Detergent Cake Mfg. Plant

Detergent Cake Manufacturing Plant – Strength, Purity & Cleaning Power

Pushpam Groups operates one of India’s most advanced detergent cake manufacturing plants, producing premium cleaning bars under its flagship brands — 707 and Ponvandu. Known for exceptional stain removal, long-lasting fragrance, and fabric-friendly formulations, our detergent cakes meet the highest standards of household cleaning products. With decades of manufacturing expertise, we’ve refined a robust production system combining modern machinery, scientific formulation, and sustainable chemistry. Each bar embodies quality, durability, and cost-effectiveness — ensuring that every wash delivers spotless results while being gentle on hands and fabrics.

State-of-the-Art Detergent Cake Production Facility

Our Detergent Cake Manufacturing Plant is built to world-class specifications with advanced mixing, plodding, and cutting lines that maintain consistent quality in every batch. Equipped with high-speed sigma mixers, triple roll mills, and hydraulic presses, our facility ensures uniform texture and smooth finishing in every cake. The production line is designed for high efficiency and hygiene, minimizing human contact during formulation and shaping. Pushpam Groups maintains temperature-controlled environments and dust-free processing zones to ensure product purity. Our infrastructure supports both large-scale production and specialized formulations for different markets and customer needs.

Product Ponvandu, 707
Area 8,000 sqft
Purpose Manual Washing
Category Cake
Date April 2, 1968
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Step 1 – Raw Material Preparation and Formulation

Every detergent cake begins with a scientifically balanced blend of ingredients including soda ash, acid slurry, fillers, colorants, and fragrance compounds. Each raw material undergoes detailed inspection for quality and moisture content before entering the process. The formulations for Ponvandu and 707 differ slightly — Ponvandu focuses on a skin-friendly, smooth formula ideal for daily use, while 707 emphasizes grease removal and industrial-grade cleaning power. Our in-house R&D team ensures that each recipe delivers consistent hardness, lather, and cleaning performance suitable for varying water conditions and washing preferences across different regions.

Step 2 – Mixing and Kneading Process

The measured raw materials are transferred into sigma mixers or edge runners, where they are kneaded into a uniform, plastic mass. This step is crucial for achieving a balanced composition of surfactants, fillers, and colorants. The homogeneous blend ensures even distribution of cleaning agents throughout the bar. The mixing temperature and speed are precisely controlled using digital systems to maintain consistent quality. For Ponvandu detergent cakes, a fine and smooth texture is preferred, while 707 detergent cakes are mixed to produce a slightly firmer consistency that enhances durability and long-term storage stability.

Step 3 – Milling and Refining

Once mixing is complete, the material passes through triple roll mills where it is finely milled to break down any remaining lumps or air pockets. This ensures a uniform and glossy texture. Milling plays a vital role in determining the appearance and hardness of the finished cake. The milled ribbons are then collected and conveyed to the plodder machine, where the material is compressed under controlled pressure. This stage aligns the particles, giving the detergent cake its compact structure and uniform density — key to long-lasting use and high washing efficiency in both 707 and Ponvandu products.

Step 4 – Extrusion and Cutting

The refined material enters the twin-screw plodder, where it is extruded into continuous bars of uniform diameter. The extruder applies steady pressure to eliminate trapped air and maintain smooth surface finish. Once extruded, the bar moves through a cutting system that slices it into exact sizes according to brand specifications. Both 707 and Ponvandu detergent cakes are available in multiple weight segments to suit household and commercial needs. This fully automated process ensures precision and hygiene, minimizing handling and ensuring that each cake maintains consistent weight, texture, and cleaning properties throughout production.

Step 5 – Stamping and Branding

After cutting, the detergent cakes are transferred to hydraulic stamping machines, which imprint the brand logos and product names onto each bar. This not only enhances brand identity but also ensures professional presentation for retail display. Pushpam Groups uses custom-designed steel molds to create distinct, high-relief impressions for both 707 and Ponvandu brands. The stamping process also compacts the bars further, improving hardness and preventing cracks during packaging and transport. Every stamped cake undergoes visual inspection to ensure uniform shape, smooth edges, and accurate branding before entering the drying and curing stage.

Step 6 – Drying, Curing, and Conditioning

Stamped cakes are arranged on trays and sent to drying tunnels or conditioning chambers where controlled airflow removes excess moisture. This step is crucial to achieve optimal hardness, prevent sweating, and extend shelf life. Depending on the product line, cakes are conditioned for 24–48 hours to stabilize the formula. The Ponvandu detergent cake line emphasizes a soft, silky finish with refreshing fragrance, while 707 cakes are conditioned for durability and high-performance washing. Our scientific curing method ensures that each cake maintains perfect balance — tough on stains, gentle on skin, and long-lasting in use.

Step 7 – Packaging and Final Dispatch

After curing, the detergent cakes move to automatic wrapping and packing machines, where they are sealed in protective wrappers. The packaging material is selected for strength, moisture resistance, and print clarity to preserve product quality. The wrapped bars are then boxed, labeled, and shrink-wrapped for transport. Each carton is coded with batch numbers for full traceability. Pushpam Groups ensures that all finished products undergo final inspection before dispatch. Our efficient logistics and warehousing systems ensure that both 707 and Ponvandu detergent cakes reach distributors and retailers across India in perfect condition, ready for consumer use.

Quality Assurance and Laboratory Testing

Quality assurance is the foundation of every operation at Pushpam Groups. Our in-house laboratory tests each batch for parameters like foam stability, detergent efficiency, hardness, and fragrance retention. Advanced analytical tools are used to ensure conformity with BIS standards and customer requirements. Continuous sampling and statistical process controls guarantee that our detergent cakes deliver the same superior results every time. The lab also conducts hand-feel and wash tests to assess user comfort. Through this robust quality system, Pushpam Groups ensures that every Ponvandu and 707 detergent cake meets its promise of excellence and reliability.

Sustainable and Safe Manufacturing Practices

Pushpam Groups is deeply committed to sustainability and environmental responsibility. Our detergent cake manufacturing facility uses eco-friendly raw materials, biodegradable surfactants, and optimized processes that minimize waste generation. Energy-efficient mixers, dust collectors, and effluent treatment systems ensure a safe and clean working environment. The company’s focus on sustainability extends to packaging, where recyclable materials are prioritized. By adopting green chemistry principles, Pushpam Groups reduces its carbon footprint without compromising product quality. Our Ponvandu and 707 detergent cakes stand as eco-conscious cleaning solutions—delivering performance that’s tough on stains but gentle on nature.

Why Choose Pushpam Groups for Detergent Cake Manufacturing

With decades of experience and two iconic brands — 707 and Ponvandu — Pushpam Groups leads the detergent cake industry with trust and innovation. Our manufacturing excellence lies in precise formulation, sustainable operations, and continuous R&D advancements. We offer both premium and economy-grade detergent cakes that satisfy diverse consumer expectations. The combination of advanced machinery, trained workforce, and brand heritage ensures unmatched performance and value. Choosing Pushpam Groups means choosing quality, reliability, and a brand that stands for performance and purity in every wash. Our detergent cakes reflect commitment you can see and feel.

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Detergent Cake Mfg. Plant

Detergent Cake Manufacturing Plant – Strength, Purity & Cleaning Power

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