Process Design

Since Lux soap is available in different variants & fragrances, it uses intermittent operations in

production. Because different variants have different processing needs, there is no standard route

that all products take through the facility. Instead, resources are grouped by function and the

product is routed to each resource as needed. The volume produced is based on direct customer

orders.

Furthermore, the production method for Lux is batch processing. Production is heavily

dependent on palm oil. Lux Soap is the combination of animal fat or plant oil and caustic soda.

The Soap needs two major raw materials: one is fat and the other one is alkali. Lux soap makers

use fat that has been processed into fatty acids. This eradicates various impurities, and it

produces as by-product water as an alternative of glycerin. Many vegetable fats, including olive

oil and coconut oil, are also used. The alkali most commonly used is sodium hydroxide and

sometimes, Potassium hydroxide is also used. Additives are used to enhance the color, texture,

and scent of the soap depending on whichever variant.

Palm oil is used for the manufacturing of Lux Soaps which is processed and bleached. This is

then divided into two proportions as per the soap requirements; to manufacture Lux and Life

buoy (another soap product produced by Unilever). After separation as per the proportions, alkali

in the form of sodium hydroxide/ Potassium hydroxide is added to the palm oil barrels. Synthetic

chemicals are added to clean and sterilize the mixture to remove any impurities. After this the

mixture is divided into categories as per the product variety, after which perfumes and colors are

added to give the soap a nice subtle fragrance and attractive color. Fragrances and perfumes are

added to the soap mixture to protect the smell of dirt and leave behind a fresh smelling aroma.

Substances to enhance the texture of soap include silica, talc, and marble pumice. Soap made

without color is of a brown or dull grey color, but Lux manufacturers color the soap to make it

more appealing to the end-user. Other material is then added according to the particular variety

of soap. After the entire process of chemicals and ingredients have been added, the soap is

further processed, cut and shaped into bars of soap according to the product specifications and

SKUs of the product. The produced soap bars are then sent to packaging, where they are

wrapped in the respective prepared packaging and transferred to warehouse until delivery has to

be made. Loading and unloading of cargo and also wrapping of cargo is handled by labor but the

process is mostly auto mated.