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.