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CONSTRUCTION OF SOAP CUTTING TABLE, SOAP MOULD AND SOAP CUTTERS

CHAPTER ONE

INTRODUCTION

1.1 Background of the Study

Soap is commonly used domestically or industrially. During production process, soap arrives in loaves or in blocks form, therefore, the need to cut the soap into bars arises. Soap cutting and scraping machines is a machine designed to be used in cutting and scrapping of soap at the same time. Although, it is believed by many that, soap cutting and scraping machine has been in existence since time immemorial in Babylonia. The Ancient soap cutting techniques make use of their hands and a long knife to cut their soap, but as time progresses, the use of hand and knife became ineffective, they later started using pasty scrapper to cut their soap, the pasty scrapper is made up of wooden handle and they have long life and less likely to bend. During the industrial revolution a wooden miter box and a cutting blade were developed for cutting soap, the wooden box acts as the guide. The straight edge of the box ensures straight cut. The miter box was designed in such a way that, you can insert a saw into the straight cut and finish sawing the notch all the way down to the base of the miter box.

Currently, soap cutting and scraping machine are designed and constructed in different form and types, such as, air Steel pipe, Handle cover (rubber) and Chain and sprocket (steel). Bearing power soap cutting machine, rotary soap cutting machine, loaves cutting machine, manual soap cutting machines. but most of them are not manually operated and they are very huge  that is bulky, expensive to be purchased by small scale industries , they require special skills for their operations, in a nutshell they are not easily set up by small scale industries most especially in rural areas,  based on these reason, we  carried out this project, to design and construct a simple soap cutting and scraping machine that is manually operated, simple and affordable  which  requires little or no special skills for its operation and can be easily set up by small scale industries even rural areas, that will also overcome the challenges of power failure which is alarming in our country today. The machine is more convenient to use, more efficient and cleaner production process.

The production of soap is a widespread industry that involves various stages, including mixing, molding, curing, and cutting. Effective and efficient tools are crucial for ensuring high-quality products and optimizing production processes. The construction of a soap cutting table, soap mold, and soap cutters plays a significant role in this regard. These tools aid in achieving uniformity in soap dimensions, improving worker safety, and enhancing overall production efficiency. Understanding the design and fabrication of these tools is essential for both small-scale soap manufacturers and large industrial producers, as it impacts product quality and operational efficiency.

1.2 Statement of the Problem

In soap manufacturing, inconsistent cutting and molding processes can lead to variations in product size and quality, affecting consumer satisfaction and operational efficiency. Many soap manufacturers face challenges related to the accuracy and consistency of soap cutting and molding, which can result in increased waste and reduced productivity. Therefore, there is a need for a well-designed soap cutting table, soap mold, and soap cutters to address these issues, ensuring uniform product dimensions and improving the overall production process.

1.3 Objectives of the Study

The main objective of this study is to determine the effectiveness of a constructed soap cutting table, soap mold, and soap cutters in improving the consistency and efficiency of soap production. Specific objectives include:

i. To evaluate the impact of the soap cutting table on the uniformity of soap dimensions.

ii. To determine the efficiency of the soap mold in producing consistent soap bars.

iii. To find out how the soap cutters affect the overall productivity and reduction of waste in the soap manufacturing process.

1.4 Research Questions

i. What is the impact of the soap cutting table on the uniformity of soap dimensions?

ii. What is the efficiency of the soap mold in producing consistent soap bars?

iii. How does the use of soap cutters affect the overall productivity and reduction of waste in the soap manufacturing process?

1.5 Research Hypotheses

Hypothesis I

H0: There is no significant impact of the soap cutting table on the uniformity of soap dimensions.

H1: There is a significant impact of the soap cutting table on the uniformity of soap dimensions.

Hypothesis II

H0: There is no significant difference in the efficiency of the soap mold in producing consistent soap bars.

H2: There is a significant difference in the efficiency of the soap mold in producing consistent soap bars.

Hypothesis III

H0: There is no significant effect of the soap cutters on overall productivity and reduction of waste in the soap manufacturing process.

H3: There is a significant effect of the soap cutters on overall productivity and reduction of waste in the soap manufacturing process.

1.6 Significance of the Study

This study is significant as it provides insights into the effectiveness of specific tools in soap production. By evaluating the soap cutting table, soap mold, and soap cutters, the study aims to contribute to improved manufacturing practices, enhance product quality, and increase operational efficiency. The findings could benefit soap manufacturers by providing practical solutions to common production challenges, thereby improving competitiveness and profitability in the industry.

1.7 Scope of the Study

The study will focus on the design and construction of a soap cutting table, soap mold, and soap cutters. It will assess their impact on the soap production process, including uniformity in soap dimensions, efficiency in molding, and productivity in cutting. The study will be limited to evaluating these tools in a controlled environment to ensure accurate and reliable results.

1.8 Limitations of the Study

The study may face limitations related to the scale of implementation and testing. Variations in raw materials, environmental conditions, and production techniques may affect the generalizability of the results. Additionally, the study's scope is limited to the evaluation of the tools themselves and may not account for other factors influencing soap production.

1.9 Definition of Terms

Soap Cutting Table: A tool used to cut soap bars into uniform sizes after the soap has been molded and cured.

Soap Mold: A container or form used to shape liquid soap into bars or other desired forms before curing.

Soap Cutters: Tools or devices designed to slice or cut soap into individual bars with precision and consistency.