Soap Maker Bubbling Over on Eaton Filters

Eaton’s DCF-800 Mechanically Cleaned Filter has helped this soap maker achieve a final product that consistently meets purity goals and has allowed for a more productive and cost-efficient manufacturing process.
Problem: Impurities in the soap due to an outdated filtering process
Solution: Eaton’s DCF-800 Mechanically Cleaned Filter
Results: The final product consistently meets purity goals and the manufacturing process is more productive and cost-efficient
Background
While maybe not quite as frightening as the famous Alfred Hitchcock shower scene, just imagine the shock of stepping into a hot shower, unwrapping your favorite bar of soap, and discovering that it’s already dirty. It can happen. That’s because soap contains glycerin, which brings with it important moisturizing properties. During the manufacturing process, glycerin is heated and added to the soap formulation before it goes to final production. However, the heating needs to be precise with little margin for error. When it is not heated properly, the soap can turn brown and even form brown specks that are small but still very much noticeable, hardly the 99 and 44/100% pure that a good soap needs to be.

Challenge
For one of the world’s largest suppliers of bar, detergent and body soaps, meeting that lofty goal is imperative to success. Supplying virtually every type of soap made, the company on any given day will see some 25 different brands of soap rolling down its production line. Relying on an outdated heating and filtering process, the company often had to reroute soap back into the assembly line to remove the brown haze and specks caused by the improperly heated glycerin to ensure that quality objectives were always achieved.  The rerouting was necessary, but was inefficient, expensive and time-consuming.  Additional labor was also required. While the final product was eventually meeting purity goals, the soap giant very much wanted to clean up the process.

Solution
In doing so, they turned to Eaton Filtration and installed a DOFF 800 filtration system for a 90-day trial run. The DOFF 800, a forerunner of the newer DCF­800 filters, is often used for trials.
Both perform a self-cleaning action by mechanically scraping collected debris from the filter screen with a disc that moves up and down the screen, parallel to the liquid flow. Collected debris is then automatically purged from the collection chamber at the bottom of the filter.  This self-cleaning action is performed without halting production and provides the highest quality filtering under continuous demand. Because the screen is cleaned continuously, a consistently high flow rate is maintained.  Uninterrupted filtering by the DCF also helps ensure consistent temperatures— a feature essential to meeting quality objectives.

Result
Before the 90-day test was even completed, the soap company was already washing its hands of the brown mess and has since ordered two new Eaton DCF-800 filters.  “Removal of the glycerin impurities was very successful,” reports Bruce Law, regional sales manager for Eaton’s filtration business. “The test unit delivered everything that we said it would.”  As a result, Law believes the costly rerouting of soap will soon be virtually eliminated.  “It’s still too early to gather a measurable return on investment,” adds Law, “but based on the results of the trial, the number of bars of soap that the company produces, and the cost to rework an out of spec product, it strikes me that the payback is going to be pretty quick.”

DCF-800 – One actuator delivers simple, reliable operation with water-like liquids. Ideal where a low initial investment is a key Our unique circular cleaning disc design (MCF design shown) ensures intimate contact with the screen to thoroughly and uniformly clean the media

 

Eaton’s Newest Customer Success Story : Paint Manufacturer

The Eaton DCF-1600 mechanically cleaned filter was installed to remedy the problems associated with large particles and foreign fibers. The quality of finished paints improved while the company reduced process costs, and gained a safer and cleaner work environment.

Read the full success story today. Click to Read

Magnetic Inserts for Fabricated and Standard Cast Pipeline Strainer Baskets from Eaton

Although a mesh lined Eaton strainer basket will catch and remove very small unwanted particles (down to 400 mesh), there are applications where microscopic iron or steel particles are present in the fluid. Because of their size they will often pass through the finest mesh screen. The problem is particularly prevalent whenever there is wear of iron or steel parts against each other in the system.

Examples are cooling or lubricating lines to bearings, liquids being processed on rolls or roller mills such as paint or ink, and any material passing through a gear system. A simple, cost-effective way to remove these damage causing particles is to install magnetic inserts in the Eaton strainer basket. All the fluid passes over the powerful magnets, which catch the fine steel or iron particles that may otherwise pass through the mesh lining of the basket.

The magnets are Alnico, guaranteed to retain their magnetism indefinitely, and so powerful they will hold metal several times their own weight. They are
completely encased and sealed in a 1/8” thick type 316 stainless steel shell— thus assuring freedom from contamination or corrosion.

Processing chocolate? Eaton’s filtration business has the perfect solution for you.

Did you know that Eaton’s filtration business has extensive experience with the processing of chocolate and other cocoa products.

Some specific examples include:

  • Milk, white and dark chocolate
  • Chocolate-based coatings and frostings
  • Chocolate beverages
  • Cocoa mass or liquor
  • Cocoa butter
  • Cocoa powder
  • Pectin for jams and marmalades

Water is introduced many times in the beginning processing stages to filter out shells, dirt, bugs and larvae. The water is recycled many times and then re-circulated – our filtration systems can help to make this process more efficient and more complete.

Our industrial filtration systems are used in a number of processes, a few specific examples include:

  • Harvesting
    Once removed from the trees, the cocoa pods are split open to release the beans that are embedded in a pulp. When the pods are broken the beans and pulp are sterile, but they become contaminated with a variety of microorganisms from the pods, laborers hands, insects, vessels used for transport etc.
  • Fermentation
    During fermentation complex chemical changes take place in both the pulp surrounding the seeds and within the seeds themselves, and the chocolate flavor is developed. The pulp surrounding the beans develops the color and flavor of the beans. Cleaning The beans are cleaned and can then undergo a form of thermal pre-treatment to separate the shell from the bean. One form of thermal pre-treatment uses infrared technology in which the beans undergo infrared radiation on a ‘ fluidized’ bed or vibrating conveyor. Water accumulates on the surface of the bean and bursts the shell.
  • Shell Removal
    The beans are then separated from the shells. Water is introduced many times in this stage to filter out shells, dirt, bugs and larvae. The water is recycled many times and then recirculated.
  • Grinding
    The nibs are ground to make cocoa liquor. There are two stages of the grinding process. In the first stage, the beans are ground using various methods and will produce liquid mass called cocoa liquor. There are two possible ways to continue to the second stage: either the cocoa liquor is further processed into cocoa butter and cocoa powder (usually only done with low-quality beans), or chocolate.
  • Pressing
    When the nibs are ground, the resulting liquid produced by the friction is called cocoa liquor. Giant presses squeeze cocoa butter from the liquor then refined.
  • Deodorizing
    Typically cocoa butter extraction is done through a solvent, then refined and deodorized. However, if it is extracted by any other method, a strong cocoa aroma will be present. If this odor is undesirable, the addition of a deodorizing process is necessary. This process is usually completed using superheated steam under a vacuum. The steam strips and distills volatile substances from the butter. This process takes anywhere from 30 minutes to 3 hours depending on the deodorization requirements.
  • Cooling
    The cocoa butter is cooled and filtered for any final particulate that might remain. It is then prepared for the storage drum.
  • Conching
    This two stage process (dry and liquid) involves the heating of the chocolate to a pre-determined temperature to add viscosity. It is also used to eliminate any unnecessary remaining moisture. Many times the following liquid stage necessitates the addition of cocoa butter.

We offer a wide variety of filters for Food and Beverage processes. Visit Eaton today to learn more about our Food and Beverage filtration products.