Production Plan

Production Plan

September 29, 2010- Homemade soaps are very popular these days and if you really want to start a home based business at smaller level first then a homemade soap business is the answer. To start a soap making business

is perhaps one of the easiest options. And why?

Reasons for Starting a Soap Making Business

There are many reasons why you should get into a handmade soap making business.

You don't have to study a lot for making soaps. It requires a little knowledge about homemade soap recipes that you can get from soap making books or even by getting yourself enrolled in soap making classes that run for very short durations. Thus, the skill level required for starting a handmade soap business is very low and that too can be acquired quickly.

You need to make very little investments for your soap making business. What all you'll need is soap making supplies, soap making tools and equipment (which are not too many or not too expensive if you start making soap in small batches) and just a little space which can be found in your home itself. So, the capital investment is low too in a handmade soap business.

You can earn a good profit from handmade soap making business. If you plan well and in advance about how to make soaps, how to attract your target customers and how to market soaps made by you, profits can be big enough. For example, if you make 50 bar soaps by investing just $20, then your cost per soap comes to 40 cents. Now if you price each bar even at $2-$3, profit is good enough.

However, like all other businesses, you need to make a good- efficient and practical- homemade soap business plan. You should also be prepared for breakthrough period- the initial period where you might have to give away your soaps as gifts or at low prices for making a market for your specific soap product. If you remain consistent on quality and customer satisfaction, your small soap business can become a big one in future that can even transform into a brand name!

Homemade Soap Business Plan

Soap Making Business

Strategic planning in detail is very crucial in a handmade soap business.

Find sources from where you can get cheap raw materials for soap making. Cheap here doesn't mean low quality. Quality will decide whether you will be successful in long term or not. So, get cheap- that is inexpensive- soap making supplies wholesale. However, buy these soap ingredients only for a couple of months initially so that you can guage the progress and then invest later in bulk soap making supplies accordingly.

Plan your production process ahead of time especially if your goal is to produce huge quantities of soap. You can decide to make batches of soaps ranging from 20 to 50 bars at a time so that these do not go waste. This is essential because when you start making soap, your skills improve day by day and naturally later batches will be better than the earlier ones.

Always study the market first so that you can know what types of handmade soaps are in demand in the locality where you aim to sell your handmade soaps. For example, some areas may have more sales in organic soaps containing natural essential oils with fragrance and in others handmade soaps without fragrance. You can either focus on making only one of these types of handmade soaps or even make both types of soaps in separate batches.

Before you start making handmade soaps, you will need to buy soap making tools and equipment. Depending upon your budget, you can go for new soap making equipment or can buy used soap making tools from other soap detergent manufacturers who offer their soap making business for sale. You can even use your kitchen utensils for the purpose apart from buying some of the soap making equipment that would not be available at home.

Marketing Plan for Selling Homemade Soap

Selling Homemade Soap

You will need to work upon marketing plan as well to sell your homemade soaps. For the first few batches of your soaps, however, you can plan to give them away as gifts to your friends or in your neighborhood. Remember that they should be of good quality- first impression is the last impression. Once, your target customers come to know that you have started a homemade soap business and also liked your free gift of own made soap, you can proceed with other strategies for selling your homemade soaps. Sell them at a craft fair or locally at a farmers market. You can even go online by making your own website for facilitating customers to buy soaps from you or use the already existing shopping sites that allow you to sell your stuff. You can even sell your homemade soaps wholesale to the local departmental store. Find out by trial, experimenting or other ways about which selling strategy works well for your homemade soap business!

Soap Packaging too plays an important role in attracting customers towards your homemade soaps. Know about packaging process for soaps.

Soaps and Detergents are cleaning products that have become an essential commodity in our daily lives. Cleaning products play an essential role in our daily lives. By safely and effectively removing soils, germs and other contaminants, they help us to stay healthy, care for our homes and possessions, and make our surroundings more lively and pleasant.

Proper public understanding of the safety and benefits of cleaning products is crucial for their effective usage. To get maximum benefit from the cleaning products, it is necessary to use the right product, which is intended for your specific requirement, and to use it in the quantity and as per directed.

TypesDepending on their cleaning action and usage, soaps and detergents can be broadly categorized into four main types, including -

Personal Cleaning products - Personal cleaning products are cleaning agents that are used to wash and clean our hands, face, body and hair. These products may include toilet soaps, liquid cleansers, face wash, shampoos and conditioners. Personal cleaning products help us remain clean and healthy by removing dirt, oil, and environmental pollutants from our body. Personal cleaning products can be categorized into two main types -

o Skin Cleaning products o Hair Cleaning products

Laundry Cleaning products - Laundry cleaning products are detergents and surface active agents, that are manufactured to wash and clean our laundry items. These products come in various forms, such as detergent cakes, powders and liquids and are formulated to meet different requirements of laundry cleaning, such as stain and soil removal, bleaching, fabric softening and conditioning and disinfectant requirements under the varying temperature, water, and usage conditions. Laundry Cleaning products can be categorized into five main types -

o Detergent Powder o Detergent Cake o Fabric Softener o Laundry Liquid o Stain & Odor Eliminator

Household Cleaning products - Household Cleaning products are cleaners that we use in our homes to wash and clean different household products, such as furniture, glass, plastic items and different types of surfaces. These products help us keep fit and healthy be killing and removing harmful bacteria and germs from

our homes and workplaces. Household Cleaning products can be categorized into four main classes -

o Floor Cleaners o Glass Cleaners o Toilet Bowl Cleaners o Wood Cleaners

Dishwashing products - Dishwashing products are cleaning agents that are formulated to wash and clean dishes and other kitchen utensils. These products are available for hand wash as well as machine wash and are made for different water, temperature and usage conditions. Dishwashing products can be categorized into four main types -

o Dishwasher Liquid o Dishwasher Powder o Dishwasher Gel o Dishwasher Tablets

A brief description of these different types of cleaning products is given below –

Dishwasher liquids are detergents that are used to assist in hand washing as well as machine washing of glasses, plates, cutlery and cooking utensils. These detergent products are usually a high-foaming mixture of surfactants with low skin irritation.

Regardless of brand, few characteristics and features are vital in a hand dishwashing liquid that include - lasting suds, mildness to hands, superior cleaning performance, safety for dishes and other washables, storage stability, pleasing appearance and fragrance, convenient packaging as well as dispensing. In formulating and designing a dishwashing liquid to meet this criterion, manufacturers typically use certain basic ingredients.

Did you know...that liquid dishwasher detergents are very versatile cleaners?

Typically, the specialized cleaners are the ideal choice for certain specific jobs. However if you can't find any suitable specialty cleaner then in that case, a liquid dish cleaner is a good choice for a variety of households cleaning jobs. So remember, even though the liquid dish detergent is an ideal cleaner for dishes, it is can also be used as a good backup for various other cleaners.

In some cases, dishwashing liquid has also found to be useful for treating birds affected by oil spills. Some dishwashing liquids are also used in the case when a diesel fuel is spilled into water. When the dish cleaning liquid is poured onto it, it dissolves the spilled diesel and disposes it in a safe manner. Most people rinse the soap off from the dishes after cleaning them, however few leave the soap to dry on the dishes. Dishwashing liquid is often used in combination with water when blowing soap bubbles.

Directions for Use

Hand WashDispense the detergent into the wash basin and start filling the basin with mild hot water. Half a teaspoon of detergent (about one brief squeeze) is adequate to begin with. Swish the water around to work up some suds and then start washing the dishes. It is most economical to use little amount of detergent and then add more detergent if the suds have almost gone.

Machine Wash

Load dishes properly o Do not block spray to top rack o Soiled surfaces should face spray

Full all cups fully and use hot water with every load

For sterling silverware care o Separate sterling silver from stainless steel o Avoid spilling directly on silver items as it may cause spots

Use extra detergent for very hard water

Buying Tips

While buying a liquid dishwasher detergent, the selection of a particular brand and type depends on the application and choice of an individual. People with extra-sensitive skin and other allergies should prefer detergent free from synthetic petrochemicals and with mild pH as they gentle on skin and hands. Petrochemicals free from synthetic petrochemicals are also good for environment and the waterways. Carefully read the ingredients and prefer those that are phosphate-free and do not contain bleach

Soaps & detergents are cleansing products that may include bar soaps and liquid gels for cleaning the hands, face or body; detergent powders or cakes for laundry cleaning purposes; household cleansers for cleaning household items such as furniture, glass, plastic items, etc; and dish cleaning products for washing kitchen utensils and dishes. Surface active agents are the prime ingredients of soaps and detergents. Other than these surface active agents, all soaps and detergents are made using a variety of ingredients that are added in soap and detergent products to give them specific properties and characteristics.

Ingredients of Soaps and Detergents

Soaps Ingredients

Soaps are prepared by the alkaline hydrolysis of fats and oils or the saponification process. This soap manufacturing process also produces a by-product 'glycerol' which is useful in foods, as an antifreeze, as a tobacco-moistening agent, and in the manufacturing of nitroglycerine and dynamite. The ingredients of soaps and detergents and their percentage (percent of total by weight) used can be listed as follows

Surfactants (30-70%) Plasticizers and binders (20-50%) Lather enhancers (0-5%) Fillers and binders (5-30%) Water (5-12%) Fragrance (0-3.0%) Opacifying agents (0-0.3%) Dyes and pigments (less than 1%)

Properties & Functions of Soaps Ingredients

All the detergent ingredients impart different properties and functions to soaps and detergents. There are certain other specific ingredients that are added in specialty soaps and detergents depending on the action or characteristics desired in the end product. For example, toilet soaps may contain antimicrobial agents to kill or inhibit bacteria which can cause odor or disease. Some other personal cleaning products may be made using abrasives for removing stubborn greasy dirt.

Glycerin is added as an ingredient of soap as an emollient and texture enhancer in personal cleaning products, especially moisturizing soaps or beauty soaps. Sorbitol is another emollient, which is used along with glycerin to help make glycerin soaps more transparent. For making an opaque toilet soap, titanium dioxide can be added to it.

Bleaches, detergent boosters, fillers and builders are laundry cleaning agents that are added to enhance the effectiveness of laundry detergents and soaps and provide special attributes and functions to these laundry cleaning products. The laundry cleaning agents brighten and whiten fabrics and help remove the stubborn stains. These laundry detergent ingredients also convert the soils into colorless, soluble particles which can be removed by detergents and are carried away in the wash water.

Fats

The fats used in soap and detergent making coming from animal or plant sources. Each fat molecule is made up of a distinctive mixture of various different triglycerides. In a triglyceride molecule, 3 fatty acid molecules are attached to one molecule of glycerine. There are different types of triglycerides; and each type consists of its own specific combination of fatty acids.

Components of fats and oils, which are used in making soap, fatty acids are weak acids that are composed of two parts -

A carboxylic acid group Hydrocarbon chain

A carboxylic acid group consists of a hydrogen (H) atom, two oxygen (O) atoms, and one carbon (C) atom, along with a hydrocarbon chain, which is attached to the carboxylic acid group. Typically, fatty acids are made up of long straight chain of carbon (C) atoms, in which each carries two hydrogen atoms.

Structure of Fats

Fats are esters in which the OR' (alcohol) part of the molecule is the trihydroxy compound, glycerol (HOCH2CHOHCH2OH). As each glycerol molecule can be esterified with a different carboxylic acid, there are three carboxylic acid portions in these molecules, which are consequently known as triacylglycerols or triglycerides. These carboxylic acid groups generally have long hydrocarbon chains of 14-20 carbons (including the carbonyl carbon). These chains are usually unbranched and, most importantly, they contain even numbers of carbon atoms. The carboxylic acids that are obtained by hydrolysis of fats are known as fatty acids.

This is interpreted to determine that the fatty acids are made up of 2-carbon atoms at a time. Each unit of 2-carbon atoms is added by reacting the alpha carbon of one acetate unit with the carbonyl carbon of the next.

Fats for SoapmakingIt has been found that almost any fat can be used in soapmaking. Fats for soap making may include animal fats, like tallow (fat from beef), lard (fat from pork), and many plants derived hydrogenated fats and oils. Traditionally, animal fats have been used, with beef

tallow considered to make the hardest soap, pork lards - medium hardness soap and chicken fat as the softest. Now days, it is generally accepted that the harder fats produce better soap.

There are variety of fats with each bring their own unique characteristics and qualities to soap. Whatever type of fat or oil is used, it is important to make sure that it is clean and free of impurities. It should not be rancid, should have excess salt in it, or have any solid particles. Rancid and dirty fat can be cleaned by heating it for a few minutes in a large container, with four parts water to one part fat. Set it aside and let it to cool down. After the fat has solidified, remove it from the container in one piece.

Best Soaps for SkincareAccording to experts, lard beats tallow and vegetable oils have found to be highly gentle and great for skin. However, soaps made with 100% lard do not lather very well but they are known to have effective in cleaning. There is a predominant perception today that you should get bubbles for the soap for its proper functioning.

Surfactants or Surface Active Agents

Also known as surfactants, surface-active agents are basic cleaning agents in soaps and detergents. These agents are added to wash water to lower its surface tension, thereby to increase the wetting and spreading properties of water. Surfactants are usually organic compounds, which are amphiphilic, meaning they are soluble in both organic solvents and water. Surface active agents have two parts, one is hydrophilic (water loving) and another is hydrophobic (water repellent). Surface-active molecules concentrate at the areas of contact or interfaces, between oil and water. One end of the molecule seeks oil, while the other end seeks water. At the interface of water and oil, surface-active agents emulsify oil and mix it into the liquid in the same way fat is mixed in milk. At the interface of water, these agents trap air molecules to produce foam.

By reducing the surface tension water, surfactants improve the cleaning performance by enabling the solution to wet a surface (for example, dishes, clothes, and countertops) quickly and effectively, and hence the soil can be readily loosened and removed. Surface active agents also emulsify oily soils and keep them suspended and dispersed so they do not settle back on the surface. To achieve superior cleaning performance, most of the cleaning products contain two or more surfactants.

Types of Surface Active Agents

Surfactants are generally classified on the basis of their ionic properties (electric charge) in water. On the basis of ionic properties, surfactants can be classified into four types -

Anionic Surfactants Non-ionic Surfactants Cationic Surfactants

Amphoteric Surfactants

Properties of Surfactants

The molecular structure of surface-active agents means that they have unusual characteristics, leading to their uses in widespread and highly specialized applications. The properties of these agents can be categorized into two types -

Adsorption Self Assembly

Structures of Common Surfactants Used in Biochemistry

AdsorptionAdsorption is the tendency of the molecule of a surfactant to collect as an interface. It is the taking up of a liquid or gas at the surface of substance, generally a solid (for example, activated charcoal adsorbs gases). The process involves molecular attraction at the surface.

The adsorption property of surfactants mean that their molecules are generally found at the interface between a water phase and an oil phase an air phase and a water phase. This molecular property results in the macroscopic properties of wetting, detergency, foaming and emulsion formation. The molecules of a surface-active agent tend to adsorb to the surface of oil droplets. While the hydrophilic heads stick out into the water phase, the hydrophobic tails stick into the oil phase.

Self AssemblySelf-assembly is the inclination of surfactant molecules to organize and coordinate themselves into the extended structures in water. The process includes the formation of micelles, liquid crystals and bilayers that are formed when the hydrophobic tails of surfactant molecules cluster together to produce small aggregates, like micelles, or large layer structures like bilayers that are similar to a cell wall. These characteristics of surfactants make them an interesting study and an area of research.

Surfactants can also organize to form micelles, which allows the hydrophobic tails to get out of the water, however it still allows the hydrophilic heads to stay in the water. There is typically between a few dozen to a couple of hundred surfactant molecules in a micelle.

Surfactants also aggregate to develop and produce extended structures in water like that of surfactant bilayers.

The concentration at which surfactants start forming micelles is known as the critical micelle concentration or CMC. When micelles are formed in water, their tails form a core, which can encapsulate an oil droplet, and their (ionic/polar) heads

produce an outer shell, which maintains a favorable contact with water. When the surfactants assemble in oil, their aggregate is referred to as reverse micelle. In a reverse micelle, the heads remain in the core and the tails maintain a favorable contact with the oil.

Thermodynamics of surface-active agents is of great importance theoretically as well as practically. This is due to the fact that these agents represent systems between the ordered and disordered states of matter.

Applications of Surface Active Agents

The surfactants have found variety of uses and applications in the detergent industry, in emulsification, lubrication, catalysis, tertiary oil recovery, and in drug delivery. Some of the important applications of surfactants include -

Used in the investigation of the denaturation of bacteriorhodopsin and in thermal stability experiments of rhodopsin

In superior performance liquid chromatography, some common techniques, like ion-exchange HPLC, reversed-phase HPLC and sizeexclusion-HPLC require surfactants to solubilize membrane proteins. Ion pair HPLC requires surfactants as reagents so as to achieve the separation conditions

The operations of removal and exchange of surfactants bound to membrane proteins are important and have been successfully applied to a variety of these proteins

Integral membrane proteins can be separated from hydrophilic proteins and can be described as such in crude surfactant extracts of membrane or cells

Surfactants are also used to encourage and push the dissociation of proteins from nucleic acids on extraction from biological material

Affinity surfactants have found uses as reversibly bound ligands in high performance affinity chromatography

Some other examples of surfactants in biochemistry include the solubilization of enzymes in apolar solvents via reversed micelles and the isolation of hydrophobic proteins

Crystallization of membrane proteins can be achieved using short chain surfactants that are believed to shield the hydrophobic inter membrane part of the molecule

AlkalisAlkalis are soluble salts that are effective in cleaning fabrics and removing dirt without excessive rubbing. A soluble salt of an alkali metal like potassium or sodium, alkalis are good grease removers, as they form emulsion, a mixture where oily or solid particles are held in suspension. The particles do not separate from the remaining liquid and hence they do not re-deposited on the surface being cleaned.

Earlier, the alkalis used in soap manufacturing process, were obtained from the ashes of plants, but now days, they are produced commercially. Today, the term alkali describes a substance, which is a base (chemically) and which reacts with an acid to neutralize it. The most common alkalis used now days in soapmaking is sodium hydroxide (NaOH), which is also known as caustic soda; and potassium hydroxide (KOH), also known as caustic potash.

Potassium based soaps form a more water-soluble product than a sodium-based soap, and hence they are known as "soft soaps." Soft soaps, alone or in combination with sodium-based soaps, is generally used to make shaving creams and other water-soluble products.

When oil is mixed with an alkali, it forms glycerin and a sodium salt of fatty acid. The fatty acids that are required to manufacture soaps are supplied by tallow, grease, fish oils, and vegetable oils. The characteristics of soap, such as hardness, lathering qualities and transparency may vary depending on the combinations of alkalis and fats used as ingredients. Alkaline cleaners can also be used to remove oil from an oil-based paint, by drying it and causing it to peel or crack. Alkali products also have a property to darken aluminum surfaces

Types

Alkaline substances vary in their strength. While most of the alkaline substances are toxic, some may be corrosive and some may irritate skin and eyes. The stronger alkalis can cause burns and, in the case swallowed, may cause death or internal injuries. On the basis of strength, alkalis can be -

Mild - An example of mild alkali is baking soda (sodium bicarbonate)

Moderate - Common examples of mild alkalis include - household ammonia, borax and trisodium phosphate (TSP)

Very Strong - Washing soda (sodium carbonate) and lye (caustic soda) are most common strong alkalis

Where does an alkali come from?

In earlier days, rainwater was filtrated through hardwood ashes in Africa, to produce potassium hydroxide solution. Bar soaps was made using sodium hydroxide, which is

what you get when you run electricity through salt water. Today, potassium hydroxide is made using a similar process.

ApplicationsAlong with its wide known use in soapmaking, additional alkalis, such as sodium carbonate, hydroxide or trisodium phosphates are used dishwashing products to aid in handling greasy food soils.

Use in Soapmaking

Acidic oils and alkaline solutions are prime ingredients in soapmaking. To produce a perfect bar of soap, oil and alkalis should be in perfect balance. The unsaponified oils are known as "Free fatty acids", which add to the moisturizing characteristics of high quality soaps. However if these oils are used in excess, the soap will not lather and will have a shortened shelf life. The use of excess alkali in a soap make it harsh and drying to the skin.

Acid V/s Alkali & Soapmaking

Acid AlkaliNormal pH is 7.0

Water should be 7.0 Acids are chemicals that have a pH lower than "neutral". An acid can be mild or extremely caustic.

Alkaline substances have a pH more than 7.0. They can be mild or corrosive.

The type of acid, which is used to make soap is a fatty acid, obtained either from animal fat or vegetable oil.

The alkali, which is used to cause the chemical reaction with the fatty acids, is either made from potash (lye water) or sodium hydroxide.

SaponificationWhen a base reacts with oil or fat, fatty acids get separated from the glycerin and the potassium of sodium component of the alkali bonds with fatty acids. The product, which is formed by the sodium or potassium and the fatty acid, is a salt. In technical terms, soap is a salt. Glycerin (also called glycerol) is a by-product, which has its own cleansing properties. It is hydroscopic, i.e. it moisturizes as it attracts water from the air.

Glycerine

Glycerin is a natural by-product of the soap manufacturing process. It is a humectant that means it attracts moisture to your skin. While commercial manufacturers remove the glycerin for its uses in more profitable expensive lotions

and creams, handcrafted soap generally retains glycerin in them. Glycerin is also highly hygroscopic that means it absorbs water from air. Because of this hygroscopic

property, pure, 100 % glycerin when placed on the tongue may raise a blister, as it is dehydrating. However when it is diluted with water, it soften your skin.

Highly glycerinated clear soaps generally contain about 15 to 20 percent pure glycerin. Known as "melt and pour soaps", these soaps melt at about 160 degrees Fahrenheit, and solidify fairly quickly. Due to their high glycerin content, these soaps are very moisturizing to the skin. However the high glycerin content also means that these soaps will dissolve more quickly in water than soaps with less glycerin content.

Where does glycerin come from?

Until 1889, people did not know how to recover glycerin from the soap manufacturing process and so glycerin required for other applications was commercially produced from the candle making industry. In 1889, a feasible method to separate glycerin from the soap was discovered. As the prime use of glycerin was to make nitroglycerin that was used to make dynamite, soap making business became a more profitable one.

The technique of separating glycerin from the soap is fairly complicated process. In the simplest terms, soap is made using fat and lye. The fats already contain glycerin, which is due to their chemical makeup. When the fats and lye react, soap is produced, and the glycerin is left out as a byproduct. However, while it is chemically separated, it is still blended into the soap mix.

While a cold process soap manufacturer would usually pour into the molds at this stage, a commercial soap manufacturer will add salt. The salt makes the soap to curdle and float to the top. After creaming off the soap, glycerin is left off. Then the pure glycerin is separated out by distillation. Finally, in the end, glycerin is de-colorized by filtering it through alcohol, or by using some other bleaching techniques.

Properties

A colorless, odorless and viscous liquid, glycerin is a chemical compound with formula HOCH2CH(OH)CH2OH. This colorless, odorless, viscous liquid is widely used in pharmaceutical formulations. Sweet in taste, glycerin is low of toxicity and has 3 hydrophilic alcoholic hydroxyl groups, which are responsible for its solubility in water and its hygroscopic characteristic. The chemical has a surface tension of 64.00 N/m at 20 °C and has a temperature coefficient of -0.0598 mN/(m K).

An important thing to know about glycerin is that it should be placed in a slotted soap dish to ensure proper drainage. In the case, there is too much water on the soap it will start to gel.

Applications

Besides making nitroglycerin, glycerin is also used in various other processes, including -

Soap making Conserving preserved fruit As a base for lotions To prevent freezing in hydraulic jacks To lubricate molds In some printing inks, in cake and candy making (because of its antiseptic

quality) Sometimes used to preserve scientific specimens in jars in biology labs Used as a solvent in the manufacture of alkyd resins and ester gum type inks

Benefits of Glycerin in Skincare

Glycerin is a humectant, which means it promotes the retention of moisture. It has no drying characteristics and hence leaves the skin smooth and silky. It has found to be really effective and god for elbows, heels, tender skin and children's skin.

Detergent BuildersDetergent builders are materials, which can be used to bind cations (mainly calcium, Ca2+, and magnesium Mg2+) contained in wash solutions that results in water softening. Builders enhance the quality of the water, thereby making the detergents work in a more effective and efficient manner.

Detergent builders soften water by holding free water ions, such as magnesium and calcium. This prevents these particles to react with other ingredients of detergent, which would have caused them to work less efficiently or precipitate from solution (soap scum). They can produce insoluble salts, which become beset in the clothes and deposit on solid surfaces inside the washing machine. In this manner, builders also help in extending the life of the washing machine. Soil molecules are sometimes bound to the clothes surface by calcium ion bridging, removal of hardness from the environment and therefore help in removal of stains. Sometimes more than one detergent builder is used in a product, to develop a builder system with more effective cleaning performance.

TypesOn the basis of characteristics and properties, detergent builders can be categorized into two types

Organic detergent builders Inorganic detergent builders

Detergents, as we know, consist of surfactants and chelating agents. Surfactants remove and clean dirt from a soiled surface, while chelating agents are used to surround unwanted metal ions that are found in cleaning solutions. Though very effective, chelating process is expensive and is not always necessary and in cases such as these, builders have found to be a good alternative. Builders improve the detergency action, and being relatively cheap, less can be used of the more expensive detergents of superior activity.

Traditionally, sodium tripolyphosphate (STPP) was the builder of choice. It offers superior water softening because of its high binding capacity for heavy metals and calcium ions, good buffering properties that contribute to detergency action and superior anti-redeposition properties. In addition, the position of STPP as a preferred builder during 1940s-1970s was further boosted because of its low toxicity. Although STPP has low toxicity, as a nutrient, it has the potential result in eutrophication (a term used to describe water that is 'over rich' in nutrients, and may to an excessive growth of algae). This led to the search for alternative products and the development of synthetic detergent Zeolite, which now days, is the principle alternative to phosphate builders.

PropertiesBuilders are basically water softeners that are used to soften wash water by extracting and binding the magnesium and calcium ions. Due to the action of builder, the availability of these ions is removed from the wash-water solution, and as result the hardness of wash-water is removed. Depending on the type of builder, other benefits may be available, such as -

Buffering of wash water in the alkaline range Help prevent the redeposition of soils after they have been removed from the

fabric by surfactants Carry absorbed liquid components in the products, like surfactants so as to

produce a dry and free flowing powder Typically improve the wetting and emulsification characteristics of detergent

AdvantagesThe prime function of detergent builders is to upgrade and prevent the cleaning efficiency of surfactants. Builders offer a number of advantages, including softening, buffering, and emulsifying. Some of the important advantages of using a builder in a wash solution are -

Soften water by deactivating the hardness minerals (metal ions such as calcium and magnesium. The softening process is followed by two processes - one is sequestration (holding metal ions in solution) and another is precipitation (removing metal ions from solution as insoluble materials).

In addition to softening, builders also provide a desirable level of alkalinity (increase pH) that improves cleaning performance. They also work as buffer to maintain suitable alkalinity in wash water.

Help emulsify oily and greasy soil by breaking it up into small parts. Different builders in reality peptize or suspend loosened dirt and keep them from settling back on the cleaned surface.

Detergent BoostersDetergent boosters are fabric care products that are designed to reinforce specific performance characteristics that are desired in laundering. These fabric care products should be used in the wash along with the recommended amount of detergent. Boosters improve the soil and stain removal, buffering, brightening and water softening performance of detergents. In addition to the detergent, they are used in the wash water to improve the cleaning performance.

The prime function of detergent boosters is to condition the water to optimize the cleaning action of detergents. These products are formulated for effective cleaning in hard water and can be used to enhance and improve the cleaning power of detergent. These products should be used as per the recommended amount of detergent for a particular size of wash load.

FormDetergent boosters come in two forms -

Powder form Liquid form

Liquid detergent boosters can be used to pretreat stains. These are formulated using optical brighteners and nonionic surfactants to deliver excellent wash performance across a comprehensive range of soil classifications and fabric types.

Some common ingredients that are used in detergent boosters, include - surfactants, builders, enzymes, borax, corrosion inhibitors and fluorescent brighteners. These ingredients are integrated in various divergent ratios that depend on the objectives and requirement of the given product. Based on a concentrated, super-potent blend of synthetic detergent complex with neutral pH additives, detergent boosters are formulated to enhance and improve the cleaning power of cleaning agents without the risks of over wetting or browning.

Laundry Cleaning AdditivesAlong with sodium hypochlorite bleach and soil & stain removers, detergent boosters are laundry cleaning additives. These additives for laundry cleaning do not include laundry conditioners, such as ironing aids and fabric softeners. Detergent boosters and soil & stain removers are more expensive and thus are used less widely than sodium hypochlorite bleach. Detergent boosters and soil & stain removers include different types of products, some of which can be defined and classified in more than one way. Bleach free boosters ensure additional safety for colors.

Properties

Formulated as powder and liquid concentrates Emulsifying with high oil absorption Superior in lowering of the surface tension and well dissolving of pigments Improves the effectiveness of detergent on whites and colors Minimize rust stains Reduce hard-water deposits Help prevent graying soap residue Helps remove mineral soap and detergent deposits, which build up in your

laundry Can be used as detergent booster in addition with a builder for all materials

ApplicationsDetergent boosters have found to be very good in lowering the surface tension and are also suitable for well dissolving of pigments. These products dramatically enhance the cleaning performance of detergents without raising the pH level. According to industry experts, savings can be made through the reduction of both labor and chemical used by adding boosters to the cleaning action. These products do not contain any cationic ingredients and are safe for uses on all carpet fibers, softens hard water thereby leaving carpets bright and soft.

Based on multiple enzyme formulation, detergent boosters improve the stain and dirt removal performance and have found to be useful for cleaning stains caused by chocolate, baby food, blood, grass, eggs etc. Boosters deliver excellent performance in removing accumulated stains on bed sheets, curtains and cushion covers. Useful for various household laundry wash applications, detergent boosters work on a big, tough stain formula to help wash clothes in an easy, effective and convenient manner.

Detergent FillersDetergent fillers are the materials, which are added in detergents to alter their physical characteristics and properties. The objective of adding fillers to detergents is to make detergents fluid or to turn the fluidized detergents in powder form. Generally the fillers are bulk components in various detergents with their primary role to modify and alter the physical properties of the material.

We can also define detergent fillers as additives that can be added in detergents (along with bleaches, bleach activators, antistatic agents, fabric softners, optical brighteners and antiredeposition agents) to improve the cleansing performance.

MaterialsThe different materials that can be used as fillers in detergents, include -

Sodium sulfate

Sodium chloride Borax Alcohols Anti-foaming agents

Borax can be used in solid detergents to make the detergent powder free-flowing. Alcohols can be added in liquid detergents to increase the solubility of compounds and to reduce the freezing point of mixture. The addition of anti-foaming agents help in lowering the production of foam thereby making the presence of detergents in wastewater less obvious. Sodium chloride or sodium sulphate can also be used as fillers. Sodium sulfate comes at an economical price and has some cleansing effect, especially when it is mixed with a cleansing agent. Corrosion inhibitors, such as sodium silicate can be added to increase the lifetime of the washing machines. Generally the usual content of fillers in detergents is about 5-45%.

Typically, a detergent is a mixture of various substances and is generally made by compounding the different ingredients, sometimes in the form of a slurry and is then spray-dried to yield free-flowing granules. A detergent contains following ingredients, in varying proportions, usually like -

A surfactant (detergent) (8-18%) A builder (20-45%) e.g. phosphates or zeolites A bleach (15-30%) e.g. sodium perborate A fluorescer - 'whiter than white' (0.1%) A filler (5-45%) e.g. sodium sulphate The detergent also contains water (4-20%) and may also contain up to 0.75%

enzyme

Fillers in CosmeticsAlong with detergents, fillers are also widely used in soap and cosmetic products. In these products, fillers are used as binding agents, which are used to give hardness to the soap cake, free-flowing properties to the powders, and more. Some of the applications include uses in talcum powder, detergents and washing powder.

ApplicationsDetergent fillers have found uses in various applications, such as -

Detergents Soaps and cosmetics Dishwasher components Household appliances Washing machine parts Electrical applications

Rinse AgentsRinse agents are cleansing agents that are used with dishwashers to help it rinse away residues, which cause spots and films on dishes and glasses. Rinse agents are available in the market for automatic dishwashers, which are designed to reduce the surface tension of water, thereby making it to sheet off the dishes during the final rinsing. The use of rinse agents prevents the formation of droplets of water, which may remain on the dish surface and are set by the drying cycle heat thereby leaving film and spots.

With the use of detergents alone, the residues of food and chemicals can redeposit on dish ware and leave spots and films. These deposits of spots and films occur as a result of the water containing detergent and mineral residue drying on the dishes. Rinse agents in these cases rinse away residues without leaving unsightly spots and as a result nothing left behind but sparkling clean glasses, dishes and cutlery.

The rinse agents now days, come in solid as well as liquid forms. The liquid rinse agents are designed for dishwashers with a rinse agent dispenser while the solid ones are designed for dishwashers that does not contain a dispenser for rinse agents. Some manufacturers also design rinse agents with a variety of scents and fragrances.

Rinse agents have also proved to be highly helpful in obtaining dry dish ware in the cases when dishwasher energy savings switches are activated or when the dishes are left to air dry.

How Does Rinse Agents WorkDishwasher detergents perform cleansing in the wash cycle but actually the spots and films form in the rinse cycle of dishwasher when detergents are already down the drain. Rinse Agents work in the rinse cycle, reduce the surface tension of water and make it to sheet off the dishes during the final rinse. More the water that runs off, better will be the rinsing effect, as the evaporated water leaves lime scale and minerals on the surface of glasses, dishes, and flatware, producing spots and film.

Superior rinsing leads to less spots and films thereby leaving the dishes, glasses and cutlery items sparkling clean with every wash. Generally the rinse agents are recommended to use in addition with the detergent for quality results in every wash. And this is the reason that the dishwashers are designed with a separate rinse agent dispenser to help you fight spots and film.

How to use Rinse AgentsGenerally the dishwashers come with a built-in liquid rinse dispenser, which is usually located near the detergent cup(s). You can use the rinse agent by simply filling the dispenser without overfilling it. Wipe and clean up any spilled products. The rinse agents are automatically released in the rinse cycle, every time the dishwasher runs to fight spot and films.

Note

In the case, the dishwasher does not have a built-in dispenser for rinse agents, you can use solid rinse agents that can be clipped to the top rack of the dishwasher for sparkling clean results without any films or spots.

How to Buy a Rinse AgentWhile buying a rinse agent for cleaning dishes in dishwashers, it is important to know what you should you look for and what really matters to you. If you have a dishwasher that has an in-built rinse agent dispenser then you should buy a liquid rinse agent, however if your dishwasher does not has an in-built, you should buy a solid rinse agent that can be clipped to the top rack of dishwasher.

Try to look for rinse agents that does not contain any toxic substances or ingredients as they may leave a hazardous film on the surface of your dishes. Rinse agents made of non-toxic substances and a special combination of nonionic surfactants, chelating agent, dye, and fragrances have found to be highly effective.

Film Removers

Film Removers are powdered alkaline products, which contain chlorine and complex phosphates. Film removers are used in dishwash cleaning products and help in removing and cleaning build-up of hard water film and cloudiness from the dishes and interior of the dishwasher.

Film removers can be used instead of an automatic dishwasher detergent in a separate cycle or can be used together with a detergent. Along with the dishwahing uses, film removers are also used for cleaning commercial vehicles.

Directions for UseTo achieve effective cleaning from film removers, carefully follow the below mentioned instructions

Dilute one part of the film remover with 2 parts of warm tap water Apply the solution liberally with a sponge on the surface needed to be cleaned

and allow it to stand till the time the soap scum begins breaking up Scrub slightly with a plastic scouring pad or a scrub brush Rinse thoroughly

Salient FeaturesFilm removers are made with a special cleansing formula, which is pH balanced, no-rinse formulation that effortlessly cleans soil and grime and dries with no streaks. Special inorganic salts are generally added in the formula that work as moisturizers and optical brighteners, which actually enhance the shine of the floor. Some manufacturers use a concentrate design (containing shine enhancer and waxes) to remove and clean stubborn grime and soiling, which can be found on vehicles used in the haulage

industry. Some manufacturers design film removers with a special formulation to remove road film, oils, grease and insects from cars and commercial vehicles.

Other Household ApplicationsApart from uses in dishwash and commercial vehicle cleaning products, film removers have also found uses in other household applications, including -

Deep cleaning counters Polisheds Stone Surfaces Ceramics Fiberglass Shower doors & floors Shower walls Bathroom vanities

Lime & Rust Removers

Lime and dust removers are cleansing products that are used to remove and clean the deposits of lime and/or rust from the interior of the dishwasher. These products are used when no dishes or other products are present inside the dishwasher. Specially designed for hygienic cleaning of dishwashers, lime and dust removers have also found uses in the cleaning of washing machines and even in typical applications, like - the removal of rust from nuts and bolts, valve interiors and exteriors, bearings, pump housings, gears, shafts - virtually any metal part where mechanical removal of rust can be impractical or may damage the metal surface.

Specially designed for effective cleaning of dishwashers and other equipment, lime and rust removers are acid based condition system that are suitable for all materials subject to oxide formation that include ferrous metals, aluminum, copper, stainless steel and zinc.

Soft water forms a build-up of detergent residues inside your machine that can result in leakages and develops an environment for bacteria to thrive thereby causing unpleasant odours. With their unique non-corrosive acid side cleaning, the lime and rust removers can be used to safely break down hard water deposits and soils. The removers can be used to clean grout, ceramic, glass, porcelain, and stainless steel while making the surface free from residues.

FeaturesSome important features of lime and rust removers, include -

Highly concentrated acid base Can be used on all metals

Brightens nonferrous metals Forms a short-term protective coating against flash rusting Completely dissolves rust, lime, scale and other corrosion Biodegradable Prepares metal surfaces and provides excellent adhesion for paints

AdvantagesSome of the important advantages of lime and rust removers include -

Eliminates limescale build-up from internal parts Removes powder build-up and odour-causing bacteria Hygienically cleans all the internal parts Improves the working and efficiency of your appliance Have proved to be a cost effective way of prolonging your appliances' life If used immediately with new appliances, reduces the detergent quantity by up to

a third

Emulsifiers

Emulsifiers are chemicals that are used in fabric softeners along with conditioning agents to make the solution stable. Without emulsifiers the softener liquid will separate into two parts / phases. Also known as a surfactant from a surface-active material, emulsifiers are used to prepare emulsions, such as creams or lotions.

Chemically, emulsifiers are functional ingredients that have both lipophilic and hydrophilic properties at once as their molecular structure has both hydrophilic as well as hydrophobic part. An emulsion is a dispersion of one non-miscible liquid droplets into another - i.e., water and oil. Without an emulsifier, the two liquids would separate quickly.

The emulsifier is absorbed in the interface between the two liquids, thereby forming a film between both products. Because of its structure, the polar part of an emulsifier molecule has an affinity with water, while the non-polar part (fatty chain) tends to be attracted to the fatty phase. The emulsifier forces one of the liquid to separate into drops, suspended and dispersed within the other liquid. As these droplets are guarded and protected by the emulsifier molecules, which surround them, they are kept isolated from each other, which ensures that two substances do not separate but are kept in the stable mixture.

Types of Emulsion

The three types of emulsifiers that are used in fabric softeners, include -

Micro-emulsions Macro-emulsions Emulsion polymers

Macro-emulsions are creamy dispersions of water and oil that are similar to hand lotions or hair conditioners. The molecules of an emulsifier surround the hydrophobic oil or silicone droplets and enable them to be dispersed in water. A micro-emulsion is similar to it chemically, however it creates oil particles, which are so tiny that light will pass around them. Therefore, micro-emulsions are characterized by their clarity and transparency as opposed to being milky white in color. Another advantage of micro-emulsions is that the silicone particles, which are so tiny penetrate into the fibers, while the macro emulsions only deposit on the surface of fiber. The third type of emulsifiers, i.e. emulsions polymers, form dispersions, which look similar to a macro-emulsion in appearance. This system do not use true emulsifiers to suspend and dissolve the oil phase, instead, it produces a stabilized web of molecules, which suspend the tiny droplets of silicone.

The emulsifying system for use in softeners should be chosen carefully to ensure an adequate level of deposition on the fabric. A blend of non-ionic emulsifiers (no charge) and cationic emulsifiers (positive charge) are generally used. Anionic surfactants (negative charge) are used rarely because the fabric conditioning agents have a positive charge that tends to destabilize an anionic emulsion.

AdvantagesSome of the advantages of emulsifiers include -

Non irritating Highly substantive Compatible with fatty esters Outstanding emolliency Long lasting silky after-feel Benefits recognizable at low use levels Broad pH functionality

Applications Emulsifiers are used in various cosmetic products, such as -

Moisturizers Gel creams Multiple emulsions Sunscreens Perfume creams Preservative free After sun products Water free Emulsifier free Body butters Cleansers Mild formulation

Dry Cleaning Fluid

Dry cleaning fluids are non-water-based solvents that are used to remove dirt and stains from clothes. In spite of the name, dry cleaning is not a completely dry process and fluids are used in this process. In the earlier days, garment scourers and dryers found various fluids, which can be used as dry cleaning solvents and include camphene, benzene, kerosene, and gasoline. All these fluids are highly inflammable and hence dry cleaning was a hazardous business till the time safer solvents were discovered.

Now days, two general types of cleaning fluids that are used for dry cleaning applications in the industry are petroleum solvents and synthetic solvents. Petroleum solvents are combustible hydrocarbon mixtures, which are similar to kerosene. Operations that use petroleum solvents are known as petroleum plants. Perchloroethylene (PERC), the most common synthetic solvent is a nonflammable halogenated hydrocarbon. PERC and other solvents can be emitted from the dry cleaning machine while operating the units or during the solvent reclamation processes.

Laundry Cleaning V/s Dry CleaningDoing laundry has been a common household activity for centuries. Whether the method was beating the garments on rocks or pressing buttons on a washing machine. The cloth washing method depends on factors, such as water and the mechanical action typically assisted by soap or a detergent. The purpose of a using a soap or detergent is to saponify the oil and dislodge the dirty soil and other matter. The prime function of soapy agent is to hold soil in suspension as it becomes loose during the wash cycle, and is afterwards flushed away during the rinse cycle.

The drying process for doing laundry at home can be done by either by hanging clothes or tumbling them in a gas or electric heated dryer.

Dry cleaning, on the other hand, is a different stuff. It is a technique used to clean without water. The cleaning fluid used in dry cleaning is a liquid and all the garments are immersed and cleaned in a liquid solvent. The fact that no water is used, the process is known as dry cleaning. The potential of the petroleum based solvents for dry cleaning applications was first discovered in the mid-19th century by Mr. Jean Baptiste Jolly (French dye-works owner), when he observed that his tablecloth became cleaner after his maid spilled kerosene on it. From this observation, Mr. Jolly started a service to wash the clothes of other people, which he termed as "nettoyage à sec," or "dry cleaning".

How to Use

Treat the spots by rubbing with hands and then place the clothes in machine

Add solvents, detergent, and sometimes a small amount of water to the machine that agitates the clothes in a manner similar to that of regular washing machines

Once clean, dry, press and shape the clothes.

Do not iron a fabric treated with dry cleaning fluid

Separate the solvent from waste residues, such as detergents, dyes, dirt, and oil, so that it can be reused.

Finally at the end, the filters that are used to clean the solvent and the solvent residues are managed and disposed of as hazardous wastes.

After allowing the clothes and fabrics to cool, lightly sponge the stained area with dry-cleaning fluid and blot onto towel or paper to help remove any residual colored staining. Make sure to always check for color fastness before using a dry cleaning fluid.

Dry cleaning fluids are highly toxic and flammable and hence it is important to carefully follow the usage instructions. Use it in a well-ventilated area and never use it in a dryer or washing machine.

Applications

Dry cleaning fluids have found to be excellent tool for removing tough dirt and stains on delicate fabrics. Easy and convenient to use, dry cleaning fluids are

Ideal for application on delicate fabrics, like silks, jusi, knits and other delicate fabric materials (suits, dresses, sweaters, Barong Tagalog, etc.)

Ideal to use on color fast clothes, rugs, drapes and upholstery

Perfect in removing stains, which are caused by solvent spills, crayons, colored pencil, inks, oil and grease

Complete convenient, just dip/soak and dry

Mildly scented, which leaves a fresh clean scent

Safe for all types of fabrics, clothes don't shrink, fade nor lose its shape

Conditioning AgentEarly fabric softener formulations were relatively simple dispersions of fatty materials, which would deposit on the fabric fibers after wash. The most common ingredient used at that time was dihydrogenated tallow dimethyl ammonium chloride (DHTDMAC) that belongs to a category of materials called as quaternary ammonium compounds, or quats. This types of ingredient was useful due to the fact that a part of the molecule has a positive charge, which attracts and binds it to negatively charged fabric fibers. This charge interaction also helps in dispersing the electrical forces, which are responsible for static cling. The other part of the molecule is fatty in nature and hence offers the slip and lubricity, which makes the fabric feel soft.

While the quats were found to very effecting in softening the fabric, they can also make them less absorbent. This is a problem for some laundry items, like diapers and towels. To overcome this problem, formulations were made that use quats in combination with other more effective ingredients. These new formulations were known as conditioning agents and have somewhat lower substantivity to fabric that makes them less potential to interfere with water absorption.

An example of a conditioning agent is Cetearyl Alcohol, PEG 40 Castor Oil, Stearalkonium Chloride -

Conditioning Agents in Soaps

Soaps have surfactant properties that means their individual molecules have a hydrophilic (water-attracting) end that dissolves in water, and a lipophilic end (fat loving) that dissolves in fatty substances. The surfactant properties of soaps make them soaps effective cleaning agents. In hard water, calcium and magnesium ions are present, which react with soap molecules to produce salts of the fatty acids, which do not dissolve in water and hence lack the surfactant properties. Hence in hard water, more soap is required to achieve the same cleaning power as in soft' water. A conditioning agent like calgon (sodium metahexaphosphate) can be used in this case in the wash water to achieve effective cleaning.

ApplicationsFor their ability to improve the cleaning performance of detergents in hard water, conditioning agents are active ingredients

in variety of soaps, detergents, cosmetic products, and hair color products.

Bleaches and Compounds

Bleaches are compounds that are used to clean, whiten and brighten fabrics and help remove the stubborn stains. Bleaches have proved to be highly effective and useful in converting the soils into colorless, soluble particles, which can be removed and carried away by detergents in the wash water. Bleaches can be used for different cleansing applications, including - laundry, dishwash cleaning and in household cleaning products.

Types of Bleaches

The bleaches can be broadly categorized into two types, that include -

Chlorine bleach Oxygen bleach

BleachesUsed for whitening, brightening and removing stains in clothes and fabrics, dishes and household products

Types Primary Function Example

Chlorine Bleach

Along with whitening, brightening and removing stains, it also works as an disinfectant

Sodium Hypochlorite

Oxygen Bleach

Oxygen bleach can be combined with bleach activators in some products for improved

Sodium Perborate Sodium Percarbonate

performance in lower temperatures. A brief description of the two types of bleaches is given below -

Chlorine BleachChlorine bleach comes in liquid as well as powder forms with the powder form being more popular. This type of bleach has found to be safe for all types of fibers excluding spandex, wool, silk, and specialty fibers like mohair, angora, and cashmere.

Liquid chlorine bleaches are more popular than powder bleaches due to their properties such as they are less expensive and kill germs too. Most of the liquid bleaches contain approximately 5% active ingredient and you can select the products that provides the best results for your specific needs.

Applications:Chlorine bleaches can be used on -

Dish towels Bath towels Sheets Color-fast prints Pillowcases Tablecloths White socks T-shirts and undershirts

Chlorine Bleach Usage InstructionsFor heavy load washing machines, you can use up to 1 cup of liquid chlorine bleach and is the machine is extra large, use 1-1/4 cup of bleach. For front loading machines, you should not use more than 1/2 cup liquid bleach. For hand washing, do not take more than 1 tablespoon of bleach for each gallon of water.

Mix the bleach with lots of water before mixing it with detergent wash water or otherwise it can make holes in the fabrics. Rinse clothes properly to remove the bleach, as if it stays in them it may weaken the clothes

.

Chlorine bleaches may damage or discolor some special fabrics or finishes, so carefully read the labels on clothes and bleach containers before using the bleach.

Oxygen BleachOxygen bleaches are light and milder than chlorine bleaches and most are combined with a brightener and water conditioner. Oxygen bleaches come in dry as well as liquid

forms and are usually labeled as "safe for all types of fabrics" or "all fabric bleach". Oxygen bleaches are preventive ones and can be used on a regular basis. These bleaches can be safely used on all types of clothes and fabrics that require bleaching and are safe for all fabrics, finishes and colored fabrics.

Oxygen Bleach Usage InstructionsOxygen bleaches can be used to with maximum benefit by properly following the given instructions -

Add oxygen bleach to the wash water Use hot water as most oxygen bleaches work best in them Carefully follow the directions and instructions given on package Rinse the clothes well For superior results, use oxygen bleach every time you wash your clothes

Bleach products Buying TipsWhile buying bleach products, it is important to know what is your specific need so that you can buy a best product. Carefully read the instructions, whether the bleach is safe for all types of fabrics and finishes or not. Never buy a chlorine bleach for usage on silk, wool, spandex stretch fabrics, blends of these fibers, or fabrics with certain dyes and finishes, as the chlorine bleach may damage them. Oxygen bleaches are usually safe for all kind of fabrics and so it does not require special care and attention. It is important to heck clothes labels and hang-tags to know if they can be safely bleached.

AmmoniaAmmonia has long been a cleaning agent, which is widely used in homes, restaurants and other public locations. The product being perfectly safe to use with little precautions, it has found applications in variety of cleansing products and is used even in the form of pure or scented ammonia in the homes.

Ammonia Cleaning

Ammonia is widely used as a base ingredient in a variety of household cleaning products like floor cleaners, glass cleaners etc. The reason for using ammonia in making these household cleaning products is that there are a very few surfaces that cannot be effectively cleaned with ammonia. The cleaning products containing ammonia can be used in their full strength and also in dilute forms by mixing them with water. For example, ammonia cleaning solution made in such a way can be effectively used to clean windows for a clear and steak-free looking room.

Ammonia Cleaning Products

Ammonia cleansing products are generally viscous white-coloured ammoniated abrasive cleaners, which are designed to clean and remove stubborn dirt from hard

surfaces in both the household as well as industrial applications without scratching. These products combine the powerful and effective cleaning action of ammonia and a scouring medium into a liquid hard surface cleaner, which makes it highly effective. Ammonia household cleaning products are easy to work with and deliver superior cleansing results.

Ammonia Cleansers Manufacturing

Ammonia cleaning products are made using a volatile alkali, which leaves no residue after drying and hence has found uses such as in making of glass cleaners and leaning products for several other polished surfaces. These cleansing products are made using technique that uses steam, natural gas or hot coke to produce hydrogen and steam that is forced through incandescent coke to produce nitrogen. After several refinements, these gases are subjected to high pressures and temperatures.

Ammonia Chemistry

Ammonia (NH3),occurs in the form of strong smelling gas or liquid. This alkaline substance has found high popularity for uses in consumer and commercial cleansing products to clean grime or fertilizer crops. Even in its very low concentration or dilute form, inhalation of ammonia or getting its solution on the skin can cause burning, fainting, or death, and so it should always be handled with care.

Ammonia has one nitrogen atom, which is tightly bonded with three hydrogen atoms. A tiny amount of the ammonia is formed, when the organic matter is decomposed and hence the gas can be found naturally in our atmosphere. However, most of the ammonia that we use is developed through artificial means by bonding the four atoms (1 Nitrogen + 3 Hydrogen) together by sheer force. After this, the gas can be pressurized to convert it into liquid form for easy distribuition to manufacturing plants.

As a gas, ammonia is lighter than air, and hence does not pool indoors, such as other dangerous gases like propane. As the gas has a highly distinctive and pungent odor, it is very clear and difficult to combust unless highly concentrated. The distinct smell of this gas makes it safer for household applications, as the people can easily recognize it and leave the toxic area to prevent fainting.

Ammonia Cleaning Applications Uses

Ammonia has found uses in a variety of household cleaning products as well as cleaning applications for commercial places like restaurant, hotel, and office cleaning. Some of the ammonia cleaning uses include:

Cleaning and disinfecting kitchen counter tops Bathroom cleaning, such as cleaning of bathroom fixtures and tiles. Ammonia is

also used in making floor cleaners, not only for bathrooms but for all household needs.

Cleaning of a variety of household products Used as an ingredient in various cleansing products, such as window sprays,

oven foam, toilet bowl cleaners, wax removers and countertop sprays among various household cleaners

It is also used in the manufacturing of plastics, pesticides, and dyes during the synthesising process

Liquid ammonia has also found to be useful in etching metals, such as aluminum and copper, refrigerate rooms or trucks, and dissolve other elements in chemistry labs

Ammonia Cleaning Precautions

While using ammonia or ammonia solutions, even in dilute form, it is important to ensure that the room or area is well ventilated. Also make that, ammonia should never be mixed with other household cleansing agents, like bleach, as the resulting fumes can be highly toxic. For just about any application other than the fabric, a mixture of ammonia with a little amount of water will do the job with same effectiveness as any other commercial cleanser for a fraction of cost.

People suffering from chronic respiratory problems should not use this chemical as it fumes may cause problems, such as a burning sensation, coughing, wheezing, shortness of breath, laryngitis and watery eyes. Exposure to ammonia fumes for a long period of time may damage to liver, kidneys and lungs.

Soap Manufacturing ProcessThe manufacturing of soaps and detergents is a complex process that involves different activities and processes. The size and complexity of these processes and activities may range from small manufacturing plants that employ a small number of people to those with hundreds and thousands of workers. products may range from all purpose products to that are used for a specific application or requirement.

Selection of Raw Materials for Soap Manufacturing

The first phase in the manufacturing of soaps and detergents is the selection of raw materials. Raw materials are selected on the basis of various factors, including - cost, human and environmental safety, compatibility with other ingredients, and the performance

characteristics and appearance of the final product. While the actual production process may vary from company to company and manufacturer to manufacturer, there are some steps, which are common to all types of cleaning products.

Saponification Process for Soap Manufacturing

Saponification processes are chemical soap manufacturing processes that produce soap from fatty acid derivatives. Saponification process for soap manufacturing involves hydrolysis of esters under basic conditions to form an alcohol and the salt of a carboxylic acid (carboxylates). Saponifiable substances are the soaps and detergent ingredients that can be converted into soap.

In Saponification soap manufacturing processe, vegetable oils and animal fats are used for making soaps. Triesters or Triglycerides are the greasy materials derived from these diverse fatty acids. Soap manufacturing is doen in a one-step or a two-step process. In the one-step soap manufacturing process, the triglyceride is treated with a strong base, for example, lye, that accelerates cleavage of the ester bond and releases the fatty acid salt and glycerol. This one step soap manufacturing process is the key industrial method for producing glycerol. Sometimes soaps may be precipitated by salting it out with saturated sodium chloride. For soap manufacturing, triglycerides are highly purified but saponification process includes other base hydrolysis of unpurified triglycerides. For example the conversion of the fat of a corpse into adipocere, sometimes known as "grave wax." This soap manufacturing process is more common where the amount of fatty tissue is high, the agents of decomposition are absent or are negligibly present, and the burial ground is particularly alkaline.

Soap Manufacturing Processes for Different Soap Types

Manufacturing of soaps and detergents can be broadly categorized into Five main types -

Bar Soaps Manufacturing Process Detergents Manufacturing Process Liquid Detergents Manufacturing Process Packaging Process Manufacturing process flow solutions

Bar Soaps Manufacturing ProcessThe manufacturing of soaps consist of a comprehensive range of processing and packaging activities. The complexity the activities involved in soap manufacturing process may vary from small plants that employ a few people to those with many hundred workers. products may range from all purposes and uses to those that for used for a specific application or requirement.

The first step in the manufacturing of bar soaps is the selection of raw materials. Raw

materials are selected on the basis of several factors, which may include human and environmental safety, cost, compatibility with other soap ingredients, and the appearance and performance characteristics of the final product. While the actual production process may vary from manufacturer to manufacturer and company to company, there are some steps that are common to all bar soaps.

Ingredients of Bar Soaps

The traditional bar soaps are made from oils, fats or their fatty acids that are reacted with inorganic water soluble bases. The prime sources of fats are beef and mutton tallow, while coconut, palm and palm kernel oils are the main oils that are used in soap manufacturing. The raw materials of a bar soap can be pretreated to remove impurities and to achieve the desired color, odor and performance characteristics desired in the finished bar.

Chemical Process in Bar Soap Manufacturing

Bar soap can be manufactured by either using batch or continuous process. Soap was manufactured by using batch kettle boiling method, until shortly after World War II, when continuous processes were developed. Now days, continuous process of soap making are preferred because of their speed, flexibility and cost economy.

Both the batch as well as continuos soaps making processes produce the soap in liquid form (known as neat soap), and a valuable by-product, glycerin.

Batch Process - Flow Chart

Continuous Process - Flow Chart

The glycerin is recovered from the soap mixture using the chemical treatment, which is followed by evaporation and refining. Refined glycerin is a valuable and expensive industrial material that is used in various products including cosmetics, foods, drugs, and many more.

The next steps after the saponification or neutralization process is drying. Vacuum spray drying is a technique, which is used to convert the neat soap into pellets of dry soap. The moisture content of the soap pellets may vary depending on the desired characteristics and properties of the soap bar.

In the final stage of processing, the dry soap pellets pass through a bar soap finishing line. The first unit in the line is a mixer (known as amalgamator), in which the soap pellets are blended together with colorants, fragrances, and many other ingredients as per the desired characteristics and properties in the final product. The mixture is then homogenized and refined using refining plodders and rolling mills to achieve thorough blending and a standard texture. In the end, the mixture is continuously extruded from the plodder, cut into bars of desired sizes and stamped into its final shape in a soap press.

Some of bar soaps available today are known as "combo bars" as they get their cleaning action from a combination of synthetic surfactants and soaps. Another bar soap bars, known as "syndet bars," feature surfactants as their prime cleansing ingredients. The processing technique for producing the synthetic base materials for these bars is very different from that, which is used in traditional soap making. However, with some minor modifications and adjustments, the finishing line equipment are same for both.

Industrial Bar Soap Making

The industrial soap making involves four basis steps -

Saponification Glycerin Removal Soap Purification Finishing

These different steps involve various processing steps and operations in their own. A brief description of these different steps is given below -

SaponificationThe saponification process involves the mixing of tallow (animal fat) and coconut oil with sodium hydroxide and the application of heat. The process results in formation of soap, which is a salt of long chain carboxylic acid.

Glycerin RemovalGlycerin is more valuable than soap, and hence most of it is removed for its uses in more expensive cosmetic products. Some of the glycerin is left in the soap to make it soft and smooth. Soap is generally not very soluble in salt water, while glycerin is, hence the salt is added to the wet soap thereby causing it to separate out into glycerin and soap in salty water.

Soap PurificationIn the soap purification stage, any remaining sodium hydroxide is neutralized with a weak acid, like citric acid and two thirds of the remaining water is removed to obtain pure soap.

FinishingThe final stage of industrial soap manufacturing process, finishing stage involves mixing of additives, such as colors, preservatives, and perfume into soap, which is then shaped into bars for sale.

Toilet Soap Manufacturing

Toilet soap generally has less water and more fatty material than laundry soap and because of this, the base soap intended for manufacturing toilet soap usually has extra fatty acids that are blended with preservatives before it is vacuum dried. These measures ensure that there is no unreacted caustic remains in the soap by the time it reaches the consumer, and also make the soap softer. Additives, such as perfume, dye and opacifier are then mixed to the dried soap and the mixture is milled to ensure even mixing. It is then plodded and extruded out as a continuous bar, which is cut into billets and stamped ready for packaging and sale.

Detergents Manufacturing Process

Detergents are manufactured using a synthetic surfactant in place of the metal fatty acid salts that are used in soaps. Made in powder detergents, these detergents are sold as laundry powders, hard surface cleansers, dishwashing detergents, fabric conditioners etc. Most of the powder detergents have soap in their mixture of ingredients, however it

generally functions more as a foam depressant than as a surfactant.

Chemical Processes

Powder detergents are manufactured using various processes, such as spray drying, agglomeration, dry mixing or a combination of these. A brief description of these different processes is given below -

Spray Drying ProcessThe different stages / operations performed in a spray drying process, are -

Dry and liquid ingredients are first combined into a slurry, or thick suspension, in a tank known as crutcher.

The slurry is heated and then pumped to the top of a tower where it is sprayed through nozzles (under high pressure) to create small droplets. The droplets fall through a current of hot air, thereby forming hollow granules as they dry.

Collected from the bottom of the spray tower, the dried granules are screened to obtain a relatively standard size.

After the granules have been cooled, heat sensitive ingredients, which are not compatible with the spray drying temperatures (like bleach, enzymes and fragrance) are added.

Traditional spray drying process produces relatively low-density detergent powders. Advancements in technology have enabled the soap and detergent manufacturers to reduce the air inside the granules during spray drying to obtain higher densities. The high-density detergent powders can be packed in much smaller packages than those needed previously.

AgglomerationAgglomeration is detergent powder manufacturing chemical technique that results in high-density powders. The process involves blending of dry raw materials with liquid ingredients. The

technique involves machines, such as a liquid binder, rolling or shear mixing that causes the ingredients to collide and adhere to each other, producing larger particles.

Dry MixingDry mixing is a detergent powder manufacturing technique, which is used to blend dry raw materials. The technique may also involve the addition of small quantities of a liquid.

IngredientsMentioned in the table below are the ingredients of a detergent base powder -

SolidsIngredient FunctionSodium tripolyphsophate(STP) Water softener, pH buffers (to reduce alkalinity).Sodium sulphate Bulking and free-flowing agent.Soap noodles Causes rapid foam collapse during rinsing.

ZeoliteWater softener (absorbs Ca 2+ and Mg 2+) in countries where STP is not used; granulating agent for concentrated detergents.

Sodium carboxymethyl celluloseIncreases the negative charge on cellulosic fibers, like cotton and rayon, causing them to repel dirt particles (which are positively charged).

LiquidsIngredient FunctionLinear 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.

FluorescerAbsorbs UV light and emits blue light, causing aging cotton to appear white rather than yellow.

WaterDissolves the various ingredients, causing them to mix better.

Environmental ImplicationsDetergent powder manufacturing has some specific environmental issues that are not associated with any other industry. These issues include dust control and volatile organic emissions. Dust present during the process of delivery and transfer of bulk powdered detergent is a potential problem. In order to filter out most of the dust, dry and wet cyclones are used, and all the emissions are monitored.

If the dust level in these does exceeds the acceptable limits, appropriate remedial action must be taken. The permissible dust levels in emissions are under below 50-mg m -3. The spray-drying tower also releases volatile organics, which can be minimized by

having tight specifications specifying what can be added as a primary detergent active material. Spot checks must be made on the total hydrocarbon content of the exhaust gases using a flame ionization detector.

Liquid Detergents Manufacturing Process

The liquid detergent manufacturing consists of a wide range processing and packaging operations and the size and complexities of these operations may vary depending on factors, such as the size of plant and the manufacturing process undertaken. products may range from an all-purpose laundry cleaner to specialty cleaner such as glass cleaner.

The first step in the manufacturing of liquid detergents is the selection of raw materials. Raw materials are selected on the basis of several factors, such as human and environmental safety, cost, compatibility with other ingredients and the form and he specific properties desired in the final product. While the actual production processes may vary from manufacturer to manufacturer, some processes and techniques are common for all.

Chemical ProcessesFor manufacturing liquid detergent, both the batch as well as continuous blending processes is used. Both batch and continuous blending processes are used to manufacture liquid and gel cleaning products. Stabilizers may be added during manufacturing to ensure the uniformity and stability of the finished product.

In a typical continuous process, dry and liquid ingredients are added and blended to a uniform mixture using in-line or static mixers.

Recently, more concentrated liquid products have been introduced and a technique for developing these products is through the use of new high-energy mixing processes in combination with stabilizing agents.

To make liquid detergent, the dry powder is simply mixed back in with a solution consisting of chemicals and water, called as "solubilizers." These chemicals help the water and detergent to blend together more evenly. The amount of light reflected, in comparison to the amount reflected by a sample of the original fabric, is a measure of the degree of cleanliness. A reflection rate of 98 % is considered as quite good and shows that the detergent has cleaned properly.

Manufacture Process - Stages Involved - The different stages involved in soap manufacturing include -

Soap premix manufacture - Liquid detergents contain a combination of soap and synthetic surfactants. These are made first as a premix, after which other ingredients are blended into it. This stage simply consists of neutralizing fatty acids with either caustic soda (NaOH) or potassium hydroxide.

Ingredient mixing - All ingredients except the enzymes are added and mixed at a high temperature. The ingredients used in the manufacturing of liquid detergents are usually sodium tripolyphosphate, caustic soda, sulphonic acid, perfume and water.

Enzyme addition - In this stage, the mixture is cooled and milled, and the enzymes are added in powder form.

Soap Packaging ProcessThe final stage of the detergents and soap manufacturing process is the packaging. In this stage, the finished product is packed for final supply to consumer. During the packaging stage, bar soaps are either wrapped or cartooned in single packs or multipacks. Detergents, including household cleaners, dishwashing cleansers and laundry cleansers are packaged in cartons, bottles, pouches, bags or cans.

Soap Packaging Benefits

Packaging is one of most important steps in soaps and detergents manufacturing and hence should be given prime consideration by soap and detergents manufacturers. Some of the important benefits of soap packaging include -

Enhances the marketability of product Improves the appearance and attractiveness of product Increases the shelf appeal of product Increases the shelf life of product Reduces the waste during production Makes the product easy and convenient to use The product can be packed in different sizes to meet the varying demands of

consumers

Soap Packaging - Factors to Consider

The selection of products and materials for packaging depends on the consideration of several factors, which include - product compatibility and stability, cost, package safety, solid waste impact, shelf appeal and ease of use. Due to some regulatory measures of governing bodies and authorities, some of the factors that manufacturers consider these days for packaging are -

Use of packaging material made from recyclable, reusable or bio-degradable material.

The label on the package is provided with information regarding the soap and detergents ingredients used. The package labels now days are generally accompanied by detailed instructions for proper use to maximize the performance and minimize wastage.

Soap Packaging Types

Soap manufacturers use different types of packaging products and solutions to make their products easy and convenient to use and to maximize the performance of product. Some of the soap packaging options that are used by companies in the soap and detergent industry are -

Small sachets - for offering products in very small quantity for one time use. Generally powder detergents and washing gels are offer in sachets.

Cartoons - Soaps and detergents are offered in cartoons for bulk supply. Poly packs - Soaps and detergents are offered in poly packs of different sizes to

meet the varying demands of consumers. Plastic bottles - Generally liquid detergents specialty spray cleansers are

packaged in plastic bottles to make their usage convenient and effective. Tubes - Tubes are most widely used for packaging personal care and cosmetic

products. Paper wrap - Soap bars are generally wrapped or cartooned in single packs or

multi packs for the convenience of users.

Soap Packaging Machines

A variety of packaging machines is used by the soap and detergent industry for superior and convenient packaging of the products. Some of the most common packaging machines used in soap and detergent industry are -

Soap wrapping machine Soap and detergent filling machine Sealing machine Cutting machine Horizontal form fill-sealing machine Saponification section Roller machine Stamping machine Mixer machine Rotary sealing machine

Manufacturing Process Flow Solutions

Flow solutions in soap and detergents manufacturing refer to the set of equipment, including pumps and compressors that are used to control the different raw materials movement and flow control activities. These solutions are formulated to move natural and synthetic raw material feed stocks from the facilities of petrochemical and oleo chemical processing to transport and storage, then throughout the blending, filling and bottling operations within the detergent production facility or the batch or continuous process at the soap plant.

From vegetable or fish oils and glycerin to animal fats and alkaline solutions, like caustic soda and potash or surfactants to builders, additives, enzymes, fragrances, and brightening agents to fillers, these pumps and compressors are specifically designed to satisfy the rigorous requirements of modern synthetic detergent and soap manufacturing.

The various equipment used to control and facilitate the flow solutions of detergents and soap manufacturing are -

Vane Pumps o SNP Sliding Vane Pumps o SMVP Seal-Less Mag-Drive Vane Pumps o Motor Speed Vane Pumps

Eccentric Disc Pumps Centrifugal Pumps Peristaltic Hose Pumps Gas Compressors Rotary Vane Compressor

Soap Manufacturing Machines

Soap and detergent manufacturing machines include a wide range of machines and equipment that are used for the processing, manufacturing and packaging of soaps and detergents. Keeping track with the changing requirements and lifestyles of people, continuously increasing demand for these products and the stringent norms and regulations of regulatory authorities, manufacturers are offering a wide range of latest technology machines for manufacturing high quality soaps and detergents.

A comprehensive range of soap and detergent manufacturing machines are available in the market that are used to perform various functions, such as saponification, mixing, cutting, rolling, spraying, drying, screening, coloring, sealing, packaging, etc.

Modern day soap and detergent manufacturing machines are very easy to handle and operate and are available in different sizes and production capacities to meet the

individual specific requirements of manufacturers.

TypesMachines for manufacturing soap and detergents can be broadly categorized into two main types -

Soap Making Machines Detergent Making Machines

Buying TipsProper understanding of different types of soap and detergent manufacturing machines, their functions and usage is crucial for making an informed buying decision. Different types of machines are available in industry that serve different functions and purposes. It is very important that you know your requirement and manufacturing objective, so that you can buy a right product designed for your specific need.

To get optimum benefit from your machine and to save labor, buy a machine with right production capacity that meets your requirement. Prefer machines with robust design and structure, as durability and flawless performance are most important factor. Buy machines that are easy to handle and operate and require less labor.

In current days, soap is the essential commodity of human life. The uses of different soaps with desirable colors and perfumes are starting from the beginning of the day. Hence there is very big demand of different soaps at everywhere. The best quality of soaps can be manufactured using sophisticated machines and technology.

The term soap refers to a specific type of detergent in which the water-solubilized group is carboxylate and the positive ion is typically sodium or potassium. The largest market for soap is for toilet soap, which is used for personal bathing and cleaning applications. Synthetic detergents replaced he usage of soap powders for home laundering during the last years of 1940s, because the carboxylate ions of the soap react with the calcium and magnesium ions in the natural hard water to produce insoluble materials, known as lime soap.

A wide range of soap making machines is available in industry that performs different functions and operations. Generally the soap making machines can be of two types - Laundry soap making machines (used in laundry) and Toilet soap making machinery (used for bathing).

The most important soap manufacturing machines that are used now days are -

Mixer Machine Soap Cutting Machine Duplex Vacuum Plodder Soap Saponification Section

These machines come in different capacities for production in different volumes and are available with various features.

Mixer Machine

Mixing machines are equipment that are used in the soap manufacturing process to mix different materials used in soapmaking. A variety of soap mixing machines are available in the industry, which can be selected on the basis of requirement and the type of soap bar to be manufactured. A brief description of the different soap machines available in the market is given below :

Soap Mixer MachineSoap mixer machines are important soap manufacturing equipment that are used to mix the different raw materials used in soapmaking. The machine can be used to mix a variety of additives with raw soap and produce hard paste form. Available in a variety of sizes, dimensions, weights and mixing capacities, the latest technology mixing machines are easy to use and operate and require minimum maintenance.

The modern day soap mixer machines are carefully designed to develop soap chips in a uniform texture with color and perfume. The mixing action is attained by using the specially shaped "Z" blades that are fitted on parallel shafts mounted with close clearance in a double 'U' shaped trough. With the help of blades, the mass is rolled; folded back and pushed down to join the separate layers. This action is repeated till the time the desired uniformity is obtained. The tilting arrangement in small unit is achieve through manual procedure and in larger units it is further incorporated with a gearbox and motor that are operated by electric control.

Sigma MixerSigma mixer is a latest technology kneader/mixer, which is suitable for kneading and mixing of viscous fluids and semi-solids of medium and high-density ingredients. The

equipment has found to be highly useful in the manufacturing of toilet soaps, detergent cakes, pigments, clay coating, food product, pharmaceuticals and various other products for different classes of soft and hard nature.

In the sigma mixer complete dispersion is attained through the most desirable combination of folding, stretching, kneading and tearing action. Mixing / Kneading is achieved by pressing the material against the trough wall. As the arms of mixer rotate, they tear the loose part of mass in the mixer and carrying to those parts to other portions of trough, thereby re-distributing the contents. After the completion of mixing, the discharge of the material can be carried out by various techniques, such as tilting the trough manually or automatically and bottom discharge by facilitating the bottom opening.

Multifunctional Mixing MachineMultifunctional mixing machines are those, which can be used to mix different raw materials, used in soap manufacturing with maximum efficiency. Based on latest technology, the machine has found uses in different manufacturing requirements and facilitates the better mixing and crushing of soap noodles thus the mixing is fast and homogenous.

Besides the soap manufacturing, multifunctional mixing machine has found uses in different other industrial applications, including -

ElectronicsElectrode slurry, ceramic slurry, magnetic material, electronic gooey, electronic component seal glue, silica gel printing ink, electronic dope, PVC plastic, thermoplastic, and other slurries.

Chemical IndustryIn chemical industry, the multifunctional mixing machine is used for mixing of different types of seal glue, mucilage glue, synthetic resin rubber, silica oil, paint, dope, printing ink, abrasive, lube, waxen product, synthetic rubber, synthetic resin, all kinds of powder stuff and ceramic paint.

Medicine IndustryThe usage includes all kinds of medical ointment, macromolecule gel, capsule, syrup and tooth medicine.

Food Processing IndustryFood processing applications of multifunctional mixing machine include different kinds of mixture of mash and ointment, condiment, jam and chocolate jam.

Cosmetics and Commodities IndustryIn cosmetics industry multifunctional mixing machine is used in the manufacturing of

skin-care creams, facial mask, nail polish, tooth paste, soap, shampoo, eye black, lipstick, lotion, gel, face powder, body-cleaning lotion and face-cleaning cream.

Soap Cutting MachineSoap cutting machine is the equipment used in soap manufacturing process to cut soap bars into desired lengths, sizes and forms. In these machines, soap cutters are usually placed downstream from a plodding machine and the soap bars that come from the plodder enter the cutter and come into contact with an incremental encoder, which sends a signal to the cutting system. For details, read bar soap manufacturing process

The cutting system provides a horizontal and vertical blade shift, to cut bars into the specified lengths and sizes. The soap cutting machines are designed and manufactured with two conveyors for separate cutting unit, which are used to feed the soap bars into the cutter and then carry them out of the cutter.

Types of Soap Cutting Machines

Soap cutting machines are only one category of soap manufacturing machines. However, they too are available in many varieties nowadays. The available soap cutting machines can be categorized as -

Air powered soap cutter Manual soap cutter Loaf soap cutter Double cutting machine Bar size-cutting machines Rotary soap cutting machine

A brief description of these different types of soap cutting machines is given below Air Powered Soap CutterThese soap making machines are ideal for cold processed soap cutting, the Air Powered Soap Cutters can be used to produce thousands of perfect bars a day by a single person.

Salient Features of Air Powered Soap Cutter High production Can be custom designed to meet user specifications, bar and batch size Cuts both loaves and bars with a single piece of equipment Can be used to cut hundreds of perfect bars in just minutes Designed with 2 cutting grids and 2 cutting tables (Loaf and Bar)

Manual Soap CutterManual soap cutters are designed to cut large blocks of soap within minutes manually. The manual soap cutters come with the option of Extra cutting frame and tables for

different full size bars or hotel size bars, extra wire ( include both sizes, for bar and loaf frames) and manual cutter easy hoist system. These cutters can be custom designed to meet the unique specifications, bar and mold size.

Salient Features of Manual Soap Cutter Cuts both loafs and bars with one piece of equipment Compact in size, durable and easy to clean Easy to operate Cutting frames and tables are easily and quickly interchanged Manual Cutter Easy Hoist System

Loaf Soap CutterA loaf soap cutter is used to cut the soap loaves into bars quickly and easily with its in built cutter. Based on latest technology, the loaf soap cutters come with a heavy duty base and cutting table, wood and HDPE plastic and are provided with a extra replacement wire.

Salient Features Loaf Soap Cutter Metal parts coated with hard, baked on powder-coat

enamel Easy to use, operate and maintain Come with a variety of specifications and can be custom designed to meet user

specific specifications

Rotary Soap Cutting MachineRotary soap cutting machines are used to cut the bar soaps at fixed lengths. These machines are mounted at the mouth of plodder and operate without power. A rotary soap cutting machine is driven by the forced travel of the extruded bar from the plodder. The machine has two stainless steel guide rings that are mounted with suitable cutting knives to cut the soap bar into specified lengths and the speed and output can be synchronized with the plodder discharge capacity. The gap between the two cutting wheels can be adjusted according to the need or thickness of the soap.

Also know about Rotary Sealing Machine, used in soap packaging applications.

Bar Size Cutting Machine Bar size-cutting machines are used to cut soap slabs into bars and bars into cakes. The machine can be used easily prepare soap bars into desired shapes and dimensions. The machine is fitted with cutting frames that can be easily detached and have steel spring wires.

Double Cutting MachineDouble cutting machine is a hand operated equipment that can be used to cut slabs into bars and bars into detergent cakes. When the slabs are cut into bars, there is no need to handle or touch the bars for cutting the cakes but only to move the handle and the cakes will cut according to the specific size or as per the adjustment made in the frame size. These are fitted with cutting frames that are detachable and the

frame is with steel spring wires.

Know more about Detergent Cake Making Plant.

Duplex Vacuum Plodder

A duplex vacuum plodder is a soap-making machine that is used to extrude the final soap. Suitable for stamping, the machine comprises of two separate stages in which the first stage is a refiner and the second stage is an extruder. The second stage, i.e. extruder is used to produce the final bar shape in a long continuous billet. A vacuum chamber that functions to de-erate the soap connects these two stages. An extruder is commonly called a plodder in the soap manufacturing industry.

The Vacuum Duplex Plodder is used to extrude the final product, which is a long continuous soap bar and at this point it is completely finished. At this stage, the soap bar is actually finished and the only thing left is to change the form of bar by cutting the billets into smaller pieces and stamping a shape if needed.

The extruder screw of top noodle plodder carries the milled soap ribbons of soap from hopper and compresses the soap as it tries to pass through the noodle plate. There is a rotating knife that is used to cut the noodles as they come out of the noodle plate and finally fall in to the vacuum chamber. The bottom screw binds the soap noodles under vacuum as the soap mass from the mouth of the cone through the die under pressure.

Extruder has a seamless stainless steel pipe and there is an aluminum alloy screw that rotates inside the pipe. The pressing action binds the soap under vacuum and as the soap mass comes out of the conical mouth of the plodder it is cut into equal size bars. The pipe is jacketed to distribute water in it and the mouth of cone has the facility to hold heater and temperature sensor. After a specific temperature is achieved it can be maintained through a thermostat mechanism, which ensures that the soap bar has a shiny appearance and emerges freely. Maintaining the temperature is important as if the temperature is too high the soap surface will be blistered and in case the temperature is low, the surface will be dull.

UsesAn important equipment in the entire soap unit, plodder machines play a crucial role in giving final shape to a soap bar. The ribbon like mass, which passes through the load thrust carrier plodded the mass compactly thereby giving it high quality finesses. The thrust load carrier extrudes the mass in the form of a bar. Distinctive design of die is furnished with the mouth piece of extrusion barrel to attain a specific size of bar and then it can cuts into convenient size of cakes. The extrusion machine comes with adequate arrangements for heating and cooling and the bars for toilet soaps and detergent cakes can be taken as per the requirements.

TypesBesides the simple soap duplex plodder machines (single worm), another form of duplex vacuum plodder machines are also available that are provided with twin worms. For high T.F.M. toilet soaps, manufacturers also offer the two stage (duplex) plodders with provision for vacuum made in them to reduce moisture the content in the end soap bar being extruded. On the basis of features, design and characteristics, soap duplex plodder machines can be categorized into four types -

Single worm simplex plodder Single worm duplex plodder Double worm simplex plodder Double worm duplex plodders

Salient FeaturesNow days, the soap duplex vacuum plodder machines come with a variety of salient features, including -

Easy to use and maintenance Come with built in vacuum pump Robust design and structure Die is very easy to change that makes it possible to produce different shapes and

sizes of toilet soaps

Soap Saponification SectionSoap saponification section is a set of equipment that are used in the saponification process (the first stage in the soap making process). Saponification can be of two types -

Batch type Continuous process type

Batch MethodSemi boiled saponification for obtaining medium quality soap is attained by simple mixing and heating in a crutcher (soap mixer) and is used for producing small (1 to 5 tonnes) batches household or laundry soap. Any impurities in the raw materials will be

present in the final obtained soap and there is no wasted discharge to the drain.

Completely boiled saponification for producing high quality soap is done in kettles. This is the most common method of soap making and can be used to make laundry or toilet soap. The completely boiled soap is washed during the process to remove any glycerin or impurities. Batch size is usually 25 to 50 tonnes and 3 to 5 kettles are used in this process. The plant outputs are generally 1 to 5 tonnes per hour. The technique can be used to produce soap of international quality standards. Some wastes may require to be discharged to the drain if glycerin is not recovered from these wastes (called lye).

Continuous ProcessContinuous saponification process is suitable for producing different grades of soap of different quality standards. This system is not suitable to manufacture soaps at the production rate of less than 50 tonnes of soap per day. The system can be designed to achieve soap production rates in excess of 200 tonnes per day.

In the continuous process technique, raw materials are accurately metered using a special pump to the saponification reactor. Following the reaction, the clean soap is separated from the by-product of the reaction (rich in glycerin). The separation occurs in two main stages, at first in the rotating disk column, and secondly through centrifuge separation. The clean soap can be pumped to the storage, or directly to the vacuum spray drying section.

Because of the high value of glycerin, the plants generally come with a glycerin recovery section to purify and retain the glycerin

Saponification PanSaponification pan is a hemispherical vessel, the bottom of which is made of thick steel plates. The bottom of the pan is heated using firewood or by means of diesel burners. The boiling mixture is stirred with the help of crutches and due to the direct heating, the soap mixture requires to be continuously stirred for homogenous mixing. Boiling is carried out till the complete neutralization is achieved, after which the soap is taken to drying section for further process.

It is important to take care to ensure that soap does not stick to the bottom as if it sticks it may get burnt. The technique is a manual process and needs continuous stirring.

Saponification VesselSaponification vessel is a cylindrical vessel with a cone shaped bottom. At the inner side, the vessel has circular coils that have holes and steam is injected from these holes. In the case, soap is obtained by full boiled method, the layers of soap and lye separates out. When soap is obtained by full boiled process layers of soap and spent lye separates out. The spent lye goes to the bottom and the soap to the top. The spent lye is drained from the valve at the bottom of vessel and as the lye is drained, soap begins coming out of the valve. As the heating of soap mixture is done with steam there

is no chance of soap getting burned. The vessel can be used to obtain quality soap.

Continuous Vacuum Spray Drying Process In the continuous vacuum spray drying process technique, the clear soap from saponification section is taken to the soap feed tank after being filtered. After this the soap is sprayed into the spray drier where the desired vacuum can be maintained using a vacuum system. As the soap is flashed from the soap nozzles into the vacuum chamber, vacuum is removed. The soap sticking to the spray drier walls can be scrapped with the help of a scrapper that can be adjusted. The dried soap falls into the duplex vacuum plodder and the duplex soap descends from the top noodle plodder. Vacuum is sustained within the chamber that connects the plodders and the soap comes out of the plodder in the bar form. These bars are then cut into desired forms and stamped.

Good laundry bar soap can be obtained using the continuous vacuum drying process. For toilet soap, a duplex plodder fitted with noodle plate is used. As the soap comes out rotating knives cuts the soap noodles. The soap noodles produced and obtained from the stage are further finished to get high quality toilet soap.

Detergent Cake Making PlantDetergent cake making plant is a set of machines that are used to perform different operations required in making detergent cakes.The different machines used in a detergent cake making plant include -

Sigma Mixer Triple Roll Mill Belt Conveyor Simplex Plodder Rotary Cutter Size Cutter Cum Embosser Plodder Machine

Sigma MixerThe trough of the mixer is made of stainless steel having a pair of stainless steel cast Z shaped blades for maximum efficiency of mixing and uniformity of all ingredients. The material after mixing is discharged by manually operated bottom discharge mechanism.

The shaft on which the blades are mounted is supported by heavy-duty spherical roller bearings. The spur gears are of EN 8 casting. The drive comprises of AC electric motor with reduction gear unit mounted on the robust mild steel frame.

Triple Roll MillTriple roll mill having slant construction is fitted with finely ground and polished hollow chilled cast iron rolls. Housing with heavy duty self-aligning double row spherical roller bearings on shaft journals supports the rolls. The drive to the rolls is through machine cut helical gears of EN 8. An adjustable serrated scrapper made of spring steel with arrangement of tightening and loosening the same is mounted against the top roll. The machine has provision to rotate rolls at different speed and also has provision for setting clearance between the two rolls by means of hand wheel and screw. The drive comprises of an AC electric motor and reduction gearbox.

Belt ConveyorA belt conveyor is used for conveying soap ribbons from the Triple Roll Mill to Plodder. The conveyor has white PVC coated belt with ledges glued at fixed distance to prevent sliding of soap. Special side prevents the spillage from sides. The drive comprises of an AC electric motor and reduction gearbox.

Simplex PlodderPressure extrusion plodder for extrusion of soap bar under pressure generated by rotating screw. The barrel is fabricated of 304-quality stainless steel plate. An aluminum silicone alloy worm rotates inside barrel. The barrel is jacketed extensively on the outside for circulation of cold water.

A stainless steel 304 quality cast extrusion cone is provided at the mouth of barrel, which is jacketed for heating and equipped with heater, thermostat and temperature indicator. The drive comprises of an AC electric motor and reduction gear box.

The framework is made of mild steel and is guarded for safety.

Rotary CutterRotary cutter is friction driven to cut soap bar coming out of the plodder into predetermined length so as to be made ready for size cutting and stamping. The cutter has two rotating aluminum wheels with blades mounted on them. The height of the rotary cutter is aligned to the mouth of the plodder but can also be varied.

Size Cutter Cum EmbosserA size cutter cum embosser is used for cutting soap bars into cakes and embossing them, and operated by AC Electric motor coupled to suitable Reduction Gear unit.

Detergent Cake Plodder MachineDetergent Cake Plodder Machine is used in detergent cake industries for good finishing of detergent cake. Made of M.S. or S. S. Worm Pipe, Screw and M. S. Fabrication stand, these machines also come with fixed & adjustable die.

Detergent Mixing MachineDetergent mixing machines are equipment's that are used to mix the different raw materials and ingredients properly. These mixing machines can be used to manufacture detergent powder as well as detergent cakes. Available in a variety of designs and specifications, these machines generally come in mild steel and stainless steel construction.

Detergent mixing is the first stage in the process of detergent manufacturing after which the mixed ingredients enter the screening machine for screening. Finally the screened materials get packed by packaging machine.

TypesThere are generally two types of detergent mixing machines -

Detergent powder mixer machine Detergent cake mixer machine

Detergent Powder Mixing MachineDetergent powder mixing machines are used in detergent industries for manufacturing free flowing detergent powders. Based on latest technology, the advanced detergent powder mixing machines incorporate main drive system, and inclined mixer arms that make the mixer more efficient, low power consuming, and time & labor saving. A variety of detergent powder mixing machines are available in the industry that vary in their dimensional specifications and characteristics, such as - construction, PAN diameter, batch capacity and power rating.

Detergent Cake Mixing MachineDetergent cake mixer machines are used in detergent cake industries for mixing various raw materials and producing the detergent cake material. The detergent cake mixing machines generally come in mild steel and stainless steel construction and can be used

to produce detergent cakes in specific sizes and dimensions. These machines come in varying specifications of construction, gear size, motor power and batch capacity.

Salient FeaturesSome of the salient features of detergent mixing machines include -

Deliver superior performance with latest technology main drive system Specially designed inclined mixer arms make the mixer more efficient Easy to use and maintain Lower power consumption Saves time, money and labor

Other Detergent Mixing MachinesBesides detergent powder and detergent cake manufacturing machines, a variety of other mixing machines are available that are used in detergent manufacturing for some specific requirements and applications. A brief description of two such machines, viz. - paddle mixer and double cone blender is given below

Paddle MixerPaddle mixer machine is a high speed mixing equipment, which is used to mix different raw materials and ingredients in various manufacturing applications and requirements. Some of the uses of a paddle mixer, include - applications in manufacturing of spices, coffee, detergents, sugar, chemicals, vegetables, cements, instant foods and more.

Salient features of a paddle mixer include high speed mixing, wide open door for feeding and double door opener for discharge.

Double Cone BlenderDouble cone blender is a mixing equipment, which has found uses in mixing and blending of granules, powders, spices, detergents, pharmaceuticals, chemicals, tooth powder, and more. These machines come in a variety of specifications and characteristics and can be selected as per the requirement.

Rotary Sealing MachineRotary sealing machines are used for packaging applications in different industries and products. The machine can be used for sealing different types of drinks, syrups, milk and soymilk and many plastic cups.

The latest technology rotary sealing machines can be used to deliver big production output in a small package. These machines are designed with a 2-station rotating spindle to carry the containers into sealing position at rates at up to 25 cycles per minute, delivering an output of 1500 pieces per hour in a single head configuration. For

small size containers, a dual head tooling can be designed so that with each machine cycle two containers can be sealed thereby offering double the output.

Advance rotary sealing machines can accommodate variety of standard tray sizes over a comprehensive range of depths. Easy to operate, the machine can seal trays with multiple compartments and can even seal the dividers between compartments. Some machines are also equipped with Quick-Swap tooling system that enables the user to switch containers in about 3-4 minutes. These machines are ideal for medium to high production runs of entrees for meals-on-wheels, retail and home meal replacement.

DesignGenerally made from stainless steel, the automatic rotary sealing machines are designed for facility for liquid filling, cutting, sealing, auto temperature control, scrape collection, date printing and ultraviolet dis-infection for different types of plastic bottles and plastic vessels.

The sophisticated microcomputer-based technology provides for complete flexibility while making the machine user friendly. Parts, which are required to be cleaned or replaced, are designed so as to ensure easy access and removal with spring clamps or butterfly nuts. The different removable parts ensure quick repair and maintenance.

ApplicationsAutomatic Rotary Sealing Machines have found usage for sealing plastic inserts/plugs of LDPE, HDPE, PP etc. on to bottles of the similar material. The machine is ideal for to handle bottles of various shapes and sizes and provides perfect solution for leak proof /pilfer proof packing of Edible Oils, Petroleum products, Adhesives, detergents and a variety of products in bottles. The machine has found usage in food, detergent, drinks, brewing, medicine and other industrial applications.

Salient Features

Robust and durable construction Produces large production output in little package Easy to operate Requires minimum maintenance