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SOAP AND DETERGENTSBY:

1HistoryThe first recorded manufacture of soap was in 600BC.

A soap-like material found in clay cylinders during the excavation of ancient Babylon is evidence that soap-making was known as early as 2800 B.C.

Records show that ancient Egyptians bathed regularly and combined animal and vegetable oils with alkaline salts to create a soap-like substance.

Soap got its name, according to an ancient Roman legend, from Mount Sapo, where animals were sacrificed.

Rain washed a mixture of melted animal fat, or tallow, and wood ashes down into the clay soil along the Tiber River. Women found that this clay mixture (soap) made their wash cleaner with much less effort.

HistoryBy the second century A.D., the Greek physician, Galen, recommended soap for both medicinal and cleansing purposes.

Andrew Pears made a high-quality, transparent soap in 1789 in London

William Gossage produced low-price good-quality soap from the 1850s. HistoryRobert Spear Hudson began manufacturing a soap powder in 1837, initially by grinding the soap with a mortar and pestle.

William Hesketh Lever and his brother, James, bought a small soap works in Warrington in 1886 and founded what is still one of the largest soap businesses, formerly called Lever Brothers and now called Unilever.History History of Soap Making___________________Soap-making was an established craft in Europe by the seventh century. Vegetable and animal oils were used with ashes of plants, along with fragrance.

Italy, Spain and France were early centers of soap manufacturing, due to their ready supply of raw materials such as oil from olive trees. HistoryThe English began making soap during the 12th century.

The soap business was so good that in 1622, King James I granted a monopoly to a soap-maker for $100,000 a year. In the 19th century, soap was heavily taxed as a luxury item in several countries. When the high tax was removed, soap became available to ordinary people, and cleanliness standards improved.

History of Soap Making _A major step toward large-scale commercial soap-making occurred in 1791 when a French chemist, Nicholas Leblanc, patented a process for making soda ash*, or sodium carbonate, from common salt.

20 years later - The science of modern soap-making was born with the discovery by Michel Eugene Chevreul, (another French chemist), of the chemical nature and relationship of fats, glycerine and fatty acids.

mid-1800s - Ernest Solvay (Belgian chemist)- the ammonia process, which used common table salt, or sodium chloride, to make soda ash. Solvay's process History of Soap Making _1850 - soap-making, one of North America's fastest-growing industries. Its broad availability changed soap from a luxury item to an everyday necessity.

History of Soap Making _TerminologyA soap substitute refers to detergents or cleansing creams, other than soap, for cleaning the skin, especially removing greasy films or glandular exudates.

In modern slang, a soaper is a person who practices soap making.

Total Fatty Matter (TFM) is one of the most important characteristics describing the quality of soap. It is defined as the total amount of fatty matter, mostly fatty acids, that can be separated from a sample after splitting with mineral acid, usually hydrochloric acid.

TerminologyUnsaponifiables are components of an oily (oil, fat, wax) mixture that fail to form soaps when blended with lye.

Lye is a strongly alkaline solution, especially of potassium hydroxide, used for washing or cleansing.

What is SOAP?A soap is the sodium salt (or potassium salt) of a long chain carboxylic acid (fatty acid) which has cleansing properties in water.

It is a salt of a strong base (NaOH) and a weak acid (carboxylic acid), so a solution of soap in water is basic in nature.

has the general chemical formula RCOOX.

Sodium stearate(Chemical formula: C17H35COO-Na+)

Sodium palmitate(Chemical formula: C15H31COO-Na+)

Sodium oleate(Chemical formula: C17H33COO-Na+)

Examples of Soap

Sodium Stearate ( C17H35COO-Na+ ) :Sodium Stearate soap is the sodium salt of a long chain saturated fatty acid called stearic acid. Sodium stearate soap has along alkyl group (C17H35) and an ionic carboxylate group (COO-Na+).

Sodium Palmitate (C15H31COO-Na+) :Sodium Palmitate soap is the sodium salt of long chain saturated fatty acid called stearic acid (C15H31COOH).

STRUCTURE OF A SOAP MOLECULEA soap molecule is made up of two parts : a long hydrocarbon part and a short ionic part containing COO-Na+ group. The soap molecule is said to have a tadpole structure.

MECHANISM/ CLEANSING ACTION

MECHANISM OF SOAP

Raw MaterialsFats and Oils- used in soap-making come from animal or plant sources. Each fat or oil is made up of a distinctive mixture of several different triglycerides.

Alkali - An alkali is a soluble salt of an alkali metal like sodium or potassium. Originally, the alkalis used in soap-making were obtained from the ashes of plants, but they are now made commercially.

The common alkalis used in soap-making are sodium hydroxide (NaOH), also called caustic soda; and potassium hydroxide (KOH), also called caustic potash.

Raw Materials

Soaps are the product of the reaction between a fat and sodium hydroxide:

Soap Manufacturefat + 3NaOH glycerine + 3 soap

SOAP MANUFACTURESoap is produced industrially in four basic steps:

Saponification - A mixture of tallow (animal fat) and coconut oil is mixed with sodium hydroxide and heated. The soap produced is the salt of a long chain carboxylic acid.

*Saponification - process of making soap by the hydrolysis of fats and oils with alkalies

Glycerine removal - Glycerine is more valuable than soap, so most of it is removed. Some is left in the soap to help make it soft and smooth. Soap is not very soluble in salt water, whereas glycerine is, so salt is added to the wet soap causing it to separate out into soap and glycerine in salt water.

Soap purification - Any remaining sodium hydroxide is neutralized with a weak acid such as citric acid and two thirds of the remaining water removed.

SOAP MANUFACTUREFinishing- Additives such as preservatives, color and perfume are added and mixed in with the soap and it is shaped into bars for sale.

SOAP MANUFACTURE

3 variations in soap-making processThe cold-process, wherein the reaction takes place substantially at room temperature

the semi-boiled or hot-process, wherein the reaction takes place at near-boiling point, and

the fully boiled process, wherein the reactants are boiled at least once and the glycerol recoveredPROCESS FLOWCHART (SOAP)HOW SOAPS ARE PREPARED ?

SAPONIFICATION

This reaction is exothermic, and progresses quickly and efficiently at around 125oC inside an autoclave type reactor.Step 1 - Saponification

The raw materials are continually fed into a reactor in fixed proportions. Assuming a production rate of 1000 kg wet soap per hour and a 80:20 tallow:coconut oil mix.

Step 2 - Lye separation

The wet soap is pumped to a "static separator" - a settling vessel which does not use any mechanical action. The soap / lye mix is pumped into the tank where it separates out on the basis of weight. The spent lye settles to the bottom from where it is piped off to the glycerine recovery unit, while the soap rises to the top and is piped away for further processing.

Step 3 - Soap washing

The soap still contains most of its glycerine at this stage, and this is removed with fresh lye in a washing column. The column has rings fixed on its inside surface. The soap solution is added near the bottom of the column and the lye near the top.

Step 4 - Lye separation

The soap and lye are separated in a centrifuge, leaving a soap which is 0.5% NaCl and 0.3% NaOH, and about 31% water. The lye removed is used as fresh lye.

Step 5 - Neutralization

The NaOH is removed by reaction with a weak acid such as coconut oil (which contains significant levels of free fatty acids), coconut oil fatty acids, citric acid or phosphoric acid, with the choice of acid being made largely on economic grounds. Some preservative is also added at this stage.

CLASSIFICATIONS OF SOAPCheaper Toilet SoapsRun and Glued Up SoapsCurd SoapCold made toilet soapsMedicinal SoapSulphur SoapTar SoapCarbolic SoapPeroxide SoapMercury SoapCastile SoapEschweger SoapTransparent SoapShaying SoapPumice/ Sand SoapLiquid SoapTextile SoapWool ThrowersWASTE TREATMENT/ MINIMIZATIONThe lye is a main effluent source in this industry and it mainly consists of unreacted fatty matter, caustic soda, sodium chloride and glycerol. According to the above effluent analysis, it is shown that the effluent is highly polluted and that it should not be discharged into the surface drains. The effluent should be treated to satisfy the tolerance levels specified for discharge into inland surface waters.Treatment could be done either to recover glycerol and sodium chloride from spent lye or by increasing the glycerol content of the spent lye to an economical level.

SOAPSAdvantagesVery effective as a bactericideIt will form gels, emulsify oil and lower the surfaces tension of water. Excellent everyday cleaning agent.Good biodegradability

DisadvantagesOils and perfume are immiscible in water and if spilled create havoc, although the oils do solidify at room temperature.When used in hard water, soap can produced a scum.

**Soaps, will react with metal ions in the water and can form insoluble precipitates (soap scum).

QUALITY/SAFETY CONTROLThe manufacturing process itself is closely monitored to ensure any losses are kept to a minimum. Continuous measurements of key properties such as electrolyte levels and moisture both ensure that the final product is being made to spec, and ensures the manufacturing process is working as it was designed to. Hence the losses in the plant will indirectly be minimised because the process itself is being monitored.

QUALITY/SAFETY CONTROLTo determine the safety of a cleaning product ingredient, industry scientists evaluate the toxicity of the ingredient.

Number of Factors Affecting Exposure:- duration and frequency of exposure to the ingredient- the concentration of the ingredient at the time of exposure- the route and manner in which the exposure occurs ISO 9001CertificationISO 9001:2008 specifies requirements for aquality management systemPRODUCTS (Soap & Detergent)PRODUCTS (Soap & Detergent)Four General Categories:Personal Cleansing include bar soaps, gels, liquid soaps and heavy duty hand cleaners.Laundry available as liquids, powders, gels, sticks, spray pumps, sheets and barsDishwashing include detergents for hand and machine dishwashing as well as some specialty products. (liquids, gels, powders, solids)Household Cleaning available as liquids, gels, powders, sheets and pads for use on painted, plastic, metal, porcelain, glass and other surfaces, and on washable floor coverings.IN THE PHILIPPINESSOAP AND DETERGENT INDUSTRYIt was not until the early 20th century that more significant and advanced chemical activities began to take place.

In 1911, the first modern soap factory was built, followed quickly by others. Intensive sales and advertising drives developed the Philippines market for soap.

By the time World War II broke out, there were already 135 soap establishments in the country, with only three processors using modern methods.

THE COMPARISONSOAP AND DETERGENTSOAPThey are metal salts of long chain higher fatty acids. prepared from vegetable oils and animal fats. cannot be used effectively in hard water as they produce scum i.e., insoluble precipitates of Ca2+, Mg2+, Fe2+etc.

DETERGENTThese are sodium salts of long chain hydrocarbons like alkyl sulphates or alkyl benzene sulphonates. prepared from hydrocarbons of petroleum or coal. do not produce insoluble precipitates in hard water. They are effective in soft, hard or salt water. more soluble in waterstronger cleansing actionTHANK YOU!