SOAPS AND DETERGENTSGonzales, Manuel GabrielManipol, Mark Glenn Recinto, Margareth Rose

SOAPS

HISTORY OF SOAPS

• Made for more than 2500 years• 600 BC- first recorded soap manufacture from

goats tallow and ash purposely used medicinally• Second century AD was used for cleaning

purposes• 19th century- soaps were

used commonly in the Western world

DESCRIPTION AND IMPORTANCE

• Soaps and detergents use surfactants as the main ingredient

• removes dirt from surfaces• made from fat and caustic

soda• used as cleanser as well as

perfume• for medicinal purposes

DESCRIPTION AND IMPORTANCE

• Saponification reaction is the core process of soap manufacture given by:

• Exothermic in nature and develop quickly at around 125oC

RAW MATERIALS

PROCESS

• BATCH METHOD– Traditional method of soap manufacturing– Takes about 4-11 days to complete the process– Used for small-scale production wherein soap is

made from saponifying of oils and fats with the aid of soap pan or kettle

PROCESS

• BATCH METHOD– Involves the following steps:

1. Slow incubation period involving the addition of sodium or potassium hydroxide to triglyceride.2. Temperature of the soap mass is controlled where alkali is used up rapidly in this exothermic stage3. Gradual completion stage

PROCESS

• BATCH METHOD

PROCESS

• CONTINUOUS METHOD–More flexible, higher speed and more

economical– 6 hours of manufacturing time is enough–Oils and fats are added to sodium hydroxide in

the presence of steam and mixed inside a hydrolyser

FLOWCHART OF CONTINUOUS PROCESS

FLOWCHART OF CONTINUOUS PROCESS

START

MILLING

BUBBLING

STAMPING

SPLITTINGFINAL PACKAGING

WRAPPING

SOAP NOODLES MIXING COOLING AND FINISHING

NATURAL FATS

CAUSTIC SUBSTANCE

LEFT-OVER SOAPS

TRIMMINGS

END

MANUFACTURING PROCESS

• SPLITTING– First step in the continuous process– Splits natural fat into fatty acids and glycerin– Utilizes vertical stainless steel column with the

diameter of the barrel called a hydrolizer– Fatty acids are distilled for purification

MANUFACTURING PROCESS

• BUBBLING– Glycerine and fatty acids are mixed together

including caustic soda– Saponification occurs in this process– In order to facilitate the chemical reaction, steam

bubbles are introduced– Processed in a bubble kettle– Left over soaps at the bottom are reused

MANUFACTURING PROCESS

• MILLING– Liquid soaps sprayed over a big mantle roll and

solidify– Blades cut it to soap ribbons– Steel rollers called mills, mix and compresses soap

ribbons– Blades cut it to a more denser ribbons

MANUFACTURING PROCESS

• MILLING

MANUFACTURING PROCESS

• SOAP NOODLES– Soap ribbons fall and are pushed to an extruder

known as the noodle plate– Shape soaps into noodles and collected into vent– Soap noodles are dumped into a mixer

MANUFACTURING PROCESS

• MIXING– Additives are mixed with the soap noodles– Color dyes in powder and liquid form are added as

well as fragrant oils with the aid of steel blades

– Another noodle plate is used to facilitate further mixing of materials

MANUFACTURING PROCESS

• COOLING AND FINISHING– The soap may be poured into molds and allowed

to harden into a large slab. It may also be cooled in a special freezer.

– The slab is cut into smaller pieces of bar size, which are then stamped and wrapped. The entire continuous process, from splitting to finishing, can be accomplished in several hours.

MANUFACTURING PROCESS

• COOLING AND FINISHING

MANUFACTURING PROCESS

• STAMPING– upon molding and trimming of the soap bars, they

are stamped– it is then delivered to the final packaging

MANUFACTURING PROCESS

• WRAPPING AND FINAL PACKAGING– Plastic sheets are used to cover soap bars– Heat is then applied to seal the wrap– They are then moved and put to boxes for delivery

PARAMETERS IN SELECTING A GRADE OF AN INGREDIENT IN SOAP-MAKING

• Cleansing• Conditioning• Bubbly lather• Creamy lather• Iodine• INS

PARAMETERS IN SELECTING A GRADE OF AN INGREDIENT IN SOAP-MAKING

PARAMETERS IN SELECTING A GRADE OF AN INGREDIENT IN SOAP-MAKING

DETERGENTS

HISTORY OF DETERGENTS

HISTORY OF DETERGENTS

HISTORY OF DETERGENTS

RAW MATERIALS

Solids

Ingredient Function

Sodium tripolyphosphate (STP) Water softener, pH buffer (o reduce alkalinity)

Sodium sulphate Bulking and free-flowing agent

Soap noodles Causes rapid foam collapse during raining

Zeolite Water softener

Sodium carboxymethyl cellulose Increases the negative charge on cellulosic fibres causing them o repel dirt

particles (positively charged)

Table 1. The ingredients of detergent base powder for solids

RAW MATERIALS

Liquids

Ingredient Function

Linear alkylbenzene sulphonic acid (LAS) Surfactant – the main active ingredient

Caustic soda solution Neutralizes the LAS

Coconut diethanolamide or a fatty alcohol ethoxylate

Nonionic detergent and foam former

Fluorescer Absorbs UV light and emits blue light

Water Dissolves the various ingredients, causing them to mix better

Table 2. The ingredients of detergent base powder for liquids

RAW MATERIALS

Ingredient Function

Soda ash (anhydrous Na2CO3) Keeps the pH at 9.0-9.5 ensuring optimum detergent function

Bleach (usually sodium perborate – NaBO3)

Bleaches stains without damaging colour-fast dyes. It breaks down to high

temperatures to release H2O2

Bleach activator (ex. tetraacetylethylenediamine)

Catalyzes NaBO3 breakdown at low temperatures

Enzymes (ex. alkaline protease) Alkaline protease breaks down to proteins in the alkaline conditions created by soda

ash, helping to remove stains

Colour and perfume Creates a more aesthetically pleasing product

Table 3. Typical post dosing ingredients

FLOWCHART OF CONTINUOUS PROCESS

MANUFACTURING PROCESS

1. Blender Process2. Agglomeration Process3. Slurry Method4. For Liquid Detergent

MANUFACTURING PROCESS

• BLENDER PROCESS• Also known as the Tumbler process or the Dry-mixing

process• Used by small-time companies

1. The ingredients needed are loaded either in a tumbling blender or a ribbon blender to facilitate efficient blending of components

2. The mixture is carried out into a conveyor belt 3. It is transported and dropped into boxes or cartons for

delivery to wholesalers.

MANUFACTURING PROCESS

• AGGLOMERATION PROCESS• A continuous process which is usually applied by large-

scale detergent manufacturers1. In an agglomerator, the dry ingredients needed in the

detergent making are first fed2. Dry ingredients are blended, while allowing the liquid

ingredients to be sprayed onto the dry mix using the nozzles fitted into the agglomerator’s wall

3. A drying belt collects the output of the agglomerator device where materials become friable

4. Pulverizing of these materials is done and sizing screens are further used apon pulverizing

MANUFACTURING PROCESS

• SLURRY METHOD1. Water is added to dissolve ingredients and form

slurry2. Through the nozzles, the slurry is fed inside the

top portion of a cone-shaped container while hot, dry air is simultaneously forced into the bottom of the cone

3. Upon drying of the slurry, beads of dry detergent settle at the bottom of the cone where they can be readily collected for packaging

MANUFACTURING PROCESS

• LIQUID DETERGENTS1. Mixing all the ingredients as well as water and

various chemicals known as solubilizers2. Solubilizers allows the detergent and the water

to blend evenly

MANUFACTURING PROCESS

• PACKAGING• can be packaged into cartons, bottles, pouches, bags or

cans • considerations of certain attributes and characteristics

of the product such as compatibility and stability, cost, package safety, solid waste impact, shelf appeal and ease of use are very important in selection of the right pacjaging materials needed

PARAMETERS IN SELECTING A GRADE OF AN INGREDIENT IN DETERGENT-MAKING

PARAMETERS IN SELECTING A GRADE OF AN INGREDIENT IN DETERGENT-MAKING

REFERENCES• http://www.madehow.com/Volume-2/Soap.html#b#ixzz1nBPZ5feD• The Enclyclopædia Britannica (15th ed.); Encyclopædia Britannica, Inc.;

1979• Selinger, Ben; Chemistry calcin the Marketplace (3rd ed.); Harcourt Brace

Jovanovich; 1986• http://www.soapcalc.net/info/soapqualities.asp• http://www.fmcchemicals.com/division_alkalichemicals.asp• http://wiki.answers.com/Q/How_is_soap_different_from_detergent#ixzz

1muLr468Z• http://www.care2.com/greenliving/10009.html#ixzz1muMKB0y8