Project Overview
Basic Project Information
This project is an export delivery project for a complete bath soap production line with a rated capacity of 300kg/h for manufacturing bath soap. The production line covers raw material pretreatment, soap refining & mixing, three-roll milling, vacuum plodding and soap stamping & cutting sections, excluding the downstream automatic packaging equipment. The complete electrical system is custom-designed to match the local industrial power grid in Indonesia.
The delivery scope includes full main machine units, matched wear spare parts, operation drawings & manuals, remote technical guidance, and technical training for operators and maintenance personnel.
Client Background & Requirements
The client is a local Indonesian daily chemical manufacturer planning to expand bath soap production capacity for the local retail market. The client’s old equipment suffered from insufficient soap fineness, high defective rate of finished soap, low automation and heavy labor input, making it difficult to stably produce high-quality bath soap.
The client’s core goal is to build a continuously-operated bath soap production line, improve finished product consistency and expand market share of local bath soap products.
Production Line Configuration & Technical Parameters
Process Flow
Raw material feeding → Soap refining and mixing → Three-roll milling → Vacuum plodding → Soap stamping and cutting
Note: The production line ends at the soap forming section. Subsequent packaging processes rely on the client’s existing equipment.
Core Technical Parameters
| Item | Description |
|---|---|
| Rated Capacity | 300kg/h for bath soap, supporting long-duration continuous operation |
| Applicable Products | Multiple types of bath soap, switchable for different fragrance and moisturizing formulas |
| Material Contact Parts | 304 stainless steel, complying with daily chemical hygiene requirements |
| Power Supply System | Customized for Indonesia industrial power grid with built-in voltage fluctuation protection module |
| Production Line Scope | Raw material pretreatment → Soap refining & mixing → Three-roll milling → Vacuum plodding → Soap stamping & cutting (Automatic packaging excluded) |
| Operation Feature | Flexible production; multiple soap SKUs available by adjusting formulas |
Localized Custom Design for Indonesia
- Electric control cabinets are equipped with anti-condensation and sealed moisture-proof design to adapt to Indonesia’s hot and humid tropical climate.
- The electrical system is manufactured in accordance with Indonesian grid standards. No extra transformer modification is required on-site for the client.
- A customized wear spare parts package is provided considering the difficulty of accessory procurement in Indonesia to reduce later maintenance costs.
Project Execution Process
Equipment Manufacturing Phase
After project kickoff, our team completed component procurement, frame fabrication, full machine assembly and electrical wiring integration. All equipment is manufactured strictly following export equipment standards.
Factory Acceptance Test (FAT)
After equipment assembly, no-load test and material trial run were carried out to verify the stable 300kg/h production capacity and soap forming quality. The client completed acceptance remotely and checked the stability of the electrical system. Upon acceptance approval, we delivered the full set of operation manuals, electrical schematics and maintenance documents.
Export Sea Freight Packaging Solution (For salt fog & humid long-distance ocean shipment to Southeast Asia)
The equipment is packed in heavy-duty fumigation-free wooden cases with steel skids. Anti-rust oil is applied on machined surfaces, with moisture-proof film and desiccants inside the package. Large equipment is reasonably split, precision components are protected separately. Shipping marks are marked clearly, and packing list, weight and volume information are double-checked item by item.
Container Loading, Customs Declaration & Documentation
The whole container loading process is supervised with photos and videos retained. We prepare full export documents and assist the client with materials required for import customs clearance in Indonesia.
Post-Delivery Service Arrangement
Practical training is provided for the client’s staff, including equipment operation, formula debugging, routine maintenance and common fault troubleshooting. We supply warranty service and long-term remote technical support.
Project Challenges & Solutions
Challenge 1: Hot & humid tropical climate in Indonesia plus power grid fluctuation in industrial zones
Problem: Indonesia features year-round high temperature and high humidity. Ordinary electric cabinets are prone to condensation and short circuit. The power grid in local industrial zones is unstable, and voltage fluctuation may damage motors and frequency converters.
Solution: Anti-condensation heaters are installed inside control cabinets with sealed moisture-proof treatment. Motors adopt high moisture-proof protection grade to resist salt fog during ocean transportation and humid factory working conditions. The whole electrical system is customized for Indonesian power grid before delivery and equipped with voltage fluctuation protection modules to reduce risks of shutdown and component burnout caused by unstable voltage.
Challenge 2: Strict formula requirements for bath soap, prone to soap billet cracking and blurry stamping patterns
Problem: Bath soap adopts more complex oil formulas than laundry soap. It is hard to control soap toughness. Ordinary production lines often encounter broken soap bars and unclear surface patterns, leading to high scrap rate.
Solution: Optimize the structure of the vacuum plodder unit to match bath soap formula characteristics. Upgrade the three-roll mill unit to ensure fine and uniform soap material, stabilize soap forming appearance and lower production defect rate.
Challenge 3: Container loading for non-standard heavy equipment, high risk of rusting and deformation during long ocean shipment
Problem: The production line equipment has irregular shapes and heavy weight. The long shipping time from China to Indonesia exposes metal parts to salt fog corrosion. Improper container arrangement wastes container space and increases sea freight cost.
Solution: Conduct equipment splitting planning in advance to optimize loading scheme. Anti-rust treatment is applied separately on machined contact surfaces with full moisture-proof sealed packaging. Equipment is firmly fixed inside the container to prevent displacement and deformation caused by turbulence during ocean transit.
Project Highlights
- Customized for tropical working conditions: Moisture-proof electrical control system compatible with Indonesia local grid. No extra electrical renovation needed at client’s factory, suitable for hot and humid production environments in Southeast Asia.
- Optimized for bath soap technology: Milling, vacuum plodding and forming systems are tuned specifically for bath soap formulas, delivering fine soap texture and stable forming performance to effectively reduce defective rates.
- Remote technical support & hands-on training: Complete training documents are delivered. Remote guidance is available for client’s on-site equipment installation and commissioning to cut overseas project costs.
- Full FAT material trial before shipment: Production capacity and soap forming quality are verified before delivery to identify and resolve issues in advance and greatly reduce on-site commissioning risks.
- Professional protection solution for ocean export: Complete anti-rust and moisture-proof packaging against salt fog and humidity for long-distance shipment to Southeast Asia and avoid equipment damage during transit.
- Flexible production capacity: Multiple bath soap formulas can be switched on the same line, enabling clients to develop various soap SKUs and expand product portfolios.
Project Result Summary
The complete 300kg/h bath soap production line has finished manufacturing, FAT inspection, packaging and shipment, successfully delivered to the Indonesian client. After commissioning, the line can steadily reach the rated capacity of 300kg/h bath soap and improve the consistency of finished soap quality. It helps Indonesian daily chemical factories expand bath soap output and capture growth opportunities in the Southeast Asian personal care soap market. This project serves as a successful case of daily chemical equipment deployed in Southeast Asia and verifies the stable operation capability of this production line under tropical factory conditions in Indonesia.