ABSTRACT

The machine comprises an automated soap stamping and tableting module, the operational parameters evaluated were conveying speed, stamping and tableting speed, and time of operation while the tableting efficiency, throughput and specific energy consumption of the machine constitutes the responses or performance parameters. Response surface analysis was employed and the initial linear models developed augmented to quadratic models when it was established using the analysis of variance (ANOVA) and residual plots to estimate the performance of the soap stamping and tableting machine. The developed quadratic models was used to optimize the performance of the soap stamping and tableting machine using the D- optimality approach to establish the optimal factor settings of the soap stamping and tableting machine rounding up to the nearest whole number values are 351rpm, 21rpm, and 55 minutes for the conveying speed, stamping and tableting speed and time of operation respectively. The optimal response at these factor settings was 91.3%, 636kg/hr and 31.1kJ/kg at an optimality rate of 73%, 99.9% and 100% for the tableting efficiency, throughput and specific energy consumption respectively with an overall D-optimality value of 96%.

 TABLE OF CONTENTS

                                                                                  PAGE

Title Page                                                                                                                                i

Declaration                                                                                                                              ii

Dedication                                                                                                                              iii

Certification                                                                                                                            iv

Acknowledgements                                                                                                                v

Table of Contents                                                                                                                   vi

List of Tables                                                                                                                          ix

List of Figures                                                                                                                         xi

Nomenclature                                                                                                                          xiii

Abstract                                                                                                                                  xv       

CHAPTER 1: INTRODUCTION

1.1       Background of Study                                                                                                             1

1.2       Statement of Problem                                                                                                             2

1.3       Aim and Objectives of Study                                                                                     4

1.4      Scope of Study                                                                                                           4

1.5       Justification of the Study                                                                                           4

CHAPTER 2: LITERATURE REVIEW

2.1       Overview of Soap Production                                                                                                6

2.2       Development of Soap Production                                                                              7

2.3       Processes of Soap Making                                                                                          9

2.3.1    Semi-Boiling Process                                                                                                  9

2.3.2    Processing Method                                                                                                     10

2.4       Full-Boiling Process                                                                                                    11

2.4.1    Processing Method                                                                                                     12

2.5       Cold Process                                                                                                               13

2.6       Development of Soap Stamping Technology                                                             15

2.7       Response Surface Methodology                                                                                 17

2.7.1   Test for significance of the regression model                                                              22

2.7. 2 Test for significance on individual model coefficient                                                  23

2.7.3   Test for lack-of-fit                                                                                                       23

2.7.4   Test for residuals normality                                                                                         24

2.7.5   Optimization of response surface models                                                                    24

2.7.6   Desirability function approach                                                                                    25

2.8       Review of Stamping and Tableting Machines                                                            26

2.8.1    Major Drawbacks of the Existing Machines                                                               28

CHAPTER 3: MATERIALS AND METHODS

3.1       Materials                                                                                                                     29

3.2       Methods                                                                                                                      29

3.2.1    Machine Design and Description of the Soap Stamping and Tableting Machine      29

3.2.2    Design Concept and Considerations                                                                          33

3.2.3    Selection of Pulleys and Belts                                                                                                34

3.2.4    Selection of Drive Shaft                                                                                             36

3.2.5    Selection of Prime Mover                                                                                           38

3.3       Performance Analysis Procedure                                                                                39

3.3.1    Determination of limits of the Operational Parameters                                              44

CHAPTER 4:            RESULTS AND DISCUSSION

4.1       Performance Model Development and Analysis                                                        46

4.1.1    Analysis of the Linear Models                                                                                    48

4.1.2    Analysis of Quadratic (Second order) Models                                                           56

4.1.3    Model confirmatory test results                                                                                  62

4.2       Optimization Of The Soap Stamping and Tableting Machine

            Performance    Parameters                                                                                           63

4.2.1    The Response Surface Approach                                                                                63

4.2.2    Optimization by desirability function approach                                                         68

 

CHAPTER 5:            CONCLUSION AND RECOMMENDATIONS

5.1              Conclusion                                                                                                                  70

5.1.1    Contribution to Knowledge                                                                                        71                                                                   

5.2              Recommendations                                                                                                      71      

           References                                                                                                                 

            Appendices