Soft Toilet Soap Manufacturing

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1 Chemical Process Technology

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Bahram Khan Ghulam Mujtaba Rizwan Fazal BEC-SP09-007 BEC-SP09-015 BEC-SP09-030 2

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3 Manufacturing of Soft Toilet SOAP

SOAP : 

SOAP It comprises Sodium and Potassium salts of various fatty acids but chiefly of oleic, stearic, palmatic , lauric and myristic acids.

Classification of Soap : 

Classification of S oap Soft Soap: Sodium salts of various fatty acids. Hard Soap: Potassium salts of various fatty acids.

SOFT TOILET SOAP : 

SOFT TOILET SOAP High content of tallow (70 – 80%) High moosac /perfume Abundant lathering effect with little rubbing.

HARD TOILET SOAP : 

HARD TOILET SOAP Less content of tallow (50-60%) Produce abundant lather but effects skin However lathering effect of hard soap is less than soft toilet soap

CLASSIFICATION OF TOILET SOAPS : 

CLASSIFICATION OF TOILET SOAPS Milled soap Floating soap Medicated soap Liquid soap Transparent soap

PREPARATION OF SOAP BASE : 

PREPARATION OF SOAP BASE STEPS Raw material Receipt of raw material Bleaching or decolourising Filteration Saponification Neurilization Washing Prefitting Fitting Quality control

RAW MATERIALS For Soap: 

RAW MATERIALS For Soap Tallow Coconut oil/palm kernel oil (MALAYSIA, SRI LANKA, BANGLADESH) Good soap: tallow = 80% coconut oil = 20% RECEIPT OF RAW MATERIAL: Weighment Sampling Decenting of material

Decolorizing: 

Decolorizing It is done to remove color constituent of the fat and flavouring substance. FOR EXAMPLE: carotene, bleaching earths ( fulmont earth, galleon earth, activated carbon etc) These adsorbs on the surface not only coloring matter vut also substances suspended in the co;; oidal form. Bleachers operate under vacuum (-30” Hg) with provision of agitators

Filtration : 

Filtration We make ise of filter presses. (plates and frame type, chamber type) SAPONIFICATION: Hydrolysis(H 2 O) with alkali is known as saponification . CHEMICAL REACTION: (C 17 H 35 COO)C 3 H 5 + 3NaOH → 3C 17 H 35 COONa + C 3 H 5 (OH) 3 Glecerol stearate sodium stearate glycerine

Neutralization : 

Neutralization W ith caustic soda WASHING: through DPU(Divided Pan Unit) and RDC(Rotating Disc Unit) PREFITTING : Removal of glycrene /glycerol FITTING : Soap base formation QUALITY CONTROL: TFM< (Total Fatty Acid) , NaCl , Na 2 O

MANUFACTURE OF TOILET SOAP: 

MANUFACTURE OF TOILET SOAP HEAT EXCHANGERS Normally tube type and steam jacketed SOAP BASE is introduced in the tubes from below the heat exchanger which moves up and steam is fed at a pressure of 60 psi Inlet temperature of Heat Exchanger 1 = 80 – 105 0 C Outlet temperature of Heat Exchanger 2 = 125 0 C Inlet temperature of Heat Exchanger 2 = 125 0 C Outlet temperature of Heat Exchanger 2 = 130 0 C

Cont’d: 

Cont’d This is steam jacketed and steam is introduced in the jackets at a pressure of 60 psi. There is a safety valve on the top of flash pot to which weight is attached. Soap enters the flash pot and gets heated up by means of steam in the jacket. The water vapors from soap rise up and safety valve automatically displaces upward because of vapour pressure. The weight also rise up enabling the vapours to collect in the DASH-POT(as steam condensate).

DRYING : 

DRYING Drying is done in dryers. Following are some common dryers: Tray or shelf dryers Screen conveyor dryers Rotary dryers Screw conveyor dryers Tower dryers Flash dryers Drum dryers Spray dryers Gravity dryers Tunnel dryers Pneumatic dryers Fluidized bed dryers Turbo shelf dryers

DRUM DRYER & CHILLING DRUM : 

DRUM DRYER & CHILLING DRUM This consists of 2 rollers one over another with little space in between for the ease of rotation. The drum dryer is smaller in size and is kept hot by introducing steam press of 30 psi. Steam is passed in Drum Dryer by means of steam pipe passing through the axis of the drum. The steam pipe is perforated due to which Drum Dryer gets heated up. The Drum Dryer is under soap nozzle and is dipped in traycontaining soap solution. Soap is sprayed by means of nozzle at the top of Drum Dryer and the moisture content in soap vaporizes. Dried soap in the form of chips/noodles is stored in Chip Bins. Soap scrappers along with drums can be used to expedite process.

Cont’d : 

Cont’d

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SOAP CHIP BINS : Soap in the form of chis falls in the conveyor belt from where it is fed to mixer. MIXER : A mixer normally consists of 4 blades (2 in one direction and the other 2 in different direction) is used in order to completely homogenize the chemicals and soap chips. Addition of chemicals: TiO 2 , Sodium silicate solution, MgSO 4 , Sodium Yerosone , Tenopal , Moosac /perfume Scrappers are used for removing of soap adhered to the walls of the mixer.

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THREE ROLL MILLS: Soap chips with chemicals are taken in 3 Roll Mills for MILLING. The word MILLING refers to the fact that during processing the soap goes through several sets of heavy rolls which mix and knead it thereby diminishing various shades of colour and uniformity of colour is obtained. Because of milling operation, finished soap leathers better and grittiness is removed.

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PLODDER OF 3 ROLL MILLS: Milled soap is fed by means of conveyor to the first plodder. FIRST PLODDER: This is attached at the bottom of the chamber and operates under vacuum. Its function is to shape the soap in rolls and cool by vacuum.

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FINAL PLODDER: This also operates under a vacuum and its function is similar to that of PLODDER 1. A heater is attached with the final plodder and temperature of 40 0 C is maintained. The purpose of heater is to attain desire polishing of soap which will then not be rough. Eye piece of various sizes can be adjusted keeping in view the thickness of soap to be produced. Soap bar formation takes place.

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CUTTERS: Length of billet/tablet = 60 – 100 mm. Revolving blades cut the billet, moving on the conveyor belt. CRUSTERS/COOLING ROOMS: Process of cooling is carried out at 15 0 C.

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STAMPERS: Stamping of soap for a particular brand name. WRAPPING: Two machines are mostly used: ACMA & GD PACKING: Sopa tablets are then pascked in cartons. QUALITY SPEC’s: Weight : 95 g – 140 g TFM : 76 – 78 %

DEFECTS Of Soaps: 

DEFECTS Of Soaps RANCIDITY AND DISCOLURING: A soap that begins to give a foul and un pleasant smell is called Rancid Soap. SWEATING: Water accumulates over the surface of soap rendering it STICKY mainly when humidity is over 72% in rainy season. Other factors could be due to presence of glycerol, NaCl , free alkali, hygroscopic nature of the salts ot unsaturated fatty acids. CRACKING/GRITTINESS: Improper processing particularly during MILLING PROCESS.

Thank You!: 

Thank You!