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•Issues in manufacturing
DESCRIPTION
SOAP THEORY
• Soaps are sodium or potassium salts of long chain fatty acids
• Alkaline hydrolysis of esters or Saponification
• Exothermic in nature
SOAP MOLECULES – MICELLES
• Has two ends with different properties
1. Hydrophobic (a long hydrocarbon part) – end hate water
2. Hydrophilic ( a short ionic part) – end love water
SOAP MECHANISM
COMPOSITION OF SOAP
50% of fats
Coconut 15%
Sources of
RAW MATERIALS Glycerides
Perfumes &
perfumes Rosin
Fixatives
Fillers Sodium
Chloride
Binding
Materials
TYPES OF SOAP
Continuous process
BATCH PROCESS
• The kettle is supplied with steam with a mixture of melted fats, grease, oil in a proper
amount for the mixture. The amount of caustic soda is regulated to undergo the
hydrolysis reaction. The boiling is continued until the saponification is completes. The final
product contains soaps, water, glycerol, unused alkalis, sodium chloride, sodium
carbonate, sodium sulfate as impurities. After this saponification is complete and the
steam is cut off with the separation of salt on the surface for the batch process to stop
and deliver the soap product.
In the continuous process the raw materials oils and fats and
CONTINUOUS PROCESS the catalyst usually zinc oxide are blended and fed into a
hydrolyser or splitting tower fitted with steam coils through
which steam is passed for heating the charge. The splitting of
fat takes place continuously in a counter current manner and
about 250 0C and 40 atm pressure. The fat raises again the
aqueous phase which also dissolves glycerol in reaction. The
fatty acids were discharged from the hydrolyser to a flash tank
called decanter where excess of water is separated. They fatty
acids are the passed to a heat exchanger and then to a
vacuum still and distilled. The distillate was collected as
overhead and bottoms are stored for recovery. Then the
distillate neutralized by caustic soda in a continuous neutralizer.
As the result of this soap is obtained which is withdrawn hot
into an agitator tank. This soap contains Water, NaOH and
NaCl. This is dried in a high pressure steam exchanger by heat
and pressure, finally collected in a flash tank. The pasty mass
is missed with air and cooled to 65 0C. Here the soap is
continuously extracted and collected into soap frames where it
solidifies on cooling. Then it is cut into bars as usual. The
particular process delivers the product in a day whereas the
batch process operates for few more days.
Bubbles
mar
appear
Soap look Soap look
scummy cloudy &
crumbly
Common
appearance
problem
Soap Soap
streaked cracked &
brittle
Fuzz
cover the
soap
PROBLEM WITH SOAP MANUFACTURING
ENERGY CRISIS
Negative impact to company
The most victim is Pakistani SMEs
Cost production increases & had to cut profit
UNSTABLE CONDITION
Political situation, inflation, production cost & economic slump
The investor not interested in investing any soap or raw material to the
company
• As a coating
- applied in a moveable part of equipment (fastener the process)
CONCLUSION
• Soap is essential use in daily life & have a big market from the previous
century ages.
• Faisalabad, the biggest producer of soap hub in the country
• Faisalabad soap industry can achieve competitive advantage and can be
dominant market force in the global competition based on value chains of
itself.
• But, Faisalabad is far behind the global market due to not mature from the
previous discussion to achieved core-competency in the global soap market.
Q&A
THANK YOU