AUTOMATION IN SOAP MANUFACTURING

(Kettle process)

Submitted in partial fulfillment of the requirements

of the degree of
Bachelor of Instrumentation Engineering

by
Hitesh Meriya (44)
Panindra Mysorekar (47)
Dinesh Sonawane (72)
Vipul Geevarghese (11)

Supervisor :
Mrs. NilimaWarke

Instrumentation Enginering
Vivekanand Education Society’s Institute Of Technology,Chembur
2018-19
 CERTIFICATE

This is to certify that the project entitled “Automation in Soap Manufacturing”(kettle process)
is a bonafide work of “Hitesh Meriya(44), Panindra Mysorekar(47), Dinesh Sonawane(72)
and Vipul Geevarghese(11)” submitted to the University of Mumbai in partial fulfillment of the
requirement for the award of the degree of “Bachelor Of Engineering” in “Instrumentation
Engineering”.

-----------------------------------

Mrs. Nilima Warke

Supervisor/Guide

------------------------------- ----------------------------------

Dr. P.P Vaidya Dr. J.M Nair

Head of Department Principal
 Thesis Approval for Project Report Approval for B. E

This thesis / dissertation/project report entitled “Automation in Soap Manufacturing(kettle process)”

by Hitesh Meriya, Panindra Mysorekar, Dinesh Sonawane and Vipul Geevarghese is approved for
the degree of Bachelor Of Engineering (Instrumentation Engineering).

Examiners

1.---------------------------------------------

2.---------------------------------------------

Date:

Place:
 Declaration

I declare that this written submission represents my ideas in my own words and where
others' ideas or words have been included, I have adequately cited and referenced the original
sources. I also declare that I have adhered to all principles of academic honesty and integrity
and have not misrepresented or fabricated or falsified any idea/data/fact/source in my
submission. I understand that any violation of the above will be cause for disciplinary action
by the Institute and can also evoke penal action from the sources which have thus not been
properly cited or from whom proper permission has not been taken when needed.

Mr. Hitesh Meriya (44)

--------------------------------

Mr. Panindra Mysorekar (47)

--------------------------------

Mr. Dinesh Sonawane (72)

--------------------------------

Mr. Vipul Geevarghese (11)

--------------------------------
 ABSTRACT

Process Automation involves use of instrumentation and computer technology in various

industries like paper, food, mining and cement to operate efficiently and safely. Many small
scale industries purchase soap globules which are commonly known as soap noodles from large
scale industries like (Hindustan Unilever and godrej industries) for manufacturing toilet soap
which is the final product. Many local industries manually mix fats and alkali to make soap.
This process consumes a lot of time and labour. Hence we came up with the idea of automating
The kettle process of soap manufacturing followed by small scale industries. There are two
methods of saponification process i.e Batch process and Continuous process. Batch process is
also known as kettle process. It has been decided to automate kettle process. In this process,
PLC is used as an automation tool, discrete devices such as switches and Solenoid valves are
used for quick action. The load cell is used for weighing the material in the process tank and
accordingly the control valves for feed are controlled by the PLC. The heating and stirring
process is also controlled as well. These corrective actions taken by the PLC which, automates
the process and reduces the human intervention and the errors generated by the humans during
the manual control.
The design and fabrication of hoppers, process tank and mechanical set-up is the critical part
of the project. After this, the design and selection of various components like Y-control valve,
Solenoid valve, Motor, Temperature Switch, Heater and Load Cell is done. Each components
were tested by giving standard calibrating signals. The components are tested for their
healthiness by giving external signals and supply. To design the control panel, Size Selection,
Material Selection and Input-Output listing is done. The panel drawings like General
Arrangement(GA) drawings and Wiring drawings are generated which will be helpful for
wiring, testing and troubleshooting the control panel. Hardware and Software Interfacing is
done which is required for running the set-up according to the sequence written in the program.
Apart from this, important engineering documents and drawings like Piping and
Instrumentation diagram, Process Flow Diagram, Instrument Index Sheet, Input-Output List
and Specification Sheet are also generated which is very helpful for personnel handling,
operating and understanding the project.
 ACKNOWLEDGEMENT

The success and final outcome of this project required a lot of guidance and assistance
from many people and we are extremely privileged to have got this all along the completion of
our project. All that we have done is only due to such supervision and assistance and we would
like to show our gratitude towards them. We owe our deep gratitude to our project guide Prof.
Mrs. Nilima Warke madam and our HOD P. P. Vaidya sir who has given all required
permission by providing all the necessary permits for our project. A special thanks to Mrs
Kajal Madnani madam from V.E.S.I.T purchasing manager for procurement of valves,
Motors, and Temperature switch and providing us the necessary financial assistance. We our
thankful to and fortunate enough to get constant encouragement, support and guidance from
ISA- VESIT regarding need for controller, which helped us in successfully completing our
project work. We would like to thank Prof Mr N Gopalkrishnan sir regarding PLC technical
support. We would like to tender our sincere thanks to Mr. RN Dalvi sir for their co-operation
in Workshop. We would also like to express our deep regards and gratitude to the principal Dr.
Mrs. J. M. Nair madam.
 Index
1. Introduction : .................................................................................................................... 11
1.1 Motivation ................................................................................................................... 11
1.2 Objectives .................................................................................................................. 11
2. Soap manufacturing process:........................................................................................... 12
2.1 Continuous Process : ................................................................................................. 12
2.2 Kettle Process : .......................................................................................................... 13
3. Project Description ........................................................................................................... 14
3.1 Process Flow Diagram ............................................................................................... 14
3.2 Sequence ................................................................................................................... 15
3.3 Process Description:................................................................................................... 15
4. Components : ............................................................................................................... 16
4.1 Load Cell .................................................................................................................... 16
4.2 Process Tank ............................................................................................................. 17
4.3 Hopper ....................................................................................................................... 18
4.4 PLC (Programmable Logic Controller) ........................................................................ 19
4.5 Temperature Switch : ................................................................................................. 20
4.6 Y-type Control Valve................................................................................................... 21
4.7 Solenoid Valve : ......................................................................................................... 21
4.8 Single Phase Induction Motor : ................................................................................... 22
4.9 Electric Heater : .......................................................................................................... 22
5. Engineering Documentation ............................................................................................. 23
5.1 Piping and Instrumentation Diagram : ......................................................................... 23
5.2 Mechanical Setup : ..................................................................................................... 24
5.2.1 Design of Mechanical Setup :............................................................................... 25
5.2.2 Mechanical BOM: ................................................................................................. 26
5.3 Instrument Index : ...................................................................................................... 27
5.4 Instrument specification sheets :................................................................................ 29
6 Testing of Components : ................................................................................................... 34
7. Execution sequence ..................................................................................................... 39
7.1 Flowchart.................................................................................................................... 40
8. Control panel design : ................................................................................................... 41
8.1 GA Drawing of Control panel : .................................................................................... 41
 8.2 Wiring Diagram control panel : ................................................................................... 42
8.3 Power wiring of control panel : .................................................................................... 42
8.4 Digital output wiring drawing: ................................................................................. 43
8.5 Digital Input wiring drawing: ................................................................................... 44
9. Results and conclusion: ................................................................................................ 45
9.1 Project Views :............................................................................................................ 45
9.2 Future Scope : ............................................................................................................ 47
 Figures and Diagrams
Fig No. Figure Page no.

2.1 Continuous Process 11

2.2 Kettle Process 12
3.1 Process flow diagram 13
4.1 Load cell 16
4.2 Process tank 16
4.3 Hopper 17
4.4 PLC panel 18
4.5 Temperature Switch 19
4.6 Y-Type Control Valve 20
4.7 Solenoid Valve 20
4.8 Single Phase Induction Motor 21
4.9 Electric Heater 21
5.1 P & ID 22
5.2 Mechanical Setup 23
6.1 Load Cell Testing 33
6.2 Graph 34
6.3 Temperature Switch Testing 35
6.4 Push Button and Lamp Testing 35
6.5 Valve Testing 36
6.6 Heater Testing 36
8.1 Front Panel View 40
8.2 Rear Panel View 40
8.3 Power Wiring Diagram 41
8.4 Digital Output Wiring Diagram 42
8.5 Digital Input Wiring Diagram 43
9.1 Front View of setup 44
9.2 PanelView of before start 45
9.3 Panel View After Start 45
 Tables
Table No. Table Page

3-A Reactants 10
5-A Mechanical Bill Of Materials 11
5-B Instrument Index Sheet 12
5-C Load cell 29
5-D Electric Heater 30
5-E Temperature Switch 30
5-F Single phase induction motor 31
5-G Y-type control valve 31
5-H Solenoid Valve 32
5-I PLC General specifications 33
5-J Input Output Specification 33
6-A Load Cell Testing 34
6-B Input Output List 38
8-A Bill Of Material for Control Panel 44
 CHAPTER 1

1. Introduction

Soap is a combination of animal fats or plant oil and caustic soda. Soap and detergent
manufacturing consists of a broad range of processing and packaging Operations. The size and
complexity of these operations vary from small plants employing a few people to those with
several hundred workers. Products range from large-volume types like laundry detergents that
are used on a regular basis to lower-volume specialties for less frequent cleaning needs. The
global soap and detergent market size was estimated at USD 97.26 billion in 2016.
The earliest-known use of soap dates back to the ancient Babylonians, who made soap as early
as 2800 B.C. Clay containers from that era have been found inscribed with a recipe for soap
made from animal fats combined with wood ash and water. Soap was well-known throughout
the ancient world. The ancient Egyptians made soap as early as 1550 B.C. by combining animal
and vegetable fats with alkali salts. An entire soap-making factory was discovered in the ruins
of Pompeii. Using soap for personal hygiene did not become prevalent until the late Roman
Empire. Prior to that, it was used primarily for cleaning textile fibers prior to weaving and by
physicians to treat skin disease.

1.1 Motivation
In Industrial Soap manufacturing usually the first process is to make Soap granules (Commonly
called Soap Noodles)
These Soap Noodles are supplied by manufacturers like Godrej Industries to every small scale
industry ,for the manufacturing of soap bar then further processes are getting done like Color
,Fragrance etc. The team visited Regal Soap Factory, Mumbai to understand the process.
In small scale industry most of the process getting completed by manual method

1.2 Objectives
To automate traditional kettle process for soap manufacturing using PLC
To provide the opportunities to small scale industries to be self dependant
To make the process simple.
 CHAPTER 2

2. Soap manufacturing process

2.1 Continuous Process :

Continuous process is the process adopted by large scale industries to manufacture a soap.
Since it is continuous, hence, the fast process compare to batch process.
This process consists of four unit operations
1. Splitting
2.Mixing
3.Cooling and Finishing
4.Milling

Fig 2.1 Continuous Process

2.2 Kettle Process :

Kettle process is the process adopted by small scale industries to manufacture a soap.
This is the batch process hence, the slower process compare to continuous process.
This Process Consists of four unit operations
1.Boiling
2.Salting
3.Strong Change
4.Pitching

Fig 2.2 Kettle Process

 CHAPTER 3

3. Project Description
The process is described in the form of process flow diagram.Process fl ow Diagram is the diagram
which tells the flow of process from input to the output without field instruments except critical

3.1 Process Flow Diagram

Fig 3.1 Process Flow Diagram

The above PFD has two inputs i.e one input is the fats(coconut oil) and the other is
NaOH(lye) solution and the output is soap.Firstly, the fats are added in the process tank
according to the desired proportion where it is heated upto 100℃ using heater coil. Now,
the NaOH solution is added to the process tank and it is mixed accordingly using the stirrer.
Stirring process approximately lasts for 1 hour. The product is taken out by opening the hand
valve.
3.2 Sequence

1. Check the Hopper-1(fats) and Hopper-2(alkali) is filled.

2. Fill the tank with fats/oils.
3. Start the heating process.
4. When the temperature in the process tank reaches to the set point,
5. Stop the heating process
6. Feed alkali solution in the process tank.
7. Start the stirring process for the chemical reaction to happen
between the fats and alkalies,
8. Store product in the container for drying.

3.3 Process Description:

Understanding the lye Concentration for 33 % Concentration.

Reaction NaOH solution is built using 1 part of Lye and 3 Parts of water.To create 300
gms of reactants.
Lye (100 gms) + Water (200 gms) = 300 gms of NaOH reactant .

Lye to Oil proportions (Making Soap of 8% excess fat)

Table 3-A - [Reactants]

% Excess Fat Lye in gms Coconut Oil

(gms)

6% 52.4 100

7% 51.8 100

8% 51.2 100
 CHAPTER 4

4. Components

1. Load Cell
2. Temperature Switch
3. Hopper
4. Process Tank
5. Heater Coil
6. Selec Flexys Panel TX4 PLC
7. Stirrer Motor
8. Control Valves

4.1 Load Cell

A load cell is a transducer that is used to create an electric Signal whose magnitude is directly
proportional to the force being measured. The various load cell types include hydraulic,
pneumatic, and strain gauge. Ideally shear beam type load cells must be used it consist Alloy
steel construction and hermetically sealed having IP67 protection Available from 300 kg. to
10000 kg. capacities Low profile Also available in Stainless Steel FEATURES Low profile
platform scales above 1200 x 1200mm Industrial Automation Applications Hopper, Tank
Weighing Systems Baggage Weighing APPLICATION This Load Cell is designed for low
profile platform scales. Besides it is also used for industrial automation applications, hopper,
tank weighing systems. It is made from high tool steel alloy with Electroless Nickel plating for
protecting load cells from jerk loads & corrosion. These Load Cells are temperature

compensated from 0℃ to +60℃ with moisture protection. They are IP67 protected (protection
against normal water sprinkle).
 Fig 4.1 Load Cell

4.2 Process Tank

This the heart of the soap manufacturing process .The reactants NaOH and Fatty Acids react in
this chamber .
It is important to understand the corrosive nature of NaOH .Typically 33% Lye will be used in
this project with Standard Fatty Resources like Vegetable Oils .

Fig 4.2 Process Tank

4.3 Hopper

Hopper is a large, pyramidal shaped container used in industrial processes to old particulate
matter that has been collected from expelled air. Hoppers are usually installed in groups to
allow for a greater collection quantity.

Fig 4.3 Hopper

They are employed in industrial Processes such as dust collectors, electrostatic precipitators
and baghouses/fabric filters. They are particularly used in industry for protection and storage
of materials. Most hoppers are made of steel. Hoppers are constructed in mild steel plate
suitably braced and stiffened with supporting steelwork complete with belt / vibratory feeder to
suit applications and can be skid mounted, fitted with side plates, products grid and lining plates
as required. Hoppers must be designed such that they are easy to load. More importantly,
hoppers must be designed such that they are easy to unload.
4.4 PLC (Programmable Logic Controller)

The PLC is the brain of the automated system.

A programmable logic controller (PLC) or programmable controller is an industrial digital

computer which has been ruggedizedand adapted for the control of manufacturing processes,
such as assembly lines, or robotic devices, or any activity that requires high reliability control
and ease of programming and process fault diagnosis.

PLC is used in sequential process. It is handy when the process is discrete. It is used when the
number of I/Os are in the order of 100s. The number of I/O is fixed in fixed PLC, but in modular
PLC the number of I/Os can be expanded. Fixed PLC is used in the project as it has
comparatively less no of I/Os. PLC is used here because it has better advantages over hardwired
relay logic.

The PLC used in our project is Flexys TX4 panel.

Fig 4.4 Y-PLC Panel

4.5 Temperature Switch :

A thermostat is a component which senses the temperature of a physical system and performs
actions so that the system's temperature is maintained near a desired setpoint.

Thermostats are used in any device or system that heats or cools to a se tpoint temperature,
examples include building heating, central heating, air conditioners, HVAC systems, water
heaters, as well as kitchen equipment including ovens and refrigerators and medical and
scientific incubators. In scientific literature, these devices are often broadly classified as
thermostatically controlled loads (TCLs).

A thermostat operates as a "closed loop" control device, as it seeks to reduce the error between
the desired and measured temperatures. Sometimes a thermostat combines both the sensing and
control action elements of a controlled system, such as in an automotive thermostat.

Fig 4.5 Temperature Switch

4.6 Y-type Control Valve
The y-type design is a solution for the high-pressure drop problem in Z-type valves. In this type,
seat and stem are angled at approximately 45° to the pipe axis. Y-body valves are used in high
pressure and other critical services where pressure drop is concerned.

Fig 4.6 Y-Type Control Valve

4.7 Solenoid Valve :

A solenoid valve is an electromechanical device in which thesolenoid uses an electric current

to generate a magnetic field and thereby operate a mechanism which regulates the opening of
fluid flow in a valve.
Solenoid valves differ in the characteristics of the electric current they use, the strength of the
magnetic field they generate, the mechanism they use to regulate the fluid, and the type and
characteristics of fluid they control. The mechanism varies from linear action, plunger-
type actuators to pivoted-armature actuators and rocker actuators.

Fig 4.7 – Solenoid valve

4.8 Single Phase Induction Motor :

A Single Phase Induction Motor consists of a single phase winding which is mounted on the
stator of the motor and a cage winding placed on the rotor. A pulsating magnetic field is
produced, when the stator winding of the single-phase induction motor shown below is
energised by a single phase supply.

Fig 4.8 – Single phase induction motor

4.9 Electric Heater :

A heating element converts electrical energy into heat through the process of Joule
heating. Electric current passing through the element encounters resistance, resulting in heating
of the element. Unlike the Peltier effect, this process is independent of the direction of current
flow.

Fig 4.9 – Electric Heater

 CHAPTER 5

5. Engineering Documentation
5.1 Piping and Instrumentation Diagram :
Piping and instrumentation diagram (P&ID) is a detailed diagram in the project which shows
the piping and process equipment together with the instrumentation and control devices.

Fig – 5.1 P&ID

Fig 5.1 P & ID

5.2 Mechanical Setup :

Fig 5.2 Mechanical Setup

5.2.1 Design of Mechanical Setup :

1. Hopper(2) :
Upper base diameter : 270 mm
Lower base diameter : 18.75 mm
Height : 750 mm
Slant height : 200 mm
Cylindrical height : 450mm
Conical height : 155 mm
Conical angle: 51 degree

2. Process Tank :
Diameter : 330 mm
Height : 450 mm

3. Component Housing :
Height : 1500 mm
Breadth : 900 mm
Width : 450 mm

4. Stirrer :
Length : 600 mm
5.2.2 Mechanical BOM:

Table 5-A [Mechanical Bill of Materials]

Sr No Material Dimension Quantity

1 40 mm Square 6ft 3
pipe
2 GI sheet 5ft x 5ft 1

3 Plywood 4ft x 4ft 1

4 MS Circular Sheet ɸ12.5 ” 1

5 GI threaded pipe ɸ3/4” 3

6 Flexible pipe ɸ3/4” 2

5.3 Instrument Index :
Table 5-B [Instrument Index Sheet]

No. Instrument Tag Instrument Service Loc. I/O Control Range/ Eng
No. Class type System Span g.
& Unit
Manufacturer
MODEL

1. Load Cell WE- Analog Reactn Field AI PCS 40 Kg

101 CZL-601 Tank
Bottom
outlet

2. Temp TSH Discrete Reactn Field DI/ PCS 30-110 C

Switch -101 Elcon Gold Tank NC
DLX-102 left
Side

3. Y-type CV- Electro- Hopper Field DO PCS - -

Control 101 Pneumatic Fats
Valve Outlet

4. Solenoid SOV Electrical Hopper Field DO PCS - -

Valve -101 alkali
Outlet

5. Single M- Electrical Reactn Field DO PCS 1400 RP

Phase IM 101 Tank M
Top

6. Heater H- Electrical Reactn Field DO PCS 1.5 KW

101 Tank
Rear
Bottom
Side
7. Load Cell WT- Analog Reactn Field AI PCS 0-10 V
Transmitte 101 Tank
r Bottom
outlet

8. Start Push P_St Discrete Pane DI PCS - -

Button art - l

9. Stop Push P_St Discrete Pane DI PCS - -

Button op - l

10. Start Lamp P_O Discrete Pane DO PCS - -

N - l

11. Stop Lamp P_O Discrete Pane DO PCS - -

FF - l
5.4 Instrument specification sheets :

1. Load Cell :
Table 5-C [Load Cell]

Sr no. Description Technical Specifications

1. Tag Number WE-101

2. Nominal Output 2.0mV / V

3. Precision C2/C3(0.017% & 0.02% FSO Comprehensive

error)

4. Excitation Voltage 9VDC - Maximum 15 VDC

5. Safe Load 120% of Rated Capacity

6. Ultimate Load 150% of Rated Capacity

7. Non Linearity <±0.03% of FSO (Full Scale Output)

8. Creep (30 minutes) <±0.025% of FSO

9. Zero Balance <±1% of FSO

9. Input Resistance 400 ± 10 ohms

11. Output Resistance 350 ± 5 ohms

12. Temperature Range 0℃ to +60℃

13. Insulation Resistance Above 5000 Mega ohms

14. Temp. Compensation -10C to +40C

15. Temp. Effect on Zero & Span <0.03% FSO/10C

16. Material Aluminium Alloy, Colourless anodized

17. Cable 4mm, 0.42metre

2. Electric Heater :
Table 5-D [Electric Heater]

Sr no. Description Technical Specifications

1. Tag Number H-101

2. Power Supply 230VAC

3. Power Rating 1.5KW

4. Coil Resistance 39.5ohm

5. Heater Current 6.5A

6. Service Liquid

7. MOC

8. Mounting Style Horizontal

3. Temperature Switch
Table 5-E [Temperature Switch]

Sr no. Description Technical Specifications

1. Tag Number TSH-101

2. Power Supply 230VAC

3. Temperature Range 30-110C

4. Contact Rating 15A

5. Contact Type Normally Closed

6. MOC Copper

7. Sensing Element Capillary Tube (Powder Filled)

4. Single Phase Induction Motor

Table 5-F [Single phase induction motor]

Sr No. Description Technical Specifications

1. Tag Number M-101

2. Power Supply 230VAC

3. HP Rating ¼

4. Mounting Style Vertical

5. Motor Current 0.57A

6. Type Capacitor Start Capacitor Run

7. Direction Bi-directional

8. Speed 1400 RPM

9. Shaft Size 8mm

5. Y-Type Control Valve

Table 5-G [Y type control valve]

Sr No. Description Technical Specifications

1. Tag Number CV-101

2. Working Pressure 3-6 bar

3. Port Size ¾ inch

4. Body MOC SS316

5. Actuator Linear (Piston Type)

6. Service Oils, Steam, Chemicals and Water

7. Process Connection Screwed

8. Valve Plug On-Off

9. Accessories Solenoid Actuator(24VDC)

6. Solenoid Valve
Table 5-H [Solenoid valve]

Sr No. Description Technical Specifications

1. Tag Number SOV-101

2. Coil Voltage 230VAC

3. Coil Current 0.57A

4. Coil Resistance 400 ohm

5. Port Size ¾ inch

6. Process Connection Threaded

7. MOC Brass

8. Operation On-Off

9. Mounting Style Line Mounted (Diaphragm)

7 PLC Specifications

General Specifications :

Table 5-I [PLC General Specifications]

Sr No. Description Technical Specifications

1. Power Supply 230VAC

2. Power Consumption 13VA

3. Sensor Supply 10V

4. Communication Port RS485 Slave

5. Communication Protocols ModBus RTU

6. Mounting Panel Mount

7. Program Memory 221K

8. Data Memory 32K

Input/Output Specifications :

Table 5-J [Input output specifications]

Sr No. Input/Output Inputs/Output Input/Output Input/Output

Per Card Type Voltage Range/Rating

1. Digital Input 10 PNP 7-30VDC

2. Digital Output 8 RO 5A@30VDC

3. Analog Input 5 Voltage 0-10VDC

4. Analog Output - - -
 CHAPTER 6

6 Testing of Components
1. Load Cell : The load cell used is CZL601 . It is a horizontal platform weighing type
load cell .Its maximum limit to measure weight is 40 kg. The performance
characteristics is tested . Its response is linear .Supply given to Load cell is 12 VDC.

Fig. 6.1 Load cell testing

Fig 6.1 – Load Cell Testing

Table 6-A [Load Cell Testing]

Weight Measured voltage Calculated weight

100 gms 0.16 mV 100gms

200 gms 0.21 mV 183.3gms

500 gms 0.40mV 505 gms

1000 gms 0.71 mV 1016 gms

1500 gms 1.00mV 1500 gms

2000 gms 1.31 mV 2018 gms

2500 gms 1.63 mV 2550 gms

3000 gms 1.92 mV 3003 gms

4000 gms 2.51 mV 4033 gms

5000 gms 3.11 mV 5016 gms

` `
Graphical Representation of Load Cell Observations :

Fig 6.2 – Graph

Sample Calculation :

Nominal Output : 2 mV/V

Max. Sensing Weight : 40 Kg.
Excitation Voltage : 12 V

STEP 1)
Let ,x = Load cell reading * Maximum Sensing Weight
x= 0.71 * 40
x= 0.0284v- kg.

STEP 2)
Let ,y= Nominal Output * Excitation Voltage
= 2 * 10e-3 * 12
= 0.024 V

Measured Weight = x / y
= 0.0284 / 0.024
= 1.18 Kg.
Temperature Switch test :

The temperature switch used is a basic thermostat. The power supply to it is 230 V AC. The
setpoint can be given by adjusting the knob given to it. The temperature range to It is 30- 110
degrees Celsius. The lamp is connected to temperature switch in series. The lamp is the heat
source it it. The setpoint given was 60 degrees. The temperature switch is the NC contact.
Initially the temperature is below the setpoint which is the room temperature. As long as the
temperature is below the setpoint the lamp is on. When the temperature reaches the setpoint the
contact breaks and the lamp turns off.

Fig 6.3 – Temperature Switch test

The above diagram shows Temperature switch is connected in series with the bulb , when it
reached the set temperature it will get disconnected as it will break the series and bulb will turn
off .

Push button and Lamp test:

The push- button ( NO - type) and the red lamp are interfaced with PLC. The lamp is powered
by PLC’s Relay output. With this PLC’s I/O modules are also verified. When the button is
pressed the output lamp gets energized. When the P.B is released then the Lamp turns off.

Fig 6.4 – Push Button and Lamp test

Valve tests :

1. Y-type control Valve :

Y-type control valve is pneumatically actuated. The valve operates in 3-5 Bar pressure.
It is an on off valve. It requires solenoid pilot actuator to allow and divert air supply.
The solenoid actuator requires 24V DC supply.

Fig 6.5 – Valve Testing

2. Solenoid valve test :

Solenoid valve is electrically actuated. It requires 230V AC supply. The test is performed by
providing 230V supply and allowing the water from the hopper to pass through it. The hopper
must have some minimum pressure head for successful actuation.

Motor Testing :
Motor used in the project is single phase induction motor with power rating of 0.25 HP .It
requires single phase supply of 230 VAC. It is a bidirectional operated motor .

Heater Testing :
Heater is used as a heating element to heat the process fluid upto required temperature of around
90-100 degree celsius. It requires 230 VAC supply to heat the fluid .It is a liquid heater .It is
tested by dipping it in a water container .

Fig 6.6 heater testing

INPUT-OUTPUT LIST
Table 6-B [Input Output List]

Sr No. Inputs-Outputs Type

1. Start Push Button Discrete Input

2. Stop Push Button Discrete Input

3. Start Lamp Discrete Output

4. Stop Lamp Discrete Output

5. Load Cell Analog Input

6. Heater & Temperature Switch Assembly Discrete Output

7. Electric Motor Discrete Output

8. Y-Type Control Valve Discrete Output

9. Solenoid Valve Discrete Output

 CHAPTER 7

7. Execution sequence

As the process takes more than an hour to complete, timers can be used for demonstration
purposes. By following this approach it is possible to test every component together in a single
run.

The Sequence of actuation is maintained in the program. The sequence is:

1. When the start button is pressed green light turns on and opens y – type valve
2. Y- type valve is open for 20 secs allowing the fats into the process tank
3. Later the heater heats the fats for 15 secs. After 15 secs the heater is turned off.
4. Solenoid valve is turned on for 15 sec to allow the alkalis in the tank.
5. As the alkalis fill in the tank, the motor runs for 10 seconds.
6. Finally the process stops and turns red lamp on.

The actual process involves Load cell and requires adc processing in the PLC. This process
takes long time to undergo heating. As analog sensors are used here it takes long time for the
process to reach the steady state. Practically soap manufacturing requires atleast one hour to get
completed. The final product is generally taken out after one and a half hour of the process. The
ladder diagram of the actual process is shown below.
7.1 Flowchart
 CHAPTER 8

8. Control panel design

8.1 GA Drawing of Control panel :

These drawings indicate the locations of main equipments in the plant. The main piping items,
valves, and fittings are also indicated in the General Arrangement or GA drawings. Most
often the piping is indicated using a top-view.

Fig 8.1 Front Panel View

Fig 8.2 Rear Panel View

8.2 Wiring Diagram control panel :

Wiring diagram is a simplified conventional pictorial representation of an electrical circuit.

It shows the components of the circuit as simplified shapes, and the power and signal
connections between the devices.

A wiring diagram usually gives information about the relative position and arrangement of
devices and terminals on the devices, to help in building or servicing the device. This is unlike
a schematic diagram, where the arrangement of the components' interconnections on the
diagram usually does not correspond to the components' physical locations in the finished
device. A pictorial diagram would show more detail of the physical appearance, whereas a
wiring diagram uses a more symbolic notation to emphasize interconnections over physical
appearance.

8.3 Power wiring of control panel :

Fig 8.3 Power Wiring Diagram

8.4 Digital output wiring drawing:

Fig 8.4 Digital Output Wiring Diagram

 8.5 Digital Input wiring drawing:

Fig 8.5 Digital Input Wiring Diagram

Table 8-A [Bill Of Material for Control Panel]

Item No. Design Description Make Quantity

1. Panel 450(H)x450(W)x250(D) -- 1

2. MCB For Power supply (SP, 10A) ABB 2

3. PLC Programmable Logic Controller Selec 1

4. X1 Terminals for Incoming Supply(230V) -- 3

5. X2 Terminals for Power Distribution(230V) -- 8

6. X3 Terminals for DC power Distribution(24VDC) -- 8

7. X4 Terminals for Discrete Input(10V) -- 5

8. PB1-PB2 Pushbuttons for discrete Input -- 2

9. L1-L2 Lamps for Discrete output -- 2

10. CR1-CR2 Control Relay(24VDC, 8 pin, 5A) Omron 2

11. CR3 Control Relay(24VDC, 8 pin, 10A) Omron 1

 CHAPTER 9

9. Results and conclusion

The hoppers were designed and fabricated with height 200mm and 11L volume. The process
tank has been designed and fabricated with 330 mm ɸ and 450 m height. The mechanical
setup was completed as per the design with 1500x900x450mm as the dimensions. The
components were selected and procured successfully. The components were tested and
verified by giving calibrating signals. The observations were recorded. The ladder program
was developed and simulated on software. After individual testing of components the
sequence designed for the automation was tested with a program developed on PLC. The
final setup is running smoothly without any errors. The setup is first demonstrated with
water. The setup runs smoothly with water as reactant.

9.1 Project Views :

Fig 9.1 - Front view

Fig 9.2 – Side view before start

Fig 9.2 – Side view after start

9.2 Future Scope :

Currently Automation in Soap Manufacturing Project requires an operator to operate

the whole setup but it can operated automatically by using GSM module using a smart
phone also one can use Artificial Intelligence to operate it. The product removal can
also be automated by using level sensors. The fluids inlet to the hoppers can also be
automated. This process can also be used for alternative purposes like mixing. By
simply changing the control logic and program we can use this setup for different
purposes. Also This Project currently able to produce Soap granules but for actual
manufacturing of Soap Sample , Various processes like grinding , milling , cutting can
be automated for the manufacturing of the same. Safety interlocks can be introduced in
the process for protecting the system by shutting down the heater to prevent dry run.
The maintenance feature can also be introduced to it for periodic checks. The on line
data gathering can be made possible for remote control. Live data can be sent on the
internet(IOT) for any time anywhere access. The soap manufacturing process can be
speeded up by using ethyl acetate as one of the reactants.
 BIBLIOGRAPHY

1.Thomas Hughes, “Programmable Logic Controller”, ISA Publication, 2001.

2.Gary Dunning, “Introduction to Programmable Logic controller”, Thomas Learning,
edition, 2001.

3.John. W. Webb, Ronald A Reis, “Programmable Logic Controllers – Principles and

Applications”, 3rd edition, Prentice Hall Inc., New Jersey, 1995.
4.Bela G. Liptak “Instrument Engineers handbook- Process control” Chilton book
company- 3rd edition.