Soap Manufacturing CPI

Soap Manufacturing By animal Fats. CPI Lab Report

1. UNIVERSITY OF ENGINEERING & TECHNOLOGY
LAHORE
#LAB REPORT
CHEMICAL PROCESS INDUSTRIES LAB
SUBMITTED TO : Dr. IMRAN RASHID

SUBMITTED BY : USMAN SHAHID 2018-CH-265
JAWAD QASIM 2018-CH-257
WALEED AKBAR 2018-CH-253
HAMZA SUBHANI 2018-CH-273
M. ASIF 2018-CH-285

DEPARTMENT OF CHEMICAL
ENGINEERING

2. SOAP MANUFACTURING PROCESS (BY ANIMAL FAT)
The 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.
INTRODUCTION :
Soap is a combination of animal fat or plant oil and caustic soda. When dissolved in
water, it breaks dirt away from surfaces. They are metallic salts of higher fatty acids,
particularly metals are sodium, potassium. Through the ages soap has been used to
cleanse, to cure skin sores, to dye hair, and as a salve or skin ointment. But today we
generally use soap as a cleanser or perfume. The exact origins of soap are unknown,
though Roman sources claim it dates back to at least 600 B.C., when Phoenicians
prepared it from goat's tallow and wood ash. Soap was also made by the Celts, ancient
inhabitants of Britain. Soap was used widely throughout the Roman Empire, primarily as
a medicine. Mention of soap as a cleanser does not appear until the second century A.D.
By the eighth century, soap was common in France, Italy, and Spain, but it was rarely
used in the rest of Europe until as late as the 17th century.
Manufacture of soap began in England around the end of the 12th century. Soap-makers
had to pay a heavy tax on all the soap they produced. The tax collector locked the lids on
soap boiling pans every night to prevent illegal soap manufacture after hours. Because of
the high tax, soap was a luxury item, and it did not come into common use in England
until after the tax was repealed in 1853. In the 19th century, soap was affordable and
popular throughout Europe.
Early soap manufacturers simply boiled a solution of wood ash and animal fat. A foam
substance formed at the top of the pot. When cooled, it hardened into soap. Around 1790,
French soap maker Nicolas Leblanc developed a method of extracting caustic soda
(sodium hydroxide) from common table salt (sodium chloride), replacing the wood ash
element of soap. The French chemist Eugene-Michel Chevreul put the soap-forming
process (called in English saponification) into concrete chemical terms in 1823. In
saponification, the animal fat, which is chemically neutral, splits into fatty acids, which
react with alkali carbonates to form soap, leaving glycerin as a byproduct. Soap was
made with industrial processes by the end of the 19th century, though people in rural
areas, such as the pioneers in the western United States, continued to make soap at home.
SPECIFICATION OF DIFFERENT TYPES OF SOAPS :
1. Toilet soap
2. Washing soap
3. Carbolic soap

3. 4. Shampoo soaps
THE MANUFACTURING PROCESS
1. The kettle method of making soap is still used today by small soap manufacturing
companies. This process takes from four to eleven days to complete, and the
quality of each batch is inconsistent due to the variety of oils used.
2. Around 1940, engineers and scientists developed a more efficient manufacturing
process, called the continuous process. This procedure is employed by large soap
manufacturing companies all around the world today. Exactly as the name states,
in the continuous process soap is produced continuously, rather than one batch
at a time. Technicians have more control of the production in the continuous
process, and the steps are much quicker than in the kettle method, it takes only
about six hours to complete a batch of soap.
CHEMICAL REACTIONS
Soaps are produced by the reaction between a fat and sodium or potassium hydroxide.
FAT + 3NaOH GLYCERIN + 3SOAP

4. EXPERIMENT…..

OBJECTIVES :
1. To prepare the soap sample using animal fat.
2. To test the prepared soap sample with different chemicals.
Raw Materials :
Soap requires two major raw materials: fat and alkali.
1. The alkali most commonly used today is sodium hydroxide. Potassium hydroxide
can also be used.
2. Another most important thing we require is Animal Fat. Animal fat in the past was
obtained directly from a slaughterhouse. Modern soap makers use fat that has been
processed into fatty acids. This eliminates many impurities.
3. Many vegetable fats, including olive oil, palm kernel oil, and coconut oil, are also
used in soap making. But here we will discuss about animal fat.
4. Additives are used to enhance the color, texture, and scent of soap. Fragrances and
perfumes are added to the soap mixture.
5. Abrasives to enhance the texture of soap include talc, silica, and marble pumice
(volcanic ash). Soap made without dye is a dull grey or brown color, but modern
manufacturers color soap to make it more enticing to the consumer.
APPARATUS REQUIRED :
1. BEAKER or KETTLE
2. TEST TUBE
3. BURNER
4. STIRRER
5. WATER BATH
6. FILTER PAPER
REAGENTS
1. ANIMAL FAT
2. 30% NaOH or KOH
3. Conc. HCL
4. Saturated solution of NaCl

5. PROCEDURE
1. First of all alkali and fat are taken in beaker or kettle. Then Fats and alkali are
melted in a kettle.
2. Steam coils heat the batch and bring it to a boil. After boiling, the mass thickens as
the fat reacts with the alkali, producing soap and glycerin.
3. The soap and glycerin must now be separated. The mixture is treated with salt,
causing the soap to rise to the top and the glycerin to settle to the bottom.
4. The glycerin is extracted by the process of filtration. The soap is obtained on the
filter paper.
5. Additives such as preservatives, colour and perfume can be added and mixed in
with the soap and is shaped into bars if required.
BY PRODUCT
Glycerin is a very useful byproduct of soap manufacture.
TESTS
 WITH WATER
It should be soluble in water.
 WITH CONC. HCL
If 2 drops of conc. HCL is added to soap solution it should be insoluble.
 WITH NaOH
If 2 drops of NaOH are added into insoluble soap solution then it should became
soluble.
APPLICATIONS
1. People use soap to make their skin clean. Dirt and other impurities are easily
removed from the skin whenever one uses soap. Ingredients present in soap are
strong; this is why eliminating dirt becomes easier with the use of soap.
2. Soap can be used for general situations such as bathing, cleaning and washing. On
top of that, soap is a key component in most lubricants.
3. There are two different categories of soap including bar and liquid soap. Bar soap
is recommended over liquid soap because they are less expensive and their
ingredients are stronger for cleaning than those of liquid soap.

6. 4. Factors such as demographics, environment, globalization, and economy continue
to shape the soaps and detergent industry. The effect of demographic factors can be
seen in different sectors of industry.
5. As the population of a nation grows old, the demand for cosmetic products with
softer colors, milder formulations, and the treatments for aging skin increases. New
cosmetic products are being produced to satisfy demand for these products.
6. As the consumers become better educated and informed, there is a fast growing
market for scientifically based soap and detergent products.
7. Grease and oil are nonpolar and insoluble in water. When soap and soiling oils are
mixed, the nonpolar hydrocarbon portion of the micelles break up the nonpolar oil
molecules. A different type of micelle then forms, with nonpolar soiling molecules
in the center. Thus, grease and oil and the 'dirt' attached to them are caught inside
the micelle and can be rinsed away.

REFERENCES
1. Cavitch, Susan M. The Natural Soap Book: Making Herbal and Vegetable-Based
Soaps. Storey Communications, 1995.
2. Maine, Sandy. The Soap Book: Simple Herbal Recipes. Interweave Press, 1995.
3. Spitz, Luis, ed. Soap Technologies in the 1990s. American Oil Chemists Society, 1990.
4. About Soap. Procter & Gamble, 1990. [phone]. Sheila Dow.
5. Environmental safety
www.cleaninginstitute.org%2F&h=AAQHfTRaj
6. How to make soap
www.youtube.com%2Fresults%3Fsearch_query%3Dhow%2Bits%2Bmade%2Bsoap&
h=iAQFG-Z_d
7. Central bank report
www.cbsl.gov.lk%2Fhtm%2Fenglish%2F10_pub%2Fp_1.html&h=EAQGk5PKw
8. Processes methods of soap
http://www.facebook.com/l.php?u=http%3A%2F%2Fteachsoap.com%2F2012%2F03%
2F06%2Fsoap-making-methods%2F&h=GAQFCKNbF
9. Raw materials
www.madehow.com/Volume-2/Soap.html
10. Shreves Chemical Process industries, Soap manufacturing procedure.