
The project’s intent is to design soap bar making machine, mixer with screw extruder that
performs two operations together. This machine can be operated electrically and it is capable
of producing 140kg per hour soap bar. The scope of the project is on the detail design and
analysis of each components and draw out the part and assembly drawing. Finally prepare
working animation for the designed soap making machine.
7
CHAPTER TWO
2.LITRATURE REVIEW
[2] design and develop Automated and Customized Gomay Soap Machine which works on
both the electric supply and battery also. This model introduces is the small & combined version
of automation used in big industries and the soap for which introducing this model is purely
natural and its main ingredients are cow-dung, turmeric, sandalwood, sesame oil, Sinoper etc.
The whole assembly of this setup is mounted on the main base. Extruder blade is mounted on
the shaft at one end and at other end there is a big gear attached. The extruder shaft is rotate in
two ball bearing with the help of DC motor with the help of chain drive. Chain drive connect
the heavy duty DC motor and big gear. Hopper is placed above the extruder to provide semisolid
soap material. The another motor is placed at in front of the extruder to cut the output soap bar
in circular shape with cutting blade. The cutting blade is attached with gear and rotate in with
specific rpm.
The strength of this work is that the machine is automatic hence it reduces the time and hard
work of labor, increase the productivity and production rate and minimize the damaged product
due to labor mishandling. But its limitation is the machine uses two motor these are dc motor
which rotates the extruder shaft and the second one is motor is placed at in front of the extruder
to cut the output soap bar in circular shape with cutting blade hence the machine is not cost
effective for customers which have low initial capital. The machine is fully automatic hence it
requires skilled personnel.
[3] design and develop a Pedal-powered Soap Mixer. The machine consists of a chain drive
and gear amplification mechanisms that turns impeller blades in a large stainless steel container,
where soap ingredients are stirred and blended. The machine is economically viable, can be
used by unskilled workers, save time otherwise spent in traditional mixing and can be adopted
for human-powered process units which could have intermittent operation without affecting the
end-product. Pedal power is the transfer of energy from a human source through the use of a
foot pedal and crank system.
The strength of this work is that this equipment can adequately replace electric motor-driven
mixer in rural areas where there is no or limited supply of electricity, saves cost that would
otherwise be spend to service utility bills and equipment is almost maintenance free. Its
limitation is the machine requires human efforts (human labor) and final product is usually not
uniformly mixed. Also its production rate (mixing rate) is low.
8
[4] works in design and construction of Manually Operated Soap Cutting and Scraping
Machine for Small Scale Industries.it is a machine designed to be used in cutting and scrapping
of soap at the same time. This soap cutting and scraping machine works on the principle of
crank mechanism. The rotary motion of the handle is converted to a linear reciprocating motion;
this is achieved by the use of chain and sprocket to transmit motion. The large sprocket is
connected to the arm, which move the carriage in a backward and forward movement. The front
side of the carriage was projected in such a way that it has a thick flat surface to be able to push
the loaves soap pass the cutter.
The strength of this work is that little or no special skill required in operating machine, the
cutters section of machine is interchangeable to allow various sizes of soap to be cut and the
machine gives uniform and smooth surface of cut soap. Its limitation is the machine requires
more space and recommended for small scale industries.
From those literatures we got important information about what important modifications need
in the machine to fulfill the gaps and how to design and develop the machine. It helps us to
understand the working principle of the machine. Our project that is design and modelling of
semi-automatic soap making machine for small scale industries is an attempt to solve the
problems encountered by the previous machine such as high cost, inefficient and skilled
personnel for their operation and no proper mixing. This machine was constructed using
affordable materials and is semi-automatic, and also it permits the production of different sizes
of soap by changing the shape of the die, lastly it requires no or little special skill for its
operation. So our project minimizes the cost by using one motor for plodder and mixer but,
other designs uses two motors for plodder and mixer separately and improper mixing is
eliminated by using motor driven mixer. The cutter of our machine is manually operated
because the automatic cutter is very huge that is bulky, expensive to be purchased by small
scale industries, they require special skills for their operations, in a nutshell they are not easily
set up by small scale industries most especially in rural areas, based on these reason, we carried
out this project, the cutter part of the machine is manually operated.
9
CHAPTER THREE
3.METHODOLOGIES
The mission of the project is to design a cheap and economical soap bar making machine for
local use. The methods used in this design involves gathering information about soap making
machine. Primary and secondary data collection methods were used for this project. Primary
data collection includes collecting data from direct observation of the existing machines and
advises from our teacher. The secondary data collection methods are uses in collecting data
from the published books, journals, websites and internet.
A series of methods we will follows to complete the project successfully are the following:
Define the problem and Determine the objective

customer requirements and scope of the project
Conceptual design
Litrature review on existing
Concept generation
and previous designs
Evaluate and select concept
Embodiment design Detail design

Design of each components Finalizing and creation of
and material selection final drawings
Figure 3. 1 Sequences of design methodology
10
CHAPTER FOUR
4.CONCEPTUAL DESIGN
4.1 Needs and Requirements of the Customers
The customers of the product are all Ethiopian peoples who want to manufacture soap.
They are in the needs of:
a. Less cost (cheap) machine
b. Easy to mix and operate
c. Light weight machine
d. Have good quality and safe design
e. More accurate relative to the current machines
f. Easy to maintain without skilled man
g. Easy to transport
h. Can stand in high temperature
i. High resistance to corrosion
j. Durable
k. Reduce the number of labor required
l. Save time
4.2 Concept Generation and Selection of Concepts
For concept selection, the concept has been described based on consideration. Although each
concept nominally satisfied the key customer need, the best concept still need to be choose for
further design and refinement. Firstly, the process of evaluating concept with respect to
customer needs and other criteria has been done. Next, compare the relative strengths and
weakness of the concept. Lastly, one or more concepts have been selected for further
investigation, testing and development. The criteria were chosen based on what customer need
that has been identified before. Hence it is necessary to consider technical, economic and safety
criteria at the same time.
11
4.2.1 Solution variants and selection of variants for the type of soap bar making machine
Solution variants
Selection of the type of soap bar making/ operation mechanism
Soap bar making

machine
Manually operated Electric motor driven
The advantages and disadvantages of each idea:

1.Manually operated soap bar making machine
Advantage
a) Low cost
b) Used in rural areas without electricity
c) Easy to maintenance
Disadvantage
a) Require labor force
b) Less reliability
c) Improper mixing of soap ingredients
d) Low productivity
e) Inefficiency
2.Electric motor driven soap bar making machine
Advantage
a) Easy to operate
b) Productivity
c) Efficient
d) Accurate
Disadvantage
a) High cost
12
Selection of variants
Table 4.1 Selection of solution variants for the type of soap bar making machine
Types of soap bar making machine
Selection criteria Manually operated Electric motor driven
Cost 4 2
Easy to operate 1 4
Suitability 4 3
Easy to maintain 4 2
Reliability 2 4
Durability 2 4
Efficiency 1 4
Total 18 23
Rank 2 1
Note that:
 1 means poor
 2 means good
 3 very good
 4 means excellent
Based on evaluation criteria electric motor driven soap bar making machine is best relative to
manually operated type soap bar making machine.
4.2.2 Solution variants and selection of variants for the parts of the machine
The machine has the following main parts:
1. Mixer vessel
2. Hopper
3. Screw conveyor
4. Shaft
5. Pulley
6. Belt
7. Gear
8. Bearing
13
Solution variants
Table 4.2 Solution variants for the parts of the machine
Part Solution variant
name
A B C
Mixer
vessel
Hopper
Screw Helical spiral Ribbon spiral Cut flights

conveyor
Shaft Solid shaft Hollow shaft
14
Pulley Flat pulley Grooved pulley
Belt Flat belt v-belt
Gear Spur gear Helical gear
Bearing Radial ball bearing Thrust ball bearing Roller bearing
15
Selection of variants
Table 4.3 Selection of the solution variants for the parts of the machine
Solution variants
Selection criteria Mixer vessel Hopper Screw conveyor
A B C A B A B C
Cost 3 3 3 3 3 3 3 3
Suitability 2 3 3 4 2 4 3 2
Ergonomics 2 4 3 4 3 4 3 2
Light weight 2 3 3 3 3 3 4 4
High strength 3 3 2 3 3 4 2 3
Easy to operate and - - - - - 3 3 3

maintenance
Durability 3 4 3 3 3 4 2 3
Manufacturability 3 3 3 4 3 4 2 2
Corrosion resistance 3 3 3 3 3 4 2 3
Total 21 26 23 27 23 33 24 25
Rank 3 1 2 1 2 1 3 2
Note that:
 1 means poor
 2 means good
 3 very good
Based on evaluation criteria mixer vessel B, hopper A and screw conveyor A (helical spiral)
are best relative to other variants.
16
Table 4.4 Selection of the solution variants for the parts of the machine
Solution variants
Selection criteria Pulley Belt Shaft Bearing
A B A B A B C A B C
Reliability 2 3 3 4 4 3 2 4 3 2
Ergonomics 2 3 2 3 4 2 3 4 3 3
Light weight 3 4 3 4 2 3 3 3 3 3
High strength 3 3 3 3 4 2 3 3 3 3
Easy to operate and 4 3 3 3 3 3 2 3 3 2

maintenance
Durability 3 3 3 2 4 1 2 3 3 3
Power transmission 2 4 2 4 4 3 3 3 3 3
Corrosion resistance 3 2 - - 4 2 3 3 2 2
Total 22 25 19 23 29 19 21 26 23 21
Rank 2 1 2 1 1 3 2 1 2 3
Note that:
 1 means poor
 2 means good
 3 very good
Based on evaluation criteria grooved pulley, v-belt, and shaft A (solid shaft) and radial ball
bearing are selected.
The power required to transmitted through gear is small so spur gear is appropriate. Because
helical gear is expensive and difficult to manufacture compared to spur gear.
17
Combined working structure (final product)
Figure 4. 1 3d view of the modified soap bar making machine
18
CHAPTER FIVE
5.COMPONENT DESIGN
Design specifications
 Capacity of the machine = 140Kg/hr
= 500 - 560 soap bar per hour (1 soap bar = 250gram)
 Screw conveyor capacity = 140Kg/hr
 Mixer capacity = 35 Kg/batch
5.1 General Consideration of Design
The following are the general consideration in design:
1) Type of load and stress caused by the load: The load, on a machine component, may act in
several ways due to which the internal stresses are set up.
2) Motion of the parts or kinematics of the machine: The successful operation of any machine
depends on largely upon the simplest arrangement of the parts which will give motion required.
3) Selection of a material: It is essential that a designer should have a thorough knowledge of
the properties of the material and their behavior under working conditions.
Some of the important characteristics of the materials are:
a) Strength
b) Durability
c) Flexibility
d) Resistance to heat and corrosion
e) Weld or hardened
f) Machinability etc.
4) Form and size of the part: The form and size are based on judgment. The smaller practicable
cross sectional may be used, but it may be checked that the stresses induced in the designed
cross-section may be used are reasonably safe. In order to design any machine part for form
and size, it is necessary to know the forces which the part must sustain. It is also important to
anticipate any suddenly applied or impact load which may cause failure
5) Use of the standard parts: The standard parts should be used whenever possible; parts for
which patterns are already in existence such as gear, bearing and parts which may be selected
from regular shop stock such as power screw, bolt and nuts.
19
5.2 Material selection
When selecting materials for a machine, first consideration is what materials are suitable for
the product, the way the product will be made, method of construction and cost are all vital
elements. The following factors should be considered while selecting the material:
1. Availability of the materials,
2. Suitability of the materials for the working conditions in service, and
3. The cost of materials
The important properties, which determine the utility of the material are physical (include
luster, color, size and shape, density, electric and thermal conductivity, and melting point.),
chemical (oxidation, corrosion, and diffusion) and mechanical properties (include strength,
stiffness, elasticity, plasticity, ductility, brittleness, malleability, toughness, resilience, creep
and hardness).
5.3 Design Analysis
5.3.1 Screw conveyor
Design considerations:
The two essential parameters to be established in the design or selection of a screw conveyor
for a given application are the screw size, and its rotational speed. The choice of a suitable
screw size involves consideration of the overall diameter of the screw, the diameter of the shaft,
the radial clearance between the shaft and the containing trough and the type and pitch of the
helical flight. The basic design criteria required for the selection of screw conveyor system are:
a. Properties of material to be conveyed (abrasiveness, bulk density and size)
b. The quantity to be transported
c. The distance the material is to be conveyed
d. The method by which the material is loaded in to the screw
The desired target can be achieved based on the following design specifications;
1. Capacity 140 Kg/Hr (10 working hours per day)
2. Length of the screw 1400mm
3. Screw diameter 160mm
The hourly capacity can be calculated by [7]
πD2 Kg
Q = 60∅ NPρK , Hr…………………………………………..…………… (5.1)
4
4Q
N= , RPM…………………………………………………………. (5.2)
60∅πD2 PρK
20
From practical experience [8]
60
N= for light non abrasiveload
√D
45
N= for heavy non abrasiveload
√D
30
N= for abrasiveload
√D
Where
Q = capacity of a screw conveyor
ρ = Bulk density of the material, kg/m3
D = Nominal diameter of Screw in m = 0.16m
P = Screw pitch in m for standard pitch single flight P = D
N = RPM of screw
∅ = Loading efficiency of the screw (0.25) from table
K = Factor to take into account the inclination of the conveyor = 1
1.The required RPM
Main parameters of the conveyor. Considering that the material is abrasive, we take the trough
loading efficiency ∅ = 0.125 and the screw pitch P  D =0.16m (standard pitch).
30 30
N= = = 75RPM
√D √0.16
The rotation of screw conveyor, N = 75 rpm.
2.The required power
Power Requirements of Screw Conveyor: IS: 12960:1990 “Determination of Power
Requirement of Screw Feeder—General Requirements”, has recommended the method for
calculation of power requirement of a screw conveyor. [8]
The driving power of a loaded screw conveyor may be estimated by the formula:
PT = PH + PN + PSt ……………….....................................................................(5.3)
Where
PH = power necessary for conveying the material.
PN = driving power of the conveyor at no load.
PSt = power requirement for inclination of the conveyor
Power necessary for conveying the material: PH in kW
QLCO
PH = , KW………………………………………………………………. (5.4)
367
21
Where;
CO = progress resistance coefficient (friction factor). It is depending on the material and its size.
It is generally of the order of 2 to 4.
L = Length of screw, m
Q = mass flow rate in Kg/hour
140 × 1.4 × 4
Then, PH = = 2.14KW
367
Drive power of the screw at no load, PN is comparatively low. It is proportional to the screw
diameter and total length of the screw. The recommended formula is
DL
PN = , KW…………………………………………………………………………. (5.5)
20
0.16 × 1.4
Then, PN = = 0.0112KW
20
The power requirement for inclination of the conveyor is neglected, because the screw is
horizontal.
So the total power requirement is;
PT = PH + PN + PSt = 2.14 + 0.0112 = 2.1512KW
 The power requirement for plodder machine is 2.1512Kw.
3. Axial force along the screw, P(Kg):
M
P = r tan(α+φ) , Kg………………………………………………………….………. (5.6)
102PT ×60 975PT
M= = …………………………………………..…………….….… (5.7)
2πN N
Where
M = the resisting moment(Kgm)
D
r = radius at which the force P is applied, r = (0.7 to 0.8) × 2
φ = reduced friction angle, tan  = 

α = screw helix angle
D 0.16
So , r = 0.8 × 2 = 0.8 × = 0.064m
2
φ = 38.66°(μ = 0.8)
P 0.16
tan α = πD = π×0.16 = 0.3183……………………………………………….… (5.8)
The screw helix angle, α = 17.6°

975 × 2.1512
M= = 27.97Kgm
75
22
Hence;
27.97
P= = 291.9Kg
0.064 tan(17.6 + 38.66)
 The axial force along the screw(P) = 292Kg
The extrusion shaft is the main connection from the gear to the die hence it should have the
following properties for it to work well;
i. High strength
ii. Good machinability
iii. Corrosion resistant
iv. Heat resistant
v. High wear resistant properties
The material used is carbon steel of grade 45C8 (selected)
The dimensions of screw conveyor from recommended dimension table [7]
a. Screw diameter = 160mm
b. Pitch = 160mm and Length = 1400mm
c. Tabular shaft diameter × thickness = 42.4 × 2.5 mm
d. Solid shaft diameter = 35mm
e. Trough width = 180mm
f. Thickness of trough = 5mm
g. Nominal thickness of helical screws = 5mm
h. Helix angle = 17.6
5.3.2 Mixer Basin(vessel)
The mixer machine has a number of components but this topic focuses on the design of some
of the components which are critical for proper functioning of the machine.
Design specification
a. Mixer capacity = 35Kg/batch and 140kg/Hr.
 Since the extruder capacity is 140Kg per hour so the mixer should mix 140kg per
hour. In some operations it may take up to 10 to 15 minutes to obtain a homogenous
mixture in the mixing chamber [1]. Taking 15 minutes to obtain homogenous
mixture, so the mixer should have a capacity of 35kg per batch to supply 140kg of
soap bar to extruder machine.
b. The mixer impeller is designed to rotate at relative speed of 140rpm by considering the
existing machine and previous works in the literature review.
c. The diameter of mixer impeller (shaft with stirrers) = 380mm
23
1.Determination of Volume of mixer basin
Designing for a mixer capable of mixing 35kg of soap ingredients per Batch;
m 35
The volume required for mixing , Vr = = 880 = 0.04m3
ρ
Where ρ = Relative density of soap different ingradients(detergent)
Figure 5. 1 Mixer vessel
The volume of mixer basin calculated by:

π × (0.20)2 × L
V = (0.25 × 0.40 × L) + = 0.04m3
2
L = 0.25m
Take the length of vessel, L = 0.5m for some free space in vessel and also by considering the
space needed for mixer impeller.
Thus length of mixer vessel, L = 500mm and take the thickness of the vessel 5mm.
2. Determination of total force in the mixer vessel
The total force in the mixer vessel is the sum of centrifugal force on mixture and the weight of
the mixture.
FT = FC + mg………………………………………………………………….……. (5.9)
2π × 140 2
FC = mrω2 = 35 × 0.2 × ( ) = 1504.5N
60
FT = 1504.5 + 35 × 10 = 1854.57N
Stress in the mixer vessel (σ);
F
σ = A………………………………….…………………………………………. (5.10)
Since Fc is acting on the circumference of the mixing basin; Area on which Fc acts;
A = π × r × t……………………………………………………………………. (5.11)
A = π × 200 × 4 = 800πmm2
Where, t is the thickness of mixer vessel
1854.57N
σ= = 0.74N/mm2
800π mm2
24
So, the material for mixer vessel should be selected based on this stress and the material selected
should have a yield stress greater than 0.74N/mm2 .The different chemicals of soap ingredients
mixed together inside the mixer vessel, so the materials of mixer vessel should be corrosion
resistance and wear resistance.
So the material selected is mild steel with the following justification:
i. Economical
ii. Good weld ability
iii. Good corrosion and wear resistance
iv. Available
3. The Power required for mixing
It is the power required to rotate the mixer impeller by rotating the shaft of impeller.
Mixer impeller (shaft with blades) is installed inside the mixer vessel and special designed to
mix soap ingredients very well.
The power required P in Kw;
P = F × V……………………………………………………………………..………. (5.12)
But;
πDN
V= ………………………………………………………………………..……… (5.13)
60
Where
F = force
V = velocity of mixer impeller
D = diameter
N = revolution
Therefore;
πDN π × 0.38 × 140
P=F× = 1854.57 × = 4.41Kw
60 60
 The power required for mixer machine is 4.41Kw.
5.3.3 Motor selection
Pulley and v-belt are used to transfer power from motor to plodder and mixer machine. The
total power required is the sum of power required for mixer and plodder part of soap bar making
machine. From previous calculation the power required for mixer machine is 4.41Kw and the
power requirement for plodder machine is 2.1512Kw. So, the total power required for soap bar
making machine is the sum of the two powers.
Required power = 4.41 + 2.1512 = 6.5612KW
Let us take the efficiency of belt is 90%.
25
The required motor power = 6.5612× 1.1 = 7.22KW = 9.63 Horse power
The standard horse power is 10hp.
Therefore, the selected standard motor has [15]
1. Horse power = 10
2. RPM = 900
3. Phase = 3
4. Brand = North American electric
5.3.4 Pulley and belt
The belts are used to transmit power from one shaft to another by means of pulleys which rotate
at the same speed or at different speeds. Though there are many types of belts used these days,
we choose V-belt. The V-belt is mostly used in the factories and workshops, where a great
amount of power is to be transmitted, from one pulley to another, when the two pulleys are very
near to each other. [9]
The material selected for v belt is reinforced rubber with the following justification:
i. It is strong
ii. Flexible and durable
iii. It has high coefficient of friction
The properties of rubber: Mass density = 1140 kg/m3 and Coefficient of friction = 0.3
The ultimate strength of leather belt varies from 21 to 35MPa and a factor of safety may be
taken as 8 to 10. However, the wear life of a belt is more important than actual strength. It has
been shown by experience that under average conditions an allowable stress of 2.8MPa or less
will give a reasonable belt life. An allowable stress of 1.75MPa may be expected to give a belt
life of about 15 years. [9]
For the pulleys, the most preferred material is cast iron. This is chosen due to the following
properties,
i. Tensile strength – this is about 483Mpa.
ii. High resistance to deformation.
Figure 5. 2 Belt cross section [9]
26
1.Design of the main pulley and the recommended V- belt
Design specification:
i. Required power transmission = 10hp(7.5Kw)
ii. Center distance between pulley (x) = 700mm
iii. Diameter ratio = 3
iv. Operating hours = 10hr
a. V-belt design
From table A1 dimension of standard v belts according to IS:2494-1974, since the belt is
designed to transfer 7.5kw power; we select B type belt. Standard dimensions of B type belt
are;
a. Minimum pitch diameter of pulley = 125mm
b. Top width (b) = 17mm
c. Thickness (t) = 11mm
d. Weight per meter length = 1.89N, so mass per unit length = 1.89/9.81 = 0.193 kg/m
e. Groove angle (2𝛽) in degrees = 34
Speed ratio (Rs) is given by;
N1 d
Rs = = d2 ………………………………………………………………….…. (5.14)
N2 1
Where;
d1 = Diameter of the driver (motor),
d2 = Diameter of the follower (larger pulley),
N1 = Speed of the driver (motor) in rpm
N2 = Speed of the follower in rpm
Choose the minimum pulley diameter (motor pulley) from table A2,
Let us take; d1 = 160mm = Diameter of the driver (motor)
But, diameter ratio is 3;
d2
= 3, implies d2 = 3 × 160 = 480mm
d1
And
N1 d2
= =3
N2 d1
Where, N1 = 900rpm
The revolution of large pulley (N2 ) is given,
900
N2 = = 300rpm
3
27
Figure 5. 3 Belts and Pulley
Angle of contact (θ);

r2 −r1 d2 −d1 480−160
sin α = = = = 0.2285………………………………..…. (5.15)
x 2x 2×700
α = 13.21°
For larger pulley θ2 = 180° + 2α = 220.1° = 3.60 rad
For smaller pulley; θ1 = 180° − 2α = 139.9° = 2.68 rad
While determining the angle of contact, it must be remembered that it is the angle of contact at
the smaller pulley, if both the pulleys are of the same material.
T
We know that; 2.3 log (T1 ) = μθ1 csc β [9]………………………………...………(5.16)
2
T1
2.3 log ( ) = 0.3 × 2.68 × cosec 17° = 2.75
T2
T1
= 15.69
T2
We know that the velocity of the belt,
πd1 N1 π × 0.16 × 900
v= = = 7.54m/s
60 60
Since the belt speed is less than 10m/s, therefore centrifugal tension should not be taken in to
consideration.
The maximum tension in the belt;
T = stress × area = σ × b × t………………………....………….……………. (5.17)
Take, Allowable stress (σ) = 2.5MPa
T = σ × b × t = 2.5 × 17 × 11 = 467.5N
Tension in the tight side of the belt;
T1 = T = 467.5N, neglecting centrifugal tension because belt speed is less than 10m/s.
And
T1
= 15.69; T2 = 29.80 N
T2
28
The power transmitted per belt;
= (T1 − T2 )v = (467.5 − 29.80)7.54 = 3900.26W
Designed power 7500
Number of belts required =Power transmitted per belt = 3900.26 = 1.97; say 2
Since the V-belt is to be designed for 7.5 kW, therefore from Table A1, we find that a ‘B’ type
of belt should be used.
We know that the pitch length of the belt
π (d1 −d2 )2
L = 2 (d1 + d2 ) + 2x + ………………………………………………… (5.18)
4x
π (480 − 160)2
L= (160 + 480) + 2 × 700 + = 2441.88mm
2 4 × 700
Subtracting 43 mm for ‘B’ type belt, we find that inside length of the belt =2441.88– 43 =
2398.88mm According to IS: 2494 – 1974, the nearest standard inside length of V-belt is
2438mm.
∴ Pitch length of the belt,
L1 = 2438 + 43 = 2481mm = 2.481m
Now let us find out the new center distance (x1) between the two pulleys. We know that
π (480 − 160)2
L1 = (160 + 480) + 2x1 + = 2481mm
2 4x1
x1 = 719.56mm = 0.72m
b. Dimension of pulley
The material for pulley is cast iron with following property;
Ultimate tensile strength = 100 to 200Mpa
Ultimate compressive strength = 400 to 1000Mpa
Ultimate shear strength = 120Mpa
From above larger pulley (driven pulley), d2 = 480mm and smaller pulley (motor pulley),
d1 = 160mm.
According to IS 2494-1974 dimension of V grooved pulley for B type belt from table A2;
1) w = 14mm, d = 15mm, c =10.8mm, f = 12.5mm, e = 19mm.
2) Groove angle = 34,36,38
3) Face width (B) = (n − 1)e + 2f) = 44mm
The nearest standard width of pulley = 50mm
c. Numbers of arms
The number of arms may be taken as 4 for pulley diameters from 200mm to 600mm and 6 for
diameter from 600mm to 1500mm. the pulleys less than 200mm diameters are made with solid
29
disc instead of arms [9]. So the number of arm is 4 for larger pulley and solid disc for smaller
pulley.
d. Check for safety of pulley
Centrifugal stress in pulley rim is given by;
σt = ρv 2 = 7200 × 7.542 = 0.41N/mm2
But for cast iron material ultimate tensile strength is between 100 and 200N/mm2 .
So, Centrifugal stress in pulley rim is much less than ultimate tensile strength of pulley material,
therefore the design of pulley is safe!
2.Design of pulley and V- belt for the mixer
I. Required power transmission = 4.41Kw
II. Center distance between pulley (x) = 700mm
a. V-belt design
Let us take the efficiency of belt is 90%, the designed power = 4.41×1.1=4.851Kw. From table
A1 dimension of standard v belts according to IS:2494-1974, since the belt is designed to
transfer 4.851kw power; we select B type belt. Standard dimensions of B type belt are;
a. Minimum pitch diameter of pulley = 125mm
b. Top width (b) = 17mm
c. Thickness (t) = 11mm
d. Weight per meter length = 1.89N, so mass per unit length = 1.89/9.81 = 0.193 kg/m
e. Groove angle (2β) in degrees = 34
Speed ratio (R S ) is given by;
N d
R S = N1 = d2……………………………………………………………... (5.19)
2 1
Where;
d1 = Diameter of the smaller pulley
d2 = Diameter of the larger pulley (pulley in the mixer),
N1 = Speed of the smaller pulley in rpm
N2 = Speed of the larger pulley (driven pulley) in rpm
Choose the minimum pulley diameter (smaller pulley) based on table
Let us take; d1 = 250mm
But, we know that, N1 = 300rpm and
N2 = 140rpm, it is the required rpm for the mixer
30
Then from above the formula;
300 d2
= , d = 535.71mmm
140 250 2
 The nearest standard diameter, d2 = 560mm
Angle of contact (θ);
r2 − r1 d2 − d1 560 − 250
sin α = = = = 0.258
x 2x 2 × 600
α = 14.97° ≅ 15°
For larger pulley θ2 = 180° + 2α = 210° = 3.67 rad
For smaller pulley; θ1 = 180° − 2α = 150° = 2.62 rad
While determining the angle of contact, it must be remembered that it is the angle of contact at
the smaller pulley, if both the pulleys are of the same material.
T
We know that; 2.3 log (T1 ) = μθ1 csc β,
2
T1
2.3 log ( ) = 0.3 × 2.62 × cosec 17° = 2.69
T2
T1
= 14.48
T2
We know that the velocity of the belt;
πd2 N2 π × 0.25 × 300
v= = = 5.93m/s
60 60
Since the belt speed is less than 10m/s, therefore centrifugal tension should not be taken in to
consideration.
The maximum tension in the belt;
T = stress × area = σ × b × t………………………...................................…. (5.20)
Take, Allowable stress (σ) = 2.5MPa
T = σ × b × t = 2.5 × 17 × 11 = 467.5N
Tension in the tight side of the belt;
T1 = T = 467.5N, neglecting centrifugal tension because belt speed is less than 10m/s.
And
T1
= 14.48; T2 = 32.29N
T2
The power transmitted per belt;
= (T1 − T2 )v = (467.5 − 32.29)5.93 = 2580.8W
Designed power 4851
Number of belts required = = = 1.88; say 2
Power transmitted per belt 2580.8
31
Since the V-belt is to be designed for 4.851 kW, therefore from Table A1, we find that a ‘B’
type of belt should be used.
We know that the pitch length of the belt;
π (d1 −d2 )2 π (560−250)2
L = 2 (d1 + d2 ) + 2x + = 2 (250 + 560) + 2 × 700 + = 2707mm
4x 4×700
Subtracting 43 mm for ‘B’ type belt, we find that inside length of the belt =2707– 43 = 2664mm
According to IS: 2494 – 1974, the nearest standard inside length of V-belt is 2667 mm.
∴ Pitch length of the belt,
L1 = 2667 + 43 = 2710mm = 2.71m
b. Dimension of pulley
From above larger pulley (driven pulley), d2 = 560mm and smaller pulley, d1 = 250mm.
According to IS 2494-1974 dimension of V grooved pulley for B type belt from table A2;
1) w = 14mm, d = 15mm, c =10.8mm, f = 12.5mm, e = 19mm.
2) Groove angle = 34,36,38
3) Face width (B) = (n − 1)e + 2f
4) Face width(B) = (2 − 1)19 + 2 × 12.5 = 44mm
5) Face width (B) = 44mm, the nearest standard width of pulley = 50mm
c. Numbers of arms
The number of arms may be taken as 4 for pulley diameters from 200mm to 600mm and 6 for
diameter from 600mm to 1500mm.So the number of arm is 4 for both the smaller and larger
pulley.
5.3.5 Gear
Figure 5. 4 Spur gear [9]
The gear box is used for speed reduction. In this project, the speed of the shaft is calculated to
be 75rpm for the conveyor screw to discharge the desired mass flow rate (140kg/hr) and the
speed of input shaft to gear box (the reduced speed from motor by using pulley) is calculated
to be 300rpm as shown in previous calculations. So the gear is needed to reduce speed from
300rpm to 75 rpm. The material used for manufactures of gears depend up on strength and
service conditions like wear, noise etc.
32
We select gear material; carbon steel of grade 45C8 for the following reason;
i. Hardness
ii. Toughness
iii. Flexibility
The following requirements must be met in the design of a gear drive:
a. The gear teeth should have sufficient strength so that they will not fail under static
loading or dynamic loading during normal running conditions.
b. The gear teeth should have wear characteristics so that their life is satisfactory.
c. The use of space and material should be economical.
d. The alignment of the gears and deflections of the shafts must be considered because
they effect on the performance of the gears.
i. Required power transmission = 2.1512Kw
ii. Speed of the input shaft to gearbox (N1 )= 300rpm
iii. Speed of the output shaft (speed of screw conveyor)(N2 ) = 75rpm
Let us take the efficiency of gear is 90%, the designed power = 2.1512×1.1=2.37Kw.
a. Number of teeth of each gear
Velocity ratio is given by [9];
N1 D T
= D2 = T2 ………………………………………………………………………. (5.21)
N2 1 1
Where;
N1 = Speed of the smaller gear (say pinion) = 300rpm
N2 = Speed of the larger gear (gear) = 75rpm
D1 = pitch circle diameter of smaller gear (pinion)
D2 = pitch circle diameter of larger gear (gear)
T1 = number of teeth in pinion
T2 = number of teeth in gear (larger gear)
Then; ,
300 D2 T2
= = =4
75 D1 T1
Take the system of gear tooth is 20° full depth involute, so the minimum number of teeth on
the pinion(smaller gear) is 18 from table A4.
33
So, take T1 = 18
T2
= 4, T2 = 72
18
b. Determination of the module
Here, both the pinion and gear are made of the same material (carbon steel). Therefore, the
pinion (smaller gear) is weaker. Thus, the design will be based upon the pinion.
The tangential tooth load is given by,
WT = (σO . CV )b. πm. y [9] …………………………………………………….……. (5.22)
Where, WT = tangential tooth load σO = allowable static stress
CV = velocity factor b = face width
m = module y = Form factor
Tooth form factor for the pinion for 200 full depth involute gear it is given by;
0.912
y = 0.154 − T1
, y = 0.103…………………………………………………. (5.23)
Pitch line velocity’

πD1 N1 πxmx18x300rpm
V= = = 0.283m m/s
60 60
Where m = module
Assuming steady conditions and 8-10 hours 0f service per day, the service factor CS from table
A6 is given, CS = 1.
Tangential tooth load on the pinion (WT ):
P
WT = × CS …………………………………………………………………… (5.24)
V
Where, P −power transferred

2370 8375
WT = ×1=
0.283m m
Velocity factor (Cv ):
3 3
Cv = =
3 + V 3 + 0.283m
Allowable static stress (σO )Mpa for carbon steel-heat treated is 210Mpa to 245Mpa. [9]
Take the allowable static stress (σO ) = 220Mpa.
The face width (b) may be taken as 9.5m to 12.5m for cut teeth and 6.5m to 9.5m for cast teeth.
Take b = 10m, where m is module
The tangential tooth load is given by;
WT = (σO . CV )b. πm. y…………………………………………………….…. (5.25)
34
8375 3
= 220 × ( ) 10m. πm. 0.103
m 3 + 0.283m
Solving the equation, m=2.43mm
From recommended series of standard modules in Indian standard, let us take module =5mm.
 The module m = 5mm
c. Face width,
b = 10m, b = 10×5 = 50mm
 The face width of the gear is 50mm
d. Pitch circle diameter of each gear
D1 = mT1 = 5 × 18 = 90mm
 Pitch circle diameter of pinion (smaller gear) = 90mm
D2 = mT2 = 5 × 72 = 360mm
 Pitch circle diameter of larger gear = 360mm
From table A5 by using the module m, the other proportions for the pinion and gear having 20°
full depth, are as follows;
1) Addendum (a) = 1m = 5mm
2) Dedendum (d)= 1.25m = 6.25mm.
3) Working depth = 2m = 10mm
4) Minimum total depth = 2.25m = 11.25mm.
5) Thickness of the tooth = 1.5708m = 7.854mm.
6) Minimum clearance = 0.25m = 1.25mm.
e. Checking gear for dynamic and wear load
The dynamic load is given by;
21V(b×C+WT )
WD = WT + [𝟗]……………………………………………….…. (5.26)
21V+√b×C+WT
Take the dynamic factor in the Buckingham equation as C = 80 and the material combination
factor for wear as k = 1.4
And,
8375 8375
WT = = = 1675N, And V = 0.285m = 0.285 × 5 = 1.415m/s
m 5
21 × 1.415(50 × 80 + 1675)
WD = 1675 + = 3,280N
21 × 1.415 + √50 × 80 + 1675
Static tooth load or endurance strength of the tooth;
WS = σe × b × πm × y [9] ………………………………………………………. (5.27)
From table the flexural endurance limit (σe ) for carbon steel is 252Mpa.
35
WS = 252 × 50 × 5π × 0.103 = 20,224N
Maximum or limiting load for wear;
Ww = DP × b × Q × k [9] ……………………………………….……………. (5.28)
Where, ratio factor (Q);
2V.R 2×4
Q = V.R+1 = 4+1 = 1.6……………………………………………………..…. (5.29)
Then,
Ww = 90 × 50 × 1.6 × 1.4 = 10,080N
 Since both WS and Ww are greater than WD the design is safe!
f. Number of arms for gears
If the pitch circle diameter of the pinion is less than or equal to 14.75m + 60m, then the pinion
is made solid with uniform thickness equal to face width.
 So the smaller gear is made solid and the number of arms for larger gear is four from
standard table.
g. Design of shaft for the larger gear
The material for shaft carbon steel.
The normal load acting between tooth surface;
WT 1675
WN = = = 1783N
cos 20° cos 20°
Weight of the gear;
WG = 0.00118TG . b. m2 [9] ………………………….……….………………………. (5.30)
WG = 0.00118 × 72 × 50 × 52 = 106.2N
Resulting load acting on the gear;
WR = √WN2 + WG2 + 2WN × WG × cos 20°…………………………………….……. (5.31)
The resulting load acting on the gear, WR = 1883N
Since the gear is mounted between bearing at the middle of the shaft and the distance between
the center line of bearing is 100mm.
Therefore, the bending moment on the shaft due to the resultant load is;
WR × L 1883N × 100mm
M= = = 47,075Nmm
4 4
And twisting moment on the shaft;
WT × DG 1675N × 360mm
T= = = 301,500Nmm
2 2
Equivalent twisting moment;
Te = √(M)2 + (T)2……………………………………………………………… (5.32)
36
T = √(47075)2 + (301500)2 = 305,153Nmm
We also know that equivalent twisting moment,
π
Te = 16 × τ × d3 …………………………………………………………………… (5.33)
According to American Society of Mechanical Engineers (ASME)code the design of shafts, the
maximum permissible stress in tension and compression may be taken as 84 Mpa for shafts
with allowance for keyways and the maximum permissible shear stress may be taken as 42 Mpa
for shafts with allowance for keyways [9].
Then,
π
305,153Nmm = × 42N/mm2 × d3
16
d = 33.32mm
Equivalent bending moment (Me );
1
Me = (M + Te ) = 176,114Nmm
2
The equivalent bending moment;
π
Me = 32 × σb × d3 ………………………………………………….……………. (5.34)
π
176,114Nmm = × 84N/mm2 × d3
32
d = 22.02mm
Taking the larger of the two values, d = 33.32mm
 The standard diameter of shaft for larger gear d = 35mm
Check for safety
According to maximum shear stress theory:
The maximum shear stress in the shaft;
1
τmax = 2 √(σb )2 + 4τ2 …………………………………………..………… (5.35)
where, σb = bending stress, τ = shear stress

Bending stress in the shaft due loads;
σ M
= I …………………………………………………………………….…. (5.36)
y
Where,
πD4 π × 354
I= = = 73,661.76mm4
64 64
Bending stress;
My 47075 × (35/2)
σ= = = 11.2N/mm2
I 73661.76
37
Shear stress in the shaft due to torque;
16T 16 × 301500
τ= = = 36N/mm2
πd3 π(35)3
Therefore,
1
τmax = √(11.2)2 + 4 × (36)2 = 36.5N/mm2
2
The ultimate shear stress for carbon steel is 210Mpa.
Ultimate shear stress
Factor of safety =
permissible shear stress
210
 Factor of safety = 36.5 = 5.75, so the design of shaft is safe!
Design of key for the shaft of the larger gear

From table A7 the standard dimensions of parallel, tapered and gib head keys for shaft diameter
35mm are according to IS:2292 and 2293-1974(Reaffirmed 1992);
1. Width of the key (w) = 12mm
2. Thickness of key (t) = 8mm
When the key material is same as that of the shaft, then τ = τk ;
Then L = 1.571𝑑 = 1.571×35 = 55𝑚𝑚
 The length of key is 55mm.
5.3.6 Shaft
A shaft is a rotating member usually circular cross section used to transmit power This involved
the transmission of torque and bending moment. Hence shaft design consists primarily of the
determination of the correct shaft diameter to satisfactory strength and rigidity, needed for the
required torque under various operating and loading condition.
The material used for shaft should have the following properties;
a. It should have high strength
b. It should have good machinability
c. It should have heat treatment properties
d. It should have high wear resistant properties
The material selected for shaft and key is carbon steel of grade 45C8 having [9];
1. Ultimate tensile strength = 610-700 Mpa
2. Yield strength = 350 Mpa
According to American Society of Mechanical Engineers (ASME)code the design of shafts, the
maximum permissible stress in tension and compression may be taken as 84 Mpa for shafts
38
with allowance for keyways and the maximum permissible shear stress may be taken as 42 Mpa
for shafts with allowance for keyways. In design of shaft, there are two shaft to be designed.
1.Main shaft
This shaft transmits a total of 7.5Kw at 300rpm to the plodder and mixer machine from motor.
That means 7.5Kw is supplied to pulley on this shaft, out of which 2.37 is taken off at the gear
to the plodder machine and the remaining taken off from another pulley mounted in this shaft
to the mixer part of machine. So in this shaft there are two pulleys and one gear mounted on it.
2.Mixer shaft
This shaft transfers power from main shaft to the mixer using pulley and belt. The shaft also
contains blades (mixer impellers) inside the mixer vessel for mixing purpose due rotation of
shaft.
1.Design of the main shaft
The shaft will be subjected to combined stress bending and twisting which is equivalent twisting
moment.
Figure 5. 5 Main shaft free body diagram
Take the weight of pulley A and pulley B is 80N and 40N respectively.
Weight of the gear at C;
WG = 0.00118TG . b. m2 = 0.00118 × 18 × 50 × 52 = 26.55N say 30N
Torque transmitted by the shaft;
P × 60 7500 × 60
T= = = 238.8Nm
2πN 2π × 300
Total load acting on the shaft at A (acting downward);
FA = T1A + T2A + Weight of pulley = 467.5 + 29.80 + 80 = 577N
Total load acting on the shaft at B (acting upward);
FB = T1B + T2B − Weight of pulley = 467.5 + 32.29 − 40 = 460N
39
Torque transmitted by the gear at C;
P × 60 2.37 × 60
TC = = = 75.45Nm
2πN 2π × 300
So, the tangential force acting on the gear tooth;
TC 75.45
Ftc = = = 1675N
R1 0.045
So, the total load acting on the shaft at C (acting downward);
FC = Ftc + Weight ofgear = 1675 + 30 = 1705N
Figure 5. 6 Vertical load diagram
Taking moment about E;

460 × 150 + 100 × R1 = 577 × 200 + 1705 × 50
R1 = 1316.5N
For the equilibrium of the shaft;
460 + R1 + R 2 = 577 + 1705
R 2 = 505.5N
Bending moment;
B.M at A and E = 0
B.M at B = 577×50 = 28,850 Nmm
B.M at C = 505.5×50 =25,275 Nmm
B.M at D = 577×100−460×50 = 34,700 Nmm
So , the maximum bending moment on the shaft is MD = 34,700Nmm
Te = √(M)2 + (T)2 = √(34700)2 + (238800)2 = 241,308Nmm
We also know that equivalent twisting moment;
π
Te = 16 × τ × d3 ……………………………………………………………… (5.37)
40
Then,
π
241,308Nmm = × 42N/mm2 × d3
16
d = 30.82mm
1
Me = (M + Te ) = 138,004Nmm
2
π
Me = 32 × σb × d3 ………………………………………………………….… (5.38)
π
138,004Nmm = × 84N/mm2 × d3
32
d = 25.58mm
 The standard diameter of shaft, d = 35mm
Check for safety
According to maximum shear stress theory:
1
τmax = 2 √(σb )2 + 4τ2 …………………………………………………………… (5.39)
where, σb = bending stress, τ = shear stress

σ M
= I ……………………………………………………………………………… (5.40)
y
Where,
πD4 π × 354
I= = = 73,661.76mm4
64 64
Bending stress;
My 34700 × (35/2)
σ= = = 8.24N/mm2
I 73661.76
16T 16 × 238800
τ= = = 28.37N/mm2
πd3 π(35)3
Therefore,
1
τmax = √(8.24)2 + 4 × (28.3)2 = 28.6N/mm2
2
41
Factor of safety =
210
Simulation for main shaft
b
Figure 5. 7(a) Von Misses Stress and (b) Displacements for the main shaft of diameter 35mm
The simulation shows that the design of main shaft is safe since the maximum von misses stress
(77.15N/mm2 ) less than the yield strength of the shaft material (350 N/mm2 ).
350
42
Design of key for the main shaft
Then L = 1.571𝑑 = 1.571×35 = 55𝑚𝑚
2.Design of the mixer shaft
The shaft is cylindrical with circular cross sections, pulley and bearing mounted on it. It has
bladed impeller mounted on it. The shaft will be subjected to combined stress bending and
twisting which is equivalent twisting moment.
Figure 5. 8 Mixer shaft free body diagram
Torque transmitted by the shaft;

P × 60 4850 × 60
T= = = 331Nm
2πN 2π × 140
The total weight of pulley on the shaft at A (downward);
FA = T1A + T2A + Weight of pulley = 448 + 36.63 + 50 = 535N
Forces acted on the shaft by the Centrifugal Force on Mixture at C = 1504.5N.
Taking moment about D;
535 × 580 + 1504.5 × 265 − R1 × 530 = 0
R1 = 1338N
For the equilibrium of the shaft;
535 + 1504.5 = 1338 + R 2
R 2 = 702N
Where, R1 and R 2 are upward reaction force at bearing B and D respectively.
43
Bending moment;
B.M at A and D = 0
B.M at B = 535×50 = 26,750Nmm
B.M at C = 702×265 = 186,030Nmm
So , the maximum bending moment on the shaft is MC = 186,030Nmm
Te = √(M)2 + (T)2 = √(186030)2 + (331000)2 = 379,695Nmm
We also know that equivalent twisting moment,
π
Te = 16 × τ × d3 …………………………………………………………………. (5.41)
Then,
π
379,695Nmm = × 42N/mm2 × d3
16
d = 35.84mm
1
Me = (M + Te ) = 282,862.5Nmm
2
π
Me = 32 × σb × d3 ……………………………………………………………. (5.42)
π
282,862.5Nmm = × 84N/mm2 × d3
32
d = 32.5mm
 The standard diameter of shaft, d = 40mm
Check for safety
σ M
= I ………………………………………………………………..……………. (5.43)
y
Where,
πD4 π × 404
I= = = 125,664mm4
64 64
Bending stress;
My 186,030 × (40/2)
σ= = = 30N/mm2
I 125,664
16T 16 × 331000
τ= 3
= 3
= 26.5N/mm2
πd π(40)
44
1 1
τmax = √(σb )2 + 4τ2 = √(30)2 + 4 × (26.5)2 = 30.45N/mm2
2 2
Factor of safety =
210
Simulation of mixer shaft
b
Figure 5. 9 (a) Von Misses Stress and (b) Displacements for the mixer shaft of diameter 40mm
The simulation shows that the design of mixer shaft is safe since the maximum von misses
stress (65.0N/mm2 ) less than the yield strength of the shaft material (350 N/mm2 ).
350
45
Design of key for mixer shaft
Then L = 1.571𝑑 = 1.571×40 = 62.84𝑚𝑚 say 65mm
5.3.7 Hopper
A hopper is a container used to hold and collect a mixed soap ingredient from the mixing tank.
The hopper receives the mixed soap ingredients from mixer vessel then convey it to screw by
gravity. It is made of mild steel.
Design specification
i. Capacity of hopper = 35Kg
ii. Required hopper volume = 0.04m3 = 40 × 106 mm3
Figure 5. 10 Hopper
So, the only dimension that is unknown is the height of the hopper. It can be get from the
formula of volume of the developed hopper.
1
Total volume of hopper = 200 × 400 × h + (2 × 180 × 400 × h)
2
Total volume of hopper = 140,000h mm2
Given that required hopper volume = 40 × 106 mm3
Solving for height (h)
40 × 106 mm3 = 140,000h mm2 , h = 285.7mm, take h = 300mm
 The height of hopper is equal to 300mm.
46
5.3.8 Housing barrel
The barrel is a cylindrical tube in which the extrusion of soap takes place by axial force of the
screw rotating inside it. One end of the barrel is closed with a die through which a soap bar is
released. The clearance between barrel and screw is 5 mm. The material used for a barrel is
mild steel.
Dimension of the barrel;
1. Outer diameter = 180mm
2. Inner diameter = 170mm
3. Thickness = 5mm
4. Length = 1500mm
5.3.9 Bearing selection
Bearing holds the shaft in position and enable its free rotation. The bearings chosen for main
shaft, mixer shaft and for the shaft of larger gear are radial ball bearing.
1.Bearing selection for main shaft
Specification;
i. Shaft diameter = 35mm
ii. Shaft rotation = 300rpm
From main shaft design, we got two bearing supports 𝑅1 and 𝑅2 are 1316.5N and 505.5N
respectively. So, take the larger radial force on bearing is 1316.5N for bearing selection design.
Let’s take the average life of bearing is 3 years at 10 hours per day, therefore the life bearing in
hours is;
LH = 3 × 300 × 10 = 9000hours …. (Assuming 300 working days per year)
Life of bearing in revolutions (L99 ) = 60N × LH = 60 × 300 × 9000
L99 = 162,000,000 rev
Take L90 is the life of bearing corresponding to reliability of 90 percent.
Considering life adjustment factors for the operating conditions and material to be 0.9 and 0.85
respectively, we have
1
L99 ln R 1
99 1.17
ln(1⁄0.99) 1⁄
=( ) × 0.9 × 0.85 = ( ) 1.17 × 0.9 × 0.85 = 0.1026
L90 1 ln( 1⁄ )
ln R 0.9
90
L99 162,000,000
L90 = = = 1,578,947,368
0.1026 0.1026
Now we have to calculate basic dynamic load rating first in order to choose the bearing,
Wr (radial load) = 1316.5 N, and N = 300 rpm, there is no axial load on bearing.
47
Dynamic equivalent load (W),
W = X. V. Wr + Y. Wa [9]……………………………………………………………… (5.44)
Taking V = 1 and X = 1 for self-aligning bearing, W = 1316.5N
Now we know that basic dynamic load rating is
1⁄
L K
C = W (10906 ) ……………….............................................................................… (5.45)
1,578,947,368 1
C = 1.3165KN × ( )3 = 11.64 KN
106
Service factor K S = 1.0 for uniform and steady load from table A9, so bearing should be
selected for 11.64 kN.
Based on the above values, the available bearings for the shaft is self-aligning radial ball
bearings. So, we choose the following specifications from table A8.
Main shaft bearing specification:
a. Bearing number 207
b. Bore diameter = 35mm
c. Outside diameter = 72mm
d. Width = 17mm
2.Bearing selection for the shaft of larger gear
Specification;
ii. Rotation of shaft = 75rpm
From shaft design for larger gear, the total force on shaft is 1883N each bearing supports
941.5N. So, take the radial force on bearing is 941.5N for bearing selection design.
hours is;
L99 = 40,500,000 rev
L99 40,500,000
L90 = = = 394,736,842.1
0.1026 0.1026
Dynamic equivalent load (W),
W = X. V. Wr + Y. Wa ………………………………………….………………. (5.46)
Taking V = 1 and X = 1 for self-aligning bearing, W = 941.5N
48
Now we know that basic dynamic load rating is;
1⁄
L K
C = W (10906 ) ……………………………………………………….…………. (5.47)
394,736,842.1 1
C = 941.5N × ( )3 = 7 KN
106
Service factor K S = 1.0 for uniform and steady load from table A9, so bearing should be
selected for 7 kN.
So, we choose the following specifications from table A8.
d. Width = 17mm
3.Bearing selection for mixer shaft
Specification;
ii. Shaft rotation = 140rpm
From mixer shaft design, we got two bearing supports R1 and R 2 are 1338N and 702N
respectively. So, take the larger radial force on bearing is 1338N for bearing selection design.
hours is;
L99 = 75,600,000 rev
Take L90 is the life of bearing corresponding to reliability of 90 percent.
Considering life adjustment factors for the operating conditions and material to be 0.9 and 0.85
respectively, we have;
L99 75,600,000
L90 = = = 736,842,105.3
0.1026 0.1026
Now we have to calculate basic dynamic load rating first in order to choose the bearing,
Wr (radial load) = 1338 N, and N = 140 rpm, there is no axial load on bearing.
Dynamic equivalent load (W);
W = X. V. Wr + Y. Wa ……..…………………………………….………………. (5.48)
Taking V = 1 and X = 1 for self-aligning bearing, W = 1338N
49
Now we know that basic dynamic load rating is;
1⁄
L K
C = W (10906 ) …..……………………………………………………..………. (5.49)
736,842,105.3 1
C = 1.338KN × ( )3 = 12.1 KN
106
Service factor K S = 2.0 for moderate shock load from table A9, so bearing should be selected
for 24.2KN
So, we choose the following specifications from table A8.
d. Width = 23mm
5.3.10 The die
The die block is firmly fitted at one end immediately after the edge of the extrusion shaft. The
die dimensions will determine the shape and dimensions of the bar soap. The die material must
have certain properties in order to withstand the stresses during operation. These properties
include thermal expansion and modulus of elasticity, mechanical properties, resistance to
thermal fatigue and chemical stress of die.
The selected material is low alloy heat treated steel due to its desirable properties. It is also easy
to cast in the workshop and affordable.
Figure 5. 11 Die
5.3.11 Cutter
It is used for cut a soap in to a number of bars. It is manually operated, simple and affordable
which requires little or no special skills for its operation and can be easily set up by small scale
industries even rural areas.
50
Figure 5. 12 Manual cutter
5.3.12 Frame
The main frame is made from 40mm x 40mm x 2mm rectangular hallow section mild Steel
which is capable for supporting all the machine components.
b
Figure 5. 13 (a) Von Misses Stress and (b) Displacements for the frame
The simulation shows that the frame is safe since the maximum von misses stress
(70.91N/mm2 ) less than the yield strength of the shaft material (250 N/mm2 ).
250
 Factor of safety = 70.91 = 3.5, so the frame is safe!
51
CHAPTER SIX
6.COST ANALYSIS
The cost analysis is used to determine the overall cost of the machine after manufacturing.
The total cost is the sum of the costs required to finalize the project from starting the design
up to product development (manufacturing the designed machine).
It is divided into four main costs as stated below.
1. Design cost
2. The cost of raw material
3. Operation process cost (Manufacturing cost)
4. Labor cost
1.Design cost
Design materials, design tools/ equipment (pen, print, internet, computer service) = 5000ETB
Design Labor cost =8000ETB
Total Design Cost = 13,000ETB
2.Material cost
The material cost refers to the sum of all raw materials which are consumed or used to the
produce the soap bar making machine. Those raw materials needed to produce this project are
list in the table 6.1 below.
Table 6.1Material cost
No Items needed Specification of Qty Unit Total

material Price price
(ETB) (ETB)
1 Three phase motor 10hp 1 67,960 67,960
2 Mild steel sheet metal 1m × 2m ×5mm thick 3 16,000 48,000
3 Mild steel sheet metal 1m × 2m × 3mm thick 1 7,000 7,000
4 Rectangular hallow 40mm × 40mm × 6m 2.5 2,500 6,250
section bar 2mm thick
5 Rectangular hallow 25mm × 25mm × 6m 1 1,600 1,600
section bar 2mm thick
6 Carbon steel shaft ∅40mm × 620mm 1 3,080 3,080
7 Carbon steel shaft ∅35mm × 500mm 1 2,100 2,100
8 Carbon steel spur gear ∅360mm, 50mm width 1 9,000 14,500
9 Carbon steel spur gear ∅90mm, 50mm width 1 4,000 4,500
52
10 Carbon steel key 12mm × 55mm × 8mm 6 120 720
11 Carbon steel key 14mm × 65mm × 9mm 1 150 150
12 Ball bearing Bore 35mm (6507) 4 2500 10,000
13 Ball bearing Bore 40mm (6308) 2 3000 6,000
14 Pulley Cast iron 4 - 12,000
15 Bolt and nut M12 31 40 1240
16 Mild steel electrode Pack 2 2,200 4,400
17 V-belt B type 4 950 3,600
18 Electrical heater - 1 4,500 5,500
Total material cost 195,100
3.Operation process cost

Table 6.2 Operation process cost
No Machine and tools Cost (ETB)per Working Total cost

day days
1 Lathe machine 2000 1 2000
2 Drilling machine 2000 1 2000
3 Milling machine 2000 1 2000
4 Bending machine 2000 1 2,000
5 Grinder machine 1500 2 3,000
6 Welding machine 1500 5 7,500
7 Electrode 2000 2,000
Total cost 20,500 ETB
53
4.Labor cost
Table 6.3 Labor cost
No Category of person Daily cost Working No of persons Cost (ETB)

days required
1 Machinist 600 3 2 3,600
2 Arc welder 600 5 1 3,000

3 Quality control 650 5 1 3,250
4 For assembly 600 2 2 2,400
Total cost 12,250
So the overall total cost = Total material cost + Total Design Cost + Total operation cost +
labor cost
The overall total cost = 13,000 + 195,100 + 20,500 + 12,500 = 241,100ETB
Including contingency (10%), the total cost = 265,210ETB
 So, the total cost of producing the machine is 265,210ETB
54
CHAPTER SEVEN
7.RESULT AND DISCUSSION
7.1 Result
Table 7.1 Result
No Components Result
1 Motor Power = 10hp
RPM = 900
Phase = 3
2 Screw conveyor Capacity = 140Kg/hr
Required power = 2.1512Kw
RPM = 75
Screw diameter = 160mm, Pitch = 160mm
Length = 1400mm, Solid shaft diameter = 35mm
Nominal thickness of helical screws = 5mm
Helix angle = 17.6, Length = 1.4m
3 Mixer vessel Capacity = 35Kg/batch
Height = 450mm, width = 400mm, length = 500mm
Thickness = 5mm
Power required = 4.41Kw
4 Pulley Pulley(1) d1 = 160mm,
from motor d2 = 480mm
to plodder Face width = 50mm
Pulley 2 d1 = 250mm, d2 = 560mm
Face width = 50mm
5 Belt Belt 1 Width = 17mm
Thickness =11mm
Pitch length = 2.481m
Groove angle = 34
Belt 2 Width = 17mm
Thickness =11mm
Pitch length = 2.71m
Groove angle = 34
55
6 Gear (smaller and larger) T1 = 18, T2 = 72
D1 = 90mm, D2 = 360mm
Addendum (a) = 5mm
Dedendum (d) = 6.25mm.
Working depth = 10mm
Minimum total depth = 11.25mm.
Thickness of the tooth = 7.854mm.
Module =5mm.
Face width = 50mm
7 Shaft Mixer shaft Diameter = 40mm Torque = 331Nm
Length = 620mm Max moment = 186,030Nmm
Main shaft Diameter = 35mm Torque = 238.8Nm
Length = 250mm Max moment = 34,700Nmm
Shaft for Diameter = 35mm Torque = 301.500Nm
larger gear Length = 150mm Max moment = 47,075Nmm
8 Key Key 1 Width = 12mm ,Thickness = 8mm, Length = 55mm
Key 2 Width = 14mm ,Thickness = 9mm, Length = 65mm
9 Barrel Outer diameter = 180mm
Inner diameter = 170mm
Thickness = 5mm
Length = 1500mm
10 Bearing Bearing 1 Bearing number 207
Bore diameter = 35mm
Outside diameter = 72mm
Width = 17mm
Bearing 2 Bearing number 308
Bore diameter = 40mm
Outside diameter = 90mm
Width = 23mm
As shown in the table the screw conveyor has a capacity of 140Kg /hour and mixer mixes 35Kg
of soap ingredients per batch. For this size, the total power required for both mixer and plodder
was determined to 6.56Kw. To cater for losses due to mechanical inefficiencies in the belt
drives and power loss in the bearing due to friction, the motor should have a slightly higher
56
power rating, like 7.22 kW due to power losses, assuming an efficiency of 90%. According to
this power requirement standard 10hp motor is selected. The screw conveyor is designed with
speed of 75rpm to extrude 140Kg of soap per hour. A motor with power rating of 10hp, running
at 900rpm is selected in determining the radius of the belt drive pulleys. The pulley from motor
to plodder machine was found to have a pitch diameter 0.48m on the larger pulley and 0.160m
on the motor pulley. The pulley system is designed to run on 2 v-belts. Standards from khurmi
were used in determining the dimensions of v-belts. The shaft is designed by considering
combined stress bending and twisting which is equivalent twisting moment. The diameter of
shaft is determined to be 35mm for main shaft,35mm for shafts of larger gear and 40mm for
mixer shaft. Self-aligning ball bearings were chosen for those shaft. The barrel is designed to
cover the screw conveyor which has 180mm outer diameter and 170mm inner diameter. When
calculating the safety factor for the bending and shear of the components it turned out to be
extremely safe to use. The total cost of producing the machine is 265,210ETB.
7.2 Discussion
The objective of this project was to design a soap bar making machine which is economical and
efficient. The machine which has a capacity of 140Kg /hour is designed. For this size, the power
required is determined to 10hp.
The comparison between the new and the existing system shows that a lot of improvement
occurred in the new system such as production area required, operating cost, and productivity.
It is so because combining two functions in a single unit and the machine can operate
continually can help to reduce the transfer time and distance. That leads to reduce cost and
improve the productivity of the system.
Table 7 2 Comparison between the existing and the new system
Productivity (kg/hr) Total cost

80 Kg/hr 230,000ETB
Existing machine 120 Kg/hr 300,000ETB
190 Kg/hr 420,000ETB
300 Kg/hr 600,000ETB
Modified machine 140Kg/hr 265,210ETB
57
CHAPTER EIGHT
8.CONCLUSION AND RECOMMENDATION
8.1 Conclusion
The soap bar making machine which combines two functions including extruding and mixing
in a single unit is able to improve the production cost and productivity. This machine has the
capacity to produce 140Kg of soap bar in one hour. From comparison between the new and the
existing machine, it was found that when using the modified machine, the required production
area and operating cost are reduced. Furthermore, the investment in making soap bar by using
this machine will provide job opportunity to the unemployed graduates, and new entrepreneurs
can start manufacturing soap with minimum capital requirement. Finally, we conclude that the
modified machine has potential to replace the traditional machines in the soap making industry
due to higher capacity and lower price of the modified machine.
8.2 Recommendation
Finally, we are interested to recommend the following about our design targeted to increase the
efficiency of the machine. Those are:
1. Designing a more effective way of cutting which is automatic to cut the soap in the
appropriate length from the die exit instead of manual operated cutter.
2. Designing simple die machine that has die with your own brand name.
58
REFERENCE
1. Thomssen, E. G. (1922). Soap-making manual: a practical handbook on the raw
materials, their manipulation, analysis and control in the modern soap plant. Van Nostrand.
2. M. Yogendra Shivankar, M. Yogesh Tembhurne, M. A. Jambhulkar, M. Lumit Badole, and
M. N. Sonkamble, “Design & Development of Automated & Customized Gomay Soap
Machine for Vatsalya Unique Products pvt. Ltd,” Journal of Emerging Technologies and
Innovative Research (JETIR)June 2019. [Online]. Available: www.jetir.org.
3. K.R. Ajao, K. Mustapha, M. R. Mahamood, and M. O. Iyanda, “Design and Development
of a Pedal-powered Soap Mixer,” 2010. [Online]. Available: http://www.alternative-
energy-
4. Issa A. K, Engr, M. H. Idris, and U. J. Ibrahim, “Design and Construction of Manually
Operated Soap Cutting and Scraping Machine for Small Scale Industries.” International
Journal of Engineering Research & Technology (IJERT)ISSN: 2278-0181Vol. 4 Issue 06,
June-2015. [Online]. Available: www.ijert.org.
5. B. N. Nwankwojike, “Design and Development of a Soap Stamping and Tableting Machine
for Small Scale Soap Manufacturing,” Nigerian Journal of Technology (NIJOTECH), vol.
31, no. 2, pp. 199–205, 2012.
6. Sale Yakubu (July, 2004). Design and construction of manual soap tableting machine
7. Siddhartha Ray (2001). Introduction to Material Handling. New Age International Ltd,
Publisher. New Delhi.
8. Dr. Daniel Kitaw (May 2001). Materials Handling Equipment. Addis Ababa University.
9. R.S. Khurmi and J.K. Gupta. (2005). A text book of machine design. (14th ed). Ram Nagar,
New Delhi: Eurasia publishing house.
10. William D. Callister, Jr and David G. Rethwisch, (2010). Materials Science and
Engineering an Introduction – 8th edition. John Wiley & Sons. Inc
11. Wikipedia. Mechanism of Cleansing Soaps, http://en.wikipedia.org/w/index.php? 2010.
Accessed April 5, 2023.
12. Soap|Encyclopedia.com.” https://www.encyclopedia.com/science-and
technology/chemistry/organic-chemistry/soap (accessed April 5, 2023).
13. Mixer Machine, Soap Mixer Machine, Mixer Machine Manufacturers, Soap Mixer Machine
Suppliers. http://www.detergentsandsoaps.com/mixer-machine.html(accessed April 18,
2023).
59
14. Small Soap Extruder – Small Soap Machines. https://www.smallsoapmachines.com/soap-
extruder-se-98.html (accessed April 18, 2023).
15. Electric motor catalog. https://worldwideelectric.com/wp-content/uploads/Electric-Motor-
Catalog.pdf.
60
APPENDIX 1
LIST OF STANDARD TABLES
Table A 1 Dimensions of standard v-belts according to is: 2494 – 1974[9]
Type of Power Minimum pitch Top width Thickness (t) Weight per
belt range in diameter of pulley (b) mm meter length
kw (D) mm mm in newton
A 0.7-3.5 75 13 8 1.06
B 2-15 125 17 11 1.89
C 7.5-75 200 22 14 3.43
D 20-150 355 32 19 5.96
E 30-150 500 38 23 -
Table A 2 Dimensions of standard v-grooved pulleys according to is: 2494–1974. (all dimensions in mm)
[9]
W D A C f E No. of sheave grooves Groove angle

(n) (2β) in degrees
11 12 3.3 8.7 10 15 6 32,34,38
14 15 4.2 10.8 12.5 19 9 32,34,38
19 20 5.7 14.3 17 25.5 14 34,36,38
27 28 8.1 19.9 24 37 14 34,36,38
32 33 9.6 23.4 29 44.5 20 -
Table A 3 Standard pitch length of v-belts according to is:2494-1974[9]
Type of belt Standard pitch lengths of V-belt in mm

645, 696, 747, 823, 848, 925, 950, 1001, 1026, 1051, 1102, 1128, 1204,
A
1255, 1331, 1433, 1458, 1509, 1560, 1636, 1661, 1687, 1763, 1814, 1941,
2017, 2068, 2093, 2195, 2322, 2474, 2703, 2880, 3084, 3287, 3693.
932 1008, 1059, 1110, 1212,1262, 1339, 1415, 1440, 1466, 1567, 1694,
B
1770, 1821, 1948, 2024, 2101, 2202, 2329, 2507, 2583, 2710, 2888, 3091,
3294, 3701, 4056, 4158, 4437, 4615, 4996, 5377.
C 1275, 1351, 1453, 1580, 1681, 1783, 1834, 1961, 2088, 2113,2215, 2342,
2494, 2723, 2901, 3104, 3205, 3307, 3459, 3713, 4069, 4171, 4450, 4628,
5009, 5390, 6101, 6863, 7625, 8387, 9149.
61
D 3127, 3330, 3736, 4062, 4194, 4473, 4651, 5032, 5413, 6124, 6886, 7648,
8410, 9172, 9934, 10696, 12220, 13744, 15268, 16762.
5426, 6137, 6899, 7661, 8423, 9185, 9947, 10709, 12233, 13757, 15283,
E
16805.
Table A 4 Minimum number of teeth on the pinion in order to avoid interference[9]
S.No System of gear teeth Minimum number of teeth on the pinion
1 ° 12
14 1⁄2 Composite
2 ° 32
14 1⁄2 Full depth involute
3 20° Full depth involute 18
4 20° Stub involute 14
Table A 5 Standard proportions of gear systems[9]

°
S.No Particulars 14 1⁄2 Composite or 20° Full depth 20° Stub
involute involute
Full depth
system system
involute system
1 Addendum 1m 1m 0.8 m
2 Dedendum 1.25 m 1.25 m 1m
3 Working depth 2m 2m 1.60 m
4 Minimum total depth 2.25 m 2.25 m 1.80 m
5 Tooth thickness 1.5708 m 1.5708 m 1.5708 m
6 Minimum clearance 0.25 m 0.25 m 0.2 m
7 Fillet radius at root 0.4 m 0.4 m 0.4 m
62
Table A 6 Values of service factor[9]
Types of service
Type of load Intermittent or 8-10 hours per day Continuous
3 hours per day 24 hours per day
Steady 0.8 1.00 1.25
Light shock 1.00 1.25 1.54
Medium shock 1.25 1.54 1.80
Heavy shock 1.54 1.80 2.00
Table A 7 Standard proportion of parallel, tapered and gib head keys[9]
Shaft Key cross section Shaft Key cross section

diameter(mm) diameter(mm)
Width Thickness Width Thickness
up to and up to and
(mm) (mm) (mm) (mm)
including including
6 2 2 85 25 14
8 3 3 95 28 16
10 4 4 110 32 18
12 5 5 130 36 20
17 6 6 150 40 22
22 8 7 170 45 25
30 10 8 200 50 28
38 12 8 230 56 32
44 14 9 260 63 32
50 16 10 290 70 36
58 18 11 330 80 40
65 20 12 380 90 45
75 22 14 440 100 50
63
Table A 8 Principal dimensions of radial ball bearing[9]
Bearing no Bore (mm) Outside diameter Width (mm)

(mm)
200 10 30 9
300 35 11
201 12 32 10
301 37 12
202 15 35 11
302 42 13
203 40 12
303 17 47 14
403 62 17
204 47 14
304 20 52 14
404 72 19
205 52 15
305 25 62 17
405 80 21
206 62 16
06 30 72 19
406 90 23
207 72 17
307 35 80 21
407 100 25
208 40 80 18
308 90 23
408 110 27
209 85 19
309 45 100 25
409 120 29
210 90 20
310 50 110 27
410 130 31
64
211 100 21
311 55 120 29
411 140 33
212 110 22
312 60 130 31
412 150 35
213 120 23
313 65 140 33
413 160 37
214 125 24
314 70 150 35
414 180 42
215 130 25
315 75 160 37
415 190 45
216 140 26
316 80 170 39
416 200 48
217 150 28
317 85 180 41
417 210 52
218 160 30
318 90 190 43
418 225 54
Table A 9 Values of service factor[9]

S.No Types of service Service factor for radial ball bearings
1 Uniform and steady load 1.0
2 Light shock load 1.5
3 Moderate shock load 2.0
4 Heavy shock load 2.5
5 Extreme shock load 3.0
65
APPENDIX 2
PART AND ASSEMBLY DRAWING
All dimensions in mm
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91

Design and Modelling of Soap Bar Making Machine

Uploaded by

Copyright:

Available Formats

Design and Modelling of Soap Bar Making Machine

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Design and Modelling of Soap Bar Making Machine

Uploaded by

Copyright:

Available Formats

BAHIRDAR UNIVERSITY

BAHIRDAR INSTITUTE OF TECHNOLOGY

June 8, 2015 E.C

Name of student Signature Date

1. Yalemsew Tebik ________________ _________________

Advisor Name _______________________

Advisors Signature ___________________

Name Signature Date

Key words: Soap bar making machine, Plodder and Extruder

LIST OF FIGURES .................................................................................................................viii

LIST OF SYMBOLS .................................................................................................................. x

CHAPTER ONE ......................................................................................................................... 1

1.1 Background ....................................................................................................................... 1

1.1.1 The existing soap bar making machine in Ethiopia ....................................................... 2

1.2 Definitions and Types of Soap .......................................................................................... 3

1.3.1 Description of parts and its functions ............................................................................... 4

1.4 Statement of The Problem ................................................................................................ 6

1.5 Objective ........................................................................................................................... 6

1.5.1 General objective ................................................................................................................ 6

1.5.2 Specific objective ................................................................................................................ 7

1.6 Significance of The Project ............................................................................................... 7

1.7 Scope of The Project ......................................................................................................... 7

CHAPTER TWO ........................................................................................................................ 8

2.LITRATURE REVIEW .......................................................................................................... 8

CHAPTER THREE .................................................................................................................. 10

CHAPTER FOUR .................................................................................................................... 11

4.CONCEPTUAL DESIGN ..................................................................................................... 11

4.2 Concept Generation and Selection of Concepts.............................................................. 11

4.2.1 Solution variants and selection of variants

CHAPTER FIVE ...................................................................................................................... 19

5.COMPONENT DESIGN ....................................................................................................... 19

5.1 General Consideration of Design .................................................................................... 19

5.2 Material selection ............................................................................................................ 20

5.3 Design Analysis .............................................................................................................. 20

5.3.1 Screw conveyor ................................................................................................................. 20

5.3.2 Mixer Basin(vessel) .......................................................................................................... 23

5.3.3 Motor selection.................................................................................................................. 25

5.3.4 Pulley and belt ................................................................................................................... 26

5.3.6 Shaft .................................................................................................................................... 38

5.3.7 Hopper ................................................................................................................................ 46

5.3.8 Housing barrel ................................................................................................................... 47

5.3.9 Bearing selection ............................................................................................................... 47

5.3.10 The die .............................................................................................................................. 50

5.3.11 Cutter ................................................................................................................................ 50

5.3.12 Frame ................................................................................................................................ 51

6.COST ANALYSIS ................................................................................................................ 52

CHAPTER SEVEN .................................................................................................................. 55

7.RESULT AND DISCUSSION .............................................................................................. 55

7.1 Result .............................................................................................................................. 55

7.2 Discussion ....................................................................................................................... 57

8.CONCLUSION AND RECOMMENDATION .................................................................... 58

8.1 Conclusion ...................................................................................................................... 58

8.2 Recommendation ............................................................................................................ 58

LIST OF STANDARD TABLES ............................................................................................. 61

PART AND ASSEMBLY DRAWING .................................................................................... 66

Define the problem and Determine the objective

Embodiment design Detail design

Figure 3. 1 Sequences of design methodology

Soap bar making

1. Yalemsew Tebik _