Innovative and Flexible Manufacturing

Equipped with the latest manufacturing technology and GMP-certified facilities, Derichem is redefining the role of soap base manufacturers and offers revolutionising options for soap finishers. Strategic alliance with Acidchem, mild processing conditions and flexible process routes enable Derichem to function as a fully integrated soap manufacturer.

The standard soap noodles produced by Derichem are derived exclusively from vegetable origin, utilising about 99.5% locally available raw materials of Palm Oil, Palm Stearine, Palm Kernel Oil and Sodium Hydroxide. At Derichem, the process of manufacturing soap noodles begins with the conversion of the palm-based oils into fatty acids.

The crude fatty acids are then purified to the required purity through the process of distillation, while the valuable by-product of glycerol is processed separately to yield pharmaceutical grades of glycerine with purity of 99.5 - 99.7%. The desired blend of distilled fatty acids shall then be reacted with an alkali to form soap and water. This reaction is carried out in a continuous process whereby the fatty acids and alkali are continuously fed into a neutralisation chamber. The soap thus formed is then vacuum dried to specific moisture content before being refined and extruded into lengths of soap noodles.

Derichem utilises continuous closed vessel process for its production. The processes are digitally controlled and fully automated and are designed for high efficiency, low energy and labour consumption.

There are three unique features in the Derichem Soap Noodles production.

Energy conservation through increased neutralisation efficiency.

At Derichem, the neutralisation of the fatty acids is carried out by the high concentration caustic route, which reduces drying time and cuts energy consumption (the higher the concentration, the lower the water content). This high concentration alkali route while giving more efficient and complete neutralisation is not favoured by other producers of soap noodles because of difficulties encountered. Derichem have however, overcome the difficulties involved and is currently the one of the few producers in Malaysia using the high concentrated alkali route.

Energy conservation through utilisation of gravity and innovative plant layout

Under standard designs, soap noodle plant layout is such that the soap noodles produced at floor level before being transported (vacuumed or fluidised) and carried upwards into the silo. At Derichem, the soap plant is located on the 3rd floor of a 5-storey building. The silo is situated below the plodder and extends from the 3rd floor down to the ground floor. Instead of being transported into the silo as in the traditional layout, Derichem's noodles are dropped from the plodder into the silo by the action of gravity. This special feature not only saves energy but also reduces the formation of "soap fines" thus reducing dust pollution for a healthier working environment, particularly for the soap plant personnel.

Reduction in labour requirement

In line with the Government's call for increased automation to maximise labour resource, the entire process of soap noodle manufacture from the splitting of the palm-based oil through neutralisation of the fatty acid with alkali, extrusion and through to the packaging of the finished soap noodles is fully automated.

Over time, Derichem has manufactured ingenious inventions, soaps with novel properties that are patent-pending. Derichem also has formidable flexibility in producing complex soap formulations from specialty soaps to multifunctional enhancements. With its latest manufacturing facility, Derichem is capable of emulating processing of finishing lines, extending its manufacturing capability as a soap finisher.