Saponification Jet is a simple instant saponification
device, which is used for continuous saponification. A
Jet has no moving parts and uses motive steam as the
energy source. Only 100kgs of steam per tonne of soap is
required. A Jet can be adjusted for soap outputs from 1
to 10 tonnes/hr.
The Jet operates by driving 5 bar motive steam through
an internal venturi jet to create a vacuum. The steam
venture jet is fitted with a needle valve, to control
the flow rate, hence suction volume, hence output.
Surrounding the steam jet are two further concentric
barrels, for caustic liquor and oils. The venturi vacuum
draws in both materials, where they meet in the presence
of steam. The result is instantaneous saponification,
with 90 % reacted neat soap being discharged directly
from the Jet.
The Jet unit is an accurate metering device, which has
been designed and subjected to an intensive development
process. Individual components are precision machined
from 316 stainless steel. Detailed inspection and
careful assembly then follow, to ensure high tolerances
The Jet is fitted with flanged inlets for steam, caustic
and mixed fats. It has an expansion tapered tail pipe,
through which soap is discharged. Normal practice is to
fit the Jet into a weir tank, to create a delay of 3 to
5 minutes, during which time almost all commonly used
soap fats or oils will achieve complete saponification.
Neat soap is then discharged to a feed tank, ready for
delivery to the drying system. If neutral fats are used
the secondary reaction time may extend to 30 minutes.
A fine tuning adjustment is provided at the bottom of
the Jet, for use during commissioning. This allows an
accurate balance of fats to caustic ratio to be set,
thus optimizing saponification.
Basic Manual Operation
In a basic installation the flows of mixed fats and
caustic liquor are normally delivered to the Jet from
overhead constant level tanks, through manually operated
ball valves. A first valve acts as shut-off and a second
is set during commissioning, to provide fixed flow
control. Start up and shut-down are then very simple
At the end of the production day, the fat and caustic
shut-off valves are closed and steam is allowed to clean
the jet, for a few minutes. A small steam purge line may
be fitted to the fats line, to clean this out prior to
Once the Jet has self cleaned for a short while, the
steam is turned off.
At the beginning of the day steam is turned on to warm
the jet and produce the vacuum. The overhead tanks are
confirmed full, and then the fat and caustic shut-off
valves opened. Soap forms immediately and is then
continuously delivered, as long as required.
Provided the Jet is allowed to self clean at the end of
the previous day the start up procedure only takes a few
Remote Controlled Operation
The Jet can be installed with solenoid valves on the fat
and caustic lines, plus steam regulating valve. This
allow the Jet to be regulated from a remote station,
where required by factory conditions. Specifications and
installation plans can be agreed, to suit individual
Some traditional soap makers begin continuous
saponification by using the Jet as a kettle filling
device, whilst they become used to operating it. Within
a few days it is realized that the Jet completely
replaces the boiling operation, hence kettle output can
easily be doubled.
Many Jet users install complete Jet & Weir Tank systems,
which are very compact, needing less than 10 Cubic
Metres space. Full installation details are available
for common mounting schemes.
The Jet unit is 1.35 Metres high and weighs 150 kilos.
The Jet is easy to install, low cost, tolerant to a wide
range of raw materials, simple to use and very compact.
The use of a Jet permits soap water content to be as low
as the Soap Maker wishes to use. There is no need to
have an excess of water, to assist saponification
boiling, which then has to be removed in the spray
drying plant. Some Jet users are making neat soap at
near finished water content, then simply cooling by
vacuum spraying or using the drum cooling method. This
gives a further and substantial saving of energy.