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Soap & detergent plant

Enter the soap and detergent the factory makes in a day. The list below is what that implies — saponification, vacuum dryer, amalgamator, mills, plodder, stamper and the detergent spray tower — with a rate column you fill in yourself.

How this works →

Your figures

Soap output(tonnes/day)

Operating hours(hours/day)

Finishing lines run two shifts; the saponification section is continuous.

Detergent powder output(tonnes/day)

Set to zero for a soap-only plant.

Toilet soap share(%)

Toilet soap needs milling and a vacuum plodder; laundry soap does not.

Material take-off

What to buy, at what size, and how many — worked out from the figures above.

Rates

CurrencyFabricated steel (₨/kg)Skilled labour (₨/day)

Every line is estimated from those two figures: its steel — or steel-equivalent — mass at the steel rate, stainless at 3.2×, plus its install days at the labour rate. There is no price feed behind this, so the two anchors are seeded from typical Pakistan figures as of September 2026 and are yours to correct. Type over any individual rate and yours is used instead.

Saponification & drying

Material	Size	No.	Total weight	Rate	Amount
Continuous saponification reactor, SS 316Oil and caustic, with the neat soap separated from lyeRate from 3,600 kg stainless-equivalent + 12 days labour — Reactor, mixer, separator and dosing	1,000 kg/h2.4 t each	1reactor	2.4t	estimated	4,638,000
Caustic and brine preparationLye and brine made up and held for the reactorRate from 1,100 kg stainless-equivalent + 4 days labour — Tanks, agitators, dosing pumps and lines	20 m³	2tank	—	estimated	2,836,000
Vacuum spray dryer for neat soapNeat soap at about 30% moisture down to 12% as noodlesRate from 5,200 kg stainless-equivalent + 14 days labour — Atomiser, drying chamber, vacuum set and noodle plodder	1,000 kg/h	1unit	—	estimated	6,691,000

Continuous saponification reactor, SS 316
Oil and caustic, with the neat soap separated from lye
Rate from 3,600 kg stainless-equivalent + 12 days labour — Reactor, mixer, separator and dosing
Size
1,000 kg/h · 2.4 t each
No.
1reactor
Total weight
2.4 t
Rate(estimated)
Amount
₨ 4,638,000
Caustic and brine preparation
Lye and brine made up and held for the reactor
Rate from 1,100 kg stainless-equivalent + 4 days labour — Tanks, agitators, dosing pumps and lines
Size
20 m³
No.
2tank
Total weight
—
Rate(estimated)
Amount
₨ 2,836,000
Vacuum spray dryer for neat soap
Neat soap at about 30% moisture down to 12% as noodles
Rate from 5,200 kg stainless-equivalent + 14 days labour — Atomiser, drying chamber, vacuum set and noodle plodder
Size
1,000 kg/h
No.
1unit
Total weight
—
Rate(estimated)
Amount
₨ 6,691,000

Finishing

Material	Size	No.	Total weight	Rate	Amount
Amalgamator / mixer for additivesPerfume, colour, titanium dioxide and preservative into the noodlesRate from 1,900 kg stainless-equivalent + 4 days labour — Trough, paddles, drive and dosing	1,000 kg/h	1unit	—	estimated	2,442,000
Three-roll refiner mill40% toilet soap, which has to be milled to disperse the perfumeRate from 2,400 kg + 5 days labour — Chilled rolls, frame, scraper and drive	400 kg/h	1mill	—	estimated	972,500
Duplex vacuum plodderExtrudes a continuous bar free of trapped airRate from 4,000 kg stainless-equivalent + 8 days labour — Two barrels, vacuum chamber, cone and nozzle	1,000 kg/h	1plodder	—	estimated	5,140,000
Bar cutter and soap stamping machineCut to length, then stamped to shape and brandedRate from 1,800 kg + 5 days labour — Cutter, conveyor, stamper dies and chiller	1,000 kg/h	2machine	—	estimated	1,465,000

Amalgamator / mixer for additives
Perfume, colour, titanium dioxide and preservative into the noodles
Rate from 1,900 kg stainless-equivalent + 4 days labour — Trough, paddles, drive and dosing
Size
1,000 kg/h
No.
1unit
Total weight
—
Rate(estimated)
Amount
₨ 2,442,000
Three-roll refiner mill
40% toilet soap, which has to be milled to disperse the perfume
Rate from 2,400 kg + 5 days labour — Chilled rolls, frame, scraper and drive
Size
400 kg/h
No.
1mill
Total weight
—
Rate(estimated)
Amount
₨ 972,500
Duplex vacuum plodder
Extrudes a continuous bar free of trapped air
Rate from 4,000 kg stainless-equivalent + 8 days labour — Two barrels, vacuum chamber, cone and nozzle
Size
1,000 kg/h
No.
1plodder
Total weight
—
Rate(estimated)
Amount
₨ 5,140,000
Bar cutter and soap stamping machine
Cut to length, then stamped to shape and branded
Rate from 1,800 kg + 5 days labour — Cutter, conveyor, stamper dies and chiller
Size
1,000 kg/h
No.
2machine
Total weight
—
Rate(estimated)
Amount
₨ 1,465,000

Detergent powder

Material	Size	No.	Total weight	Rate	Amount
Detergent slurry preparation, crutcherSulphonic acid, caustic, builders and water into a slurryRate from 2,100 kg stainless-equivalent + 6 days labour — Vessel, agitator, jacket and dosing	750 kg/h	2crutcher	—	estimated	5,406,000
Spray drying tower with HP pumpSlurry atomised into hot air, falling out as hollow beadsRate from 10,800 kg + 25 days labour — Tower shell, nozzles, HP pump, air heater and cyclones	750 kg/h8.3 t each	1tower	8.3t	estimated	4,382,500
Post-dosing and perfuming drumEnzymes and perfume added after drying, where heat would destroy themRate from 1,550 kg + 4 days labour — Rotating drum, spray bars and dosing	750 kg/h	1unit	—	estimated	630,000

Detergent slurry preparation, crutcher
Sulphonic acid, caustic, builders and water into a slurry
Rate from 2,100 kg stainless-equivalent + 6 days labour — Vessel, agitator, jacket and dosing
Size
750 kg/h
No.
2crutcher
Total weight
—
Rate(estimated)
Amount
₨ 5,406,000
Spray drying tower with HP pump
Slurry atomised into hot air, falling out as hollow beads
Rate from 10,800 kg + 25 days labour — Tower shell, nozzles, HP pump, air heater and cyclones
Size
750 kg/h · 8.3 t each
No.
1tower
Total weight
8.3 t
Rate(estimated)
Amount
₨ 4,382,500
Post-dosing and perfuming drum
Enzymes and perfume added after drying, where heat would destroy them
Rate from 1,550 kg + 4 days labour — Rotating drum, spray bars and dosing
Size
750 kg/h
No.
1unit
Total weight
—
Rate(estimated)
Amount
₨ 630,000

Packing & utilities

Material	Size	No.	Total weight	Rate	Amount
Soap wrapping and cartoning lineWrap, carton and shrink for despatchRate from 2,000 kg + 6 days labour — Wrapper, cartoner, conveyor and coder	1,000 kg/h	2line	—	estimated	1,630,000
Powder filling and pouch lineAuger filler into pouches or cartonsRate from 1,900 kg + 6 days labour — Auger filler, form-fill-seal and coder	750 kg/h	2line	—	estimated	1,550,000
Steam, vacuum and chilled water connectionsHeaders and take-offs from the boiler house to each machineRate from 3,000 kg + 14 days labour — Headers, traps, valves, pipework and insulation	plant-wide	1set	—	estimated	1,235,000

Soap wrapping and cartoning line
Wrap, carton and shrink for despatch
Rate from 2,000 kg + 6 days labour — Wrapper, cartoner, conveyor and coder
Size
1,000 kg/h
No.
2line
Total weight
—
Rate(estimated)
Amount
₨ 1,630,000
Powder filling and pouch line
Auger filler into pouches or cartons
Rate from 1,900 kg + 6 days labour — Auger filler, form-fill-seal and coder
Size
750 kg/h
No.
2line
Total weight
—
Rate(estimated)
Amount
₨ 1,550,000
Steam, vacuum and chilled water connections
Headers and take-offs from the boiler house to each machine
Rate from 3,000 kg + 14 days labour — Headers, traps, valves, pipework and insulation
Size
plant-wide
No.
1set
Total weight
—
Rate(estimated)
Amount
₨ 1,235,000

Material

₨ 38,668,000

10.8 t of steel to fabricate

Labour

₨ 350,000

140 days at ₨ 2,500 a day

Quotation total

₨ 39,018,000PKR

13 of 13 lines priced

10.75 t is fabricated steel only. 11 bought-in lines — pumps, machines, proprietary units — are priced but carry no steel weight of ours, and show a dash in the weight column.

Questions

What does the toilet soap share change?

The milling. Toilet soap is refined through three-roll mills to disperse perfume and colour evenly and to give the bar its finish; laundry soap is not. Set the share low and the roll mills shrink to the minimum in the list.

Why is the detergent tower so much dearer than the soap line?

Because it is tall, it is structural, and it comes with a high-pressure slurry pump, an air heater and a cyclone system. A spray tower is usually the single largest item on a combined soap and detergent project, which is why it sits on its own line.

Can I quote soap only?

Yes — set the detergent output to zero and the slurry, tower and post-dosing lines fall to their minimum. Delete them from the quotation; everything else in the list is soap-side.

What is not included?

Raw material storage for oils and chemicals, the boiler, effluent treatment, the building and the laboratory. Glycerine recovery from the spent lye is a plant of its own and is not covered.