The Detergent Cake Kneader (also known as a Soap Mixer or Sigma Mixer in the detergent industry) is an essential industrial machine designed for mixing and kneading raw materials like soap noodles, fillers, fragrances, and binders to create a uniform, homogeneous mass for detergent cake production. It ensures thorough blending, prevents lumps, and prepares the mixture for the next stages like plodding and cutting. This heavy-duty equipment is widely used in small to medium-scale detergent manufacturing units, offering robust construction for continuous operation.
Detergent Cake Kneader Video
Key Features
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Construction: Typically made from mild steel (MS) or stainless steel (SS 304/316) for corrosion resistance and hygiene. Features a U-shaped or Z-blade (sigma) mixing trough for efficient kneading.
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Mixing Mechanism: Twin sigma blades or Z-blades rotate at variable speeds to knead the semi-dry or paste-like mixture, with options for steam/jacketed heating to control temperature during mixing.
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Capacity Range: Available in batch sizes from 5 kg to 100 kg, ideal for startups to established plants.
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Production Efficiency: Mixes a batch in 10-20 minutes, depending on load and material viscosity.
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Safety and Maintenance: Equipped with safety guards, overload protection, and easy-to-clean designs. Low maintenance with durable gears and bearings.
Applications
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Primary use: Kneading detergent cake mixtures in soap and laundry bar production.
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Versatile for: Toilet soap, laundry detergent bars, and similar paste-based formulations.
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Benefits: Reduces manual labor, ensures consistent quality, and scales with business growth.
Salient Features of Sigma Mixer Kneader
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Available in Stainless Steel 316, Stainless Steel 304 and Mild Steel materials.
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Stainless Steel polish to matt & mirror finish as per customer’s requirements.
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Mild Steel finish with one coat of red oxide and two coats of epoxy paint.
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Discharge option of hand wheel operated (manual) or hydraulic operated (automatic) offered.
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Jacket for heating or cooling application can be offered.
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Mineral wool insulation with cladding on jacket.
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Tangential designed ‘Z’ blades offered for uniform mixing.
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PTFE made shaft sealing provided for food grade compatibility.
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Minimum gap between trough inner shell & blades removes possibility of sticking product.
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On demand Spray system, vacuum system
Optional Features/Accessories of Sigma Mixer
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Liquid Spray System
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Vacuum System
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Blades Cooling Arrangement
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Screw System
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Automatic Valve Discharge System
Process Operation of Detergent Cake Kneader
In Sigma mixer tangential action of mixing and kneading obtained by ‘Z’ type (SIGMA) shaped kneading blades, which rotates very accurately at different speed towards each other causing product to be transferred from one end to another end. Discharge of the finished product is achieved by tilting the container or through the valves at the bottom or by means of an extrusion screw beside the container.
The mixing action is a combination of bulk movement, stretching, folding, dividing, and recombining of the material. The shearing & tearing action of the material against blades and the side walls causes size reduction of the solids. After the time period required for sterilizing the batch has elapsed, the heating circuit shuts of the pneumatics damper (exhaust) opens and cooling operation commences.
In the tangential design, the blades rotate in the trough meeting tangentially. The front blade generally rotates faster than the rear blade usually in the ratio of 3:2. Tangential blades are generally used for material of higher viscosities such as adhesives, rubber compounds, flush colors, dyes, and pigments.
In the overlapping design, the blades overlap above the saddle of the container. Due to the overlapping action, it is necessary that the relative position of the two blades is unchanged, and as a result, both the blades rotate at the same speed. Materials that flow freely or creep down into the blades are mixed using the overlapping blade action. This design offers a faster interchange of material from one blade compartment of the mixer to the other. Overlapping blade action is used for materials of lighter viscosities such as carbon pastes, clay coating, creams, and ointments. The overlapping blade produces a lower kneading and shearing compared to the tangential blade action.
Technical Specification of Sigma Mixer Kneader
| Model | Capacity – Liters | Motor (H.P.) | ||
| Working Capacity approx. | Gross Capacity approx. | General | Heavy Duty | |
| ASM – 5 | 5 Liters | 8 Liters | 1 H.P. | 1.5 H.P. |
| ASM – 10 | 10 Liters | 15 Liters | 1 H.P. | 1.5 H.P. |
| ASM – 20 | 20 Liters | 30 Liters | 1.5 H.P. | 3 H.P. |
| ASM – 50 | 50 Liters | 80 Liters | 5 H.P. | 7.5 H.P. |
| ASM – 75 | 75 Liters | 110 Liters | 7.5 H.P. | 10 H.P. |
| ASM – 100 | 100 Liters | 150 Liters | 10 H.P. | 15 H.P. |
* Power voltage can be adjusted as per customer’s domestic power voltage requirements.
* Rights of technical improvements & modification reserved.
* Illustrations & dimensions are shown for information purpose only.
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