THE COMPLETE PRACTICAL ON SOAPS PRODUCTION

1. LAUNDRY AND BAR SOAP
2. TOILET SOAP
3. MEDICATE SOAP
4. ANTISEPTIC SOAP
5. DETERGENT
6. LIQUID DETERGENT
7. TILES CLEANER

SOAPS                                                                               

Soaps and detergents belong to the same group of chemical products called surface active agents or surfactants.These groups of products are among other properties,well -known for their detergency which is due to a reduction in water surface tension which remove  the dirt by wetting,emulsification,lathering and removal.

Soaps generally are produced through a reaction know as saponification.This reaction occurs when fats  and oil  are hydrolised in alkaline (basic) solution.In other  words it is alkaline hydrolysis of fats and oil.The result of this is the formation of glycerol and salts of the fatty acids.The  sodium or potassium salts formed is the soap.

The cleansing activity of soap could be  explained in terms of its molecule structure.Actually water can wash  off some thingwith out application of  soap.For instance  if  a  sticky sugar syrup is poured on somebody's hand , water is used  to wash  it off ,the sugar dissolves in the water  and is rinsed off.If  there is a case where  oil is poured,water used  to  wash it will just run off the surface of the oil.Other dirt though not oil could form greasy film together  over the skin or clothes (as case may be) there by making it difficult for the water to wash  off . When soap solution  is applied to a grease -coated piece of fabric ,the soap molecules  first approach the  grease spot  at the  inter-phase  of  the grease  and water.The hydrophobic(water hating)tail of the soap particles dissolves in the grease while  the hydrophilic (water loving) head dissolves in the water .The water molecules  attract the polar  ionic heads of the soap  molecules .This action helps to lift the grease spot upwards, enabling more soap particles to dissolve in the grease .

Eventually with mechanical  scrubbing, the  grease patch is emulsified.On rinsing the fabric ,the grease is removed.

There are different ways (processes) in the production of soap.They are:

1.Cold process

2.Semi- Boiled process

3.Full- Boiled process

Cold process: Here heating is not involved.It is the most elementary batch process.In a saponification  vessel (mixer)it involved the gradual addition of right quantity of  soda iye (aqueous sodium hydroxide) to  fats and oil.The mixture is kept  under  vigorous  agitation (mixing) for approximately two hairs,and the dyes, perfume and additives are  generally added at this stage.This process does  not include  the removal of impurities or  separation of the glycerine which  is produced.

Crude soap is drawn off  as soon as the bulk  of the  mixture  thickens, and is poured into the cooling frames where the saponification process continues for one  or more  days.Crude  soap is then removed from the  frame,cut in sizes and put into mould.

The process is simple,inexpensive and not highly  mechanised.It  requires only modest investment in equipment.Low-grade soaps are produced through this method.

Semi- boiled process- this differs from the cold process in the fact  that  the  saponnification mixture(fats and oil and caustic soda solution) is heated to 70-90⁰C.Dye, perfumes and  additives are added  at  the end  of the processs to  prevent them  from  evaporating.Generallyspeaking,saponification is  more  complete and  the hardening time  of  crude  soap  in  cooling  frame  is slightly  reduced.

The process allows the quantity  of soda undergoing  saponification  to be  adjusted before  the   crude soap  is drawn off .It allows the  manufacturing  waste to be  recycled,better incorporation  of the additives and wider choice  of raw materials .

Full-Boild process-This process differs from semi-boiled  process in its various glycerineextraction,wash and adjusment operations which  occurs after saponification.The temperature at which  the mixture is kept under  vigorous agitation is generally higher(100⁰C),allowing a wider range of fatty raw materials to be used.

After saponification,the mass is subjected  to several  washes using brine.The more intensely the glycerine is washing water  drawn off  several times, glycerine concentrations in the region of 15-20% can be obtained.

The cooling and drying of soap

Once saponification has  been  completed,the soap  obatined whether crude or neat,has to be  turned  into  marketable soap.This is the cooling and drying stage,which  gives  the end product  the  required consistency and hardness.Household soap generally contains 25% water (75% Fatty acids) where  as toilet  soap  undergoes forced drying until it contains only 14% or even 12% water (86 to 88%) fatty acids).

Crude soap produces a lower-quality,inexpensivesoap.That is why it does not usually undergo any drying other than  air drying,which is carried out over serveral  day  in cooling frames

• Availability: 1 In Stock