Process And Quality Factors In Laundry And Toilet Soap Production
Soap production is a complex and intricate undertaking that involves a meticulous combination of processes and quality factors to ensure the creation of high-grade products. The production of laundry and toilet soap demands a careful orchestration of various elements, encompassing raw material selection, saponification processes, and post-production quality control measures. Raw materials, including oils and alkalis, play a fundamental role, influencing the soap’s texture, cleansing ability, and overall quality. The saponification process, a chemical reaction converting these raw materials into soap, necessitates precise temperature and mixing conditions. Quality factors such as fragrance, color, and texture are paramount in crafting soaps that cater to specific consumer preferences. Additionally, stringent quality control measures throughout the production cycle, from formulation to packaging, guarantee the end product’s conformity to established standards. Adherence to these multifaceted aspects ensures the creation of exceptional laundry and toilet soaps, meeting the diverse expectations of consumers in the competitive soap manufacturing industry.
This projects is aimed at knowing the process and quality factor in Laundary and Toilet Soap Projection. Various factors affected the quality of the soap produced. These include the method used in production, types and nature of oils used, the percentage of the additives in the soap and the ratio at which oils are mixed to react with alkali.
The work was carried out using one type of oil, namely, palm kernel oil for production of laundary soap and a blend oil in the ration of 95:5 (PKO to soya bean oil) for production of Toilet Soap respectively. The oil was firstly subjected to various analytical tests.
Using both blended and unblended oil for production of Toilet and laundary soap in the ration of 2:1 of oil to alkali, soaps were produced which varied in quality as a result of either the ratio of mixing, the nature of oil or by both. Additives like sodium silicate, green pigment, pink pigment, citrolene perfume were added to improve the soaps quality and appearance.
The omo soap samples produced; laundry and toilet soap have some distinguishable properties and these properties were found to be dependent on the different properties of the oils employed.
Content page
Title page
Letter of transmittal
Approval page
Dedication
Abstract
Table of content
CHAPTER ONE
Introduction
Scope and objective of projects
Chapter two
Literature survey
History of soap making
Raw materials used for soap making
Soap manufacturing processes
Processes and steps involved in production of soap
Quality factors in soap production
Chapter three
Experimental procedures
Equipment and materials used
General procedure
Experimental procedure for laundry soap
Experimental procedure for toilt soap
Experimental analysis
Determinations of saponification value
Determination of free falty acid
Determination of free caustic alkali
Determination of moisture content
Determination of PA of soap
Chapter four
Experimental results
Discussion
CHAPTER FIVE
Conclusion
Recommendation
References
Appendices
INTRODUCTION
Soap is a class of products that serves for cleaning of human, property and surrounding. Hence, soap in its various forms, is in high demand in all society. For generations its use has increased until its manufacture has become an industry essential to the comfort and health of civilized man. In fact, modern civilization may be gauged by the per capital consumption of soap and detergents.
Soap a classical example of detergent (cleaning agent) – differs from detergent in processes of manufacture and chemical composition. These result in differences in action.
Soap depends for its washing action on the fact that its molecules possess one ionic (polar, water – attracting or hydrophilic) end and one covalent (non-polar, water repelling or hydrophobic) end which attracts oils and greases. Thus, soap molecules can make water and oils come into an emulsion which can be washed away. This is the modern concepts of surface active agents or surfactants; soap, detergents, emulsifiers, wetting agents and penetrants.
Soap is not, however, satisfactory, as it forms a scum (precipitate of insoluble calcium and magnesium salts) in hard and acidic waters. Synthetic detergents, on the other hand, do not form a scum in hard or acidic water as their calcium and magnesium salts are solute, are usually more soluble in water than soap is; enable water to spread and penetrate more fully over or through an article being cleaned and can generally be used equally well under alkaline or acidic conditions.
Soaps are essentially the sodium or potassium salts of various fatty acids, while detergents are very complex mixtures of many substances, all chosen to impart a particular action in cleaning. The polar end of the detergent molecule consists of sulphonic acid ( – SO3H) or hydrogen sulphate (-OSO3H) group present in the form of its sodium salt to increase solubility. The non-polar end of the detergent molecule is a long alkyl – substituted benzene chain. Extensively branched chains are not biochemically degradable and such detergents cause pollution in rivers and sea wage waters.
Soap also contains additives for some desired qualities. These include salt, soda ash, sodium silicate, sodium bicarbonate, perfume, colour, citric acid, borax, magnesium sulphate, and trisodium phosphate. A combination of inexpensive builders, e.g. soda ash with more effective (and expensive) tetrasoium pyrophosphate or sodium triphasphate, is sometimes superior to the phasphate used alone.
Although the use of soap has declined since World War II, majority of the world’s toilet tablets are still soap, and in the developing countries hard soap bars are still the most important fabric washing products. Also, a substantial proportion of the fabric – washing powder used in the United Kingdom is soap powder. Other uses of soaps are in textile finishing, emulsion polymerization, cosmetics and polishes.
Basically, all soap is made by saponification, that is the hydrolysis of naturally occurring fats and oil by sodium hydroxide (caustic soda) or potassium hydroxide (caustic potash). Various additives have been used to impart some specific characteristics to the products.
The qualities and properties affecting soap and also the processing (which forms the basis of this project) depend on factors such as the nature and type of oil used, the type of alkali used and also on the proportion of mixture of both major raw materials.
SCOPE AND OBJECTIVE OF PROJECT
Soap can be produced with a variety of raw materials, using several processes and thus obtaining varying qualities. However, from the literature survey, it was found that various types of oils differed, consequently, their soap products different.
In this work, soap is to be produced using palm oil and palm kernel oil respectively. The objective is to compare the qualities of the soaps made from these oils and also the processing involved for laundry and toilet soap production.
The work entails working out the soap formulas and using the formulations to produce soap. The two soaps so produced will then be tested analytically to determine their various physical and chemical properties.
From the results obtained from the various analytical test, distinguished process qualities of the two soap will then be deduced.
Finally, recommendation will be made to aid further research on the project.
Process And Quality Factors In Laundry And Toilet Soap Production:
The production of laundry and toilet soap involves various processes and quality factors to ensure that the final product meets the required standards. Here’s an overview of the key processes and quality factors in soap production:
Processes in Soap Production:
Saponification: This is the chemical reaction that converts fats or oils into soap. It involves mixing a fat or oil with an alkali (usually sodium hydroxide or potassium hydroxide) in the presence of heat. This reaction produces soap and glycerin.
Batch Mixing: In this step, the saponified mixture is blended to achieve a uniform consistency. This can involve the addition of fragrance, colorants, and other additives to enhance the soap’s properties.
Molding: The soap mixture is poured into molds to shape it into bars or other desired forms. The molds are then left to cool and solidify.
Curing: The newly molded soap is left to cure for a specific period, allowing it to harden and undergo further chemical changes. This enhances the soap’s quality and durability.
Cutting and Stamping: After curing, the soap is cut into individual bars or shapes, and it may be stamped with a logo or brand name for identification.
Quality Control: Throughout the production process, quality control measures are implemented to ensure the soap meets specific standards. This includes testing for pH, moisture content, fragrance strength, color consistency, and more.
Quality Factors in Soap Production:
Ingredient Quality: The quality of the raw materials, such as fats or oils and alkalis, significantly impacts the final soap product. Using high-quality ingredients ensures a better end result.
Saponification Reaction: Proper control of the saponification reaction is crucial to ensure complete conversion of fats or oils into soap. This affects the soap’s cleansing properties and texture.
Additives: Any additives, such as fragrances, colorants, and moisturizers, must be carefully selected and measured to achieve the desired characteristics of the soap.
Uniform Mixing: Ensuring thorough and uniform mixing of all ingredients is essential for consistent soap quality.
Curing Time: Allowing the soap to cure for the right amount of time is critical. Under-cured soap may be too soft and have a shorter lifespan, while over-cured soap can become brittle.
Cutting and Stamping Precision: Precise cutting and stamping processes result in uniform-sized and aesthetically pleasing soap bars.
Packaging: Proper packaging helps maintain the soap’s quality by protecting it from moisture, air, and contaminants.
Quality Testing: Regular testing of soap samples for attributes like pH, lather formation, cleansing ability, fragrance strength, and color consistency is necessary to ensure consistent quality.
Hygiene and Sanitation: Maintaining clean and sanitary production facilities and equipment is crucial to prevent contamination of the soap.
Environmental Considerations: Sustainable and eco-friendly practices in soap production are increasingly important to consumers. Using eco-friendly ingredients and packaging materials can enhance the quality perception of the soap.
In conclusion, soap production is a complex process that requires careful attention to various factors to ensure the production of high-quality laundry and toilet soap. Quality control measures and adherence to standardized processes are key to achieving consistent and desirable soap products.