Technology for producing soap from glycerin. Own business: production of laundry soap. Making liquid soap as a business: equipment and technology. What is laundry soap and what are its benefits?
In this article:
If for industrial production While soap requires at least premises and equipment, to make soap at home you only need a stove and utensils.
Industrial soap production. For this type of activity, animal fats, inexpensive oils (palm or coconut), rosin, naphthenic and fatty acids (they are obtained from petroleum paraffin) are used.
But an increase in the composition of natural ingredients will entail a direct proportional increase in demand for finished products. Indeed, at the moment, there are very few similar offers on the country’s market; many domestic manufacturers prefer to save on high-quality raw materials, thereby increasing their own profits.
In production homemade soap Often only high-quality ingredients are used: purified animal and vegetable fats, therefore the risk of allergies or skin damage is minimal.
However, the cost of such a hundred-gram piece of soap will be higher than a similar “industrial brother”.
Soap production equipment
Equipment for making soap in industrial settings
For industrial production, a beginner with limited financial resources will only need a gas or electric stove, several large pans and casting molds (wooden or silicone).
Subsequently, in order to increase profits and reduce usage manual labor, we can and should take care of modernizing production capacities. Today there is a lot of similar equipment, mostly made in China.
The production line includes: mixer, mill, molding machine, stamping machine, refrigerator and soap cutting machine.
Equipment for making soap at home
To make soap at home, you will need liquid scales, large stainless steel pans, injection molds, a thermometer, a measuring spoon, and a refrigerator.
Soap production technology
The manufacturing process consists of two stages: chemical and mechanical.
Chemical stage of production
At the first stage, using an aqueous solution of sodium (potassium) salts, fatty acids and alkalis, a so-called adhesive soap is obtained, which subsequently must be cleaned and treated with electrolytes (an aqueous solution of sodium chloride and alkali). Under the influence of these processes, the soap begins to separate, and “soap cream” (concentrated soap with an abundance of fatty acids) floats to the surface.
Water, glycerin and feedstock contaminants remain in the bottom layer. A certain amount of glycerin is purified and added back to the mass. The resulting soap is called sound or laundry soap.
The production technology of this soap is not characterized by high labor intensity, but with high rate quality of the finished product.
Mechanical production stage
At the mechanical stage of production, cooling, drying and mixing with various additives take place. The resulting core soap must be ground on the rollers of a sawing machine (to significantly increase fatty acids and its resistance to external adverse factors). By pressing, the product takes on the desired shape.
For production toilet soap, in the resulting purified mass it is necessary to reduce the water content from 30% to 12%. After this, various additives, perfumes, oils, dyes and vitamins are added.
Production liquid soap is not much different from the production of traditional solid soap, but this technology allows you to add more flavors, herbal extracts and essential oils. In a large vat, fats are heated along with caustic soda. As a result of their interaction, a viscous liquid is formed. When cooled, liquid soap is obtained. Often, during its manufacturing process no additional dyes are used to improve quality.
In the production of homemade soap self made High quality purified animal and vegetable fats are used.
The ingredients should be mixed in proportions according to the recipe, and an alkali solution should be added to them (for saponification of oils). Now there are two options: cold or hot cooking method.
Cold technology
Cold technology making handmade soap consists of thoroughly mixing the resulting soap mass and adding essential oil, herbal decoction, honey, etc. After this, you can pour this mass into molds and let it harden for 2-4 days. After the specified time has passed, the soap is removed from the molds, cut and left to “ripen” for some more time (from 1 month to a year - depending on the variety).
Hot technology
Hot way is a more acceptable option for increasing production profitability.
It consists of accelerating the saponification reaction by heating the soap mass in a water bath or in the oven, subject to thorough stirring. After a couple of hours, until the mass hardens, you can safely add all kinds of additives and pour it into molds. After the soap hardens, you need to take it out, cut it and leave it alone for only 2 weeks.
The technology for making soap at home is very monotonous, but differs in the variety of necessary ingredients (depending on the recipe and, accordingly, on the intended type of soap).
The process of making soap using an example - master class
Let's look at the step-by-step process of preparing one of its types.
We will need (Fig. 1):
- 100 g soap base
- dye
- fragrance
- base oil
- mold.
A piece of soap base needs to be cut into pieces (Fig. 2) and melted in a water bath (Fig. 3).
Then add a few drops of base oil (no more than a third of a teaspoon) (Fig. 4), dye (Fig. 5) and stir thoroughly.
Then you can add fragrance (5 drops) to the cooled mass (Fig. 6) and begin pouring the mass into molds. (Fig. 7)
If bubbles have formed on the surface, then with the help of alcohol we will be able to get rid of them. To speed up the hardening process, the soap can be placed in the refrigerator.
Only after complete hardening can it be removed from the mold. (Fig. 8)
Soap production business plan
The main costs and expenses that need to be incurred to produce the first batch of industrially produced soap are as follows.
Period under review- 6 months, estimated production volume– 2500 kilograms of finished products.
Soap production costs
- Renting premises(at least 30 sq. m.), which will accommodate production capacity and perform warehouse functions (creating optimal conditions for the safety of finished products) - 30,760 rubles (about $1,000). For 6 months – 184,560 rubles.
- Communal payments: 3076 rub/month. Total for six months - 18,456 rubles.
- Necessary equipment: stove - 3000 rubles, 3 vats (large pans) - 2000 rubles, 25-30 molds for pouring - 6000 rubles. Total: 11,000 rubles.
- Raw materials: 3000 kg. soap base will cost 565,000 rubles. (many suppliers give a discount for large volumes), additives and oils - 95,000 rubles, vitamins and fruit acids - 60,000 rubles. This expense item amounts to 720,000 rubles.
- Wage employees . For such a small volume of production, 4 people will be enough: cook - 9228 rubles. ($200), his assistant - 7690 rubles. ($150) and 2 packs of soap - 6152 rubles each. (100 dollars). Our wage fund will be 29,222 rubles.
- Soap packaging will play a role not only business card enterprise, but also perform a protective function. It is desirable that for each type of soap the packaging should also be varied. Let’s assume the use of two types of packaging for the entire production volume: plastic – 100,000 rubles and cardboard – 110,000 rubles. Total: 210,000 rubles.
Consequently, the minimum financial requirements for organizing such a business are 1,162,238 rubles.
Economic effect
Now let's analyze economic effect from the invested costs.
The minimum price for a 100-gram bar of soap is 100 rubles, and we have produced 25,000 packages of soap. Therefore, the profit from sales is 2.5 million rubles, and therefore the net income for six months of work is equal to 1,337,762 rubles, which is 222,960 rubles/month.
The business plan for producing soap at home is similar to the above, with the exception of the costs of renting premises, paying staff and utilities. And the production itself will not be on such a large scale, so the costs of purchasing raw materials will be significantly reduced.
Soap sales
To sell soap you need to work with various stores and regularly supply them with your products. You may have to lower your price a little at first to get them interested in your offer. But then, when the consumer appreciates the quality, it will be possible to gradually increase the price to a level justified by production needs.
You can also cooperate with pharmacies, but in this case there will be a markup of about 40% on your product.
Another option is to create a branded outlet in a regular market. Don’t skimp on branded clothing with your own logo - this will be an excellent advertising move that will soon compensate for all material and moral costs.
Handmade soap created at home can be purchased by people with incomes not lower than the average level. This is also a great gift for all kinds of holidays. Reducing its cost will not be profitable, since the revenue in this case will not cover the costs of purchasing high-quality raw materials. Therefore, cooperation with cosmetics stores, household chemicals stores and pharmacies will also be relevant here.
It is acceptable to sell soap via the Internet and send products by mail to remote cities of the country.
The production of laundry soap involves 2 stages: soap making and processing of the soap mixture into a finished product. Due to the naturalness of the products used in the production of laundry soap, it is environmentally friendly.
The production process may include the use of not only fats and oils of animal and vegetable origin, but also acidic, synthetic and technical fats.
Product characteristics
It is easy to start such a business due to the widespread use of these products in domestic and industrial environments. Features of the detergent:
- High performance;
- Use at any temperature;
- No allergic reactions to the skin;
- Low cost and cost of sales;
- Complete decomposition into biological components;
- Fire safety and non-toxicity;
- Duration of storage.
Solid varieties are distinguished by their purity, environmental friendliness and first-class quality, corresponding to GOST 30266-95. The soap raw material composition does not include surrogate materials and substances. Products are manufactured with an antibacterial effect and without preservatives, using modern technologies.
Application of soap making product
Used laundry soap for cleaning and washing heavy dirt and hands. To do this, a small amount of the product is rubbed and soaped onto damp skin to remove dirt, after which the foam is washed off with water. 
This soap is recommended for washing fabrics made from pure cotton, cotton and wool blend products. This way you can wash and disinfect baby clothes. Dosage for hand or machine washing - 20 g of product and 6 liters of water per 1 kg of laundry. Fruit stains are removed by adding 12-18 g of soda ash to the indicated dosage.
As a plasticizing additive, laundry soap is used in the preparation of oil-adhesive, PVA-based and acrylic putties. To produce a plasticizer, 5-9% of the product is used for the entire weight of the putty.
This product is preferred for cleaning parts in certain areas of the technology-related industry. Soap finds its use in both farming and agricultural industries.
Ensuring the safety of soap products
It’s not enough to learn how to make laundry soap, you also need to know how to ensure its safety. Recommended storage temperature for environment must be at least 0°C in original packaging, which should not be aluminum or galvanized. The warehouse premises must be well ventilated. 
It is permissible to stack products in stacks up to 2.6 m in height and with a distance between them of 0.6 m. The humidity level in the warehouse should not be high. The intermediate product is stored temporarily during the period when soap production is stopped.
In the absence of cooking production, soap sheets are transported to other regions for their further processing into finished goods.
Range
The variety of laundry soap is off the charts. Traditionally, this product is classified according to the following criteria:
- Purpose;
- Consistency (solid, liquid, ointment and powder);
- Volume of acid fats (groups 1, 2 and 3);
- Preparation method: sawed, cored or glued production;
- Color: normal or lightened;
- Fillers: aromatic, coloring, abrasive or antibacterial additives;
- Shape: rectangular or complex.
The production of laundry soap, as well as its testing and acceptance, must comply with state standards. This is a universal product that is in great demand, despite the wide selection of detergents on the market.
This product is purchased by individuals and almost all enterprises. Such demand will not slow down the search for its consumer, which makes this business profitable.
The quantity and complexity of the soap depends on the range of soap produced. technical equipment. Therefore, the first decision is made on the type of soap being created, which will have its end consumers.
Equipment for the production of
In order to save money, organizing such a business will not require a large amount of equipment. 
A 50 kg per hour line is sufficient, consisting of: 2 digesters, a melting tank, a mixer, a 2-stage screw press for sawing, cutting and marking equipment, stamping molds and a compressor.
To accommodate necessary equipment, which will be serviced by one person, will require renting a room of 16 sq. m. The initial investment is up to half a million rubles. Later the line can be supplemented with auxiliary devices. The profitability of such production is about 50%.
Direct production
For production, you will need raw materials - animal and vegetable fats and oils or their mixtures and waste. The highest fatty acids are washed with caustic alkalis to obtain hard, soft or liquid soaps.
It is possible to use fat substitutes and fillers to reduce fat consumption and give the material plasticity and foaminess.
After melting in the boilers, a solution of caustic soda is added to the fat in a thin stream, continuously stirring the constantly boiling raw material. They start with a weak solution - 8-10%, then 18-20% and finally 32-33%.
Adding small portions of water to the boiler will ensure the liquid state of the raw material. By adding alkali, it will become dark and homogeneous. Ready mass checked for fluidity with a wooden spatula and should look like long transparent threads of boiled soapy bone glue.
After settling, the mass is poured into molds and allowed to cool in natural conditions for 24 hours. The bars or layers are cut into pieces weighing 400 g and a stamp is applied to them. Packing is done in wooden boxes.
The process of making toilet soap is quite complicated. They usually contain more than 10 different components that must be compatible. Their quantity is strictly balanced, since the finished product must be stable over a wide temperature range during storage.
There are two main stages in the production of toilet soap:
- The first is soap making, which is a chemical process of interaction of triglycerides of fatty acids with alkali (saponification reaction). It ends with the preparation of aqueous solutions of K or Na salts of fatty acids of various concentrations;
- 2nd - giving the soap a marketable appearance by performing the following operations: cooling and hardening of the concentrated soap solution, drying, mechanical processing, molding into pieces, packaging of finished products.
Solid soaps are produced by hot, cold, melting and planing.
Figure 4 - Methods for making soap
Hot cooking of toilet soap is carried out by direct or indirect methods.
Direct method. Soaps, obtained by reacting fats with caustic alkalis, are a mixture of sodium or potassium salts of fatty acids, mainly stearic, palmitic and oleic. The interaction of solid fats and their fatty acids with sodium alkali produces solid soaps, and the interaction of liquid fats and their fatty acids with potassium alkali produces ointment-like and liquid soaps.
As a result of saponification of fats with alkaline reagents and neutralization of fatty acids, adhesive soap of 40-60% concentration is formed. To obtain it, two main methods are used: hot saponification of fatty raw materials with caustic alkalis and neutralization of fatty acids with soda ash (carbonate method).
Hot saponification is carried out in open boilers with a molten fat mixture, gradually adding an aqueous solution of caustic alkali. Cooking at a temperature of 100-104 °C with stirring continues for 5-10 hours. In this case, saponification of fats occurs and the resulting fatty acids are neutralized to form soap and glycerin.
The method of hot saponification of fats has significant disadvantages: glycerin, obtained from the breakdown of fats, is not used, and saponification requires expensive caustic alkalis. Therefore, split fats are more often used to make laundry soap.
When heated in the presence of mineral acids, fats are broken down into fatty acids and glycerol, which are separated from each other. Non-reactive breakdown of fats can be carried out under pressure and at elevated temperatures.
Soap is produced using the carbonate method in open boilers by gradually adding fatty acids to a solution of soda ash. Since the split fats contain a certain amount (5-7%) of undigested fat, which is not saponified by soda ash, a small amount of caustic alkali is added at the end of cooking.
Chilled solid adhesive soap contains 40-47% fatty acids (in the form of sodium salts). It is cut into pieces. To improve the quality of soap, a certain amount of soda ash, potash, liquid glass and other auxiliary substances are added to soap glue, which increase the hardness of the soap, help soften the water, and enhance the cleaning effect.
Indirect method involves treating a hot soap solution with electrolytes (table salt - NaCl). This process, called salting out, causes the soap solution to coagulate.
Salting out is a process necessary to obtain the highest grades of laundry and toilet soap. A certain amount of electrolyte is added to boiling soap glue ( table salt), as a result of which it delaminates. The floating concentrated soap mass (core), called core soap, is separated from the saline solution. This process increases the concentration of soap (releases some of the water and glycerin) and cleans it of coloring and protein substances and other contaminants. Fully salted kernel soap contains 60-63% fatty acids. This soap is often called sound soap. Solid toilet soap is most often obtained by the indirect method.
Cold way . The preparation of toilet soaps using the cold method by stirring has many advantages, which mainly boil down to the fact that here coloring and perfumery are carried out simultaneously, constituting, as it were, one operation, after which all that remains is to cut and mold the hardened soap mass.
To prepare soap using the cold method, take coconut oil, previously cleared of random dirt, and saponify it with strong soda lye at low temperature and constant stirring. In order for the resulting soap to be neutral, it is necessary to make several preliminary tests and accurately determine the quantitative ratio of fat and alkali. When the saponification process reaches the point where the contents of the cauldron turn into a homogeneous and difficult to stir mass, then coloring and perfume substances are added to it, which after prolonged stirring are evenly distributed throughout the mass.
Remelting. The preparation of toilet soaps by melting is carried out as follows: ordinary sound soap is cut into pieces and thrown into a cauldron inserted into another cauldron with boiling water (water bath). So much water must be added to the soap so that the sample taken has a good consistency, after which the soap is poured into molds and mixed with coloring and perfume substances. The amount of added water poured for remelting depends on the property of the soap: for hard, strong soap you need to take more water than when using other varieties that already contain a lot of water. In general, enough water is poured so that when it cools, you get a solid soap that foams strongly in the water. If the soap taken for remelting is heavily contaminated, then it must be melted with big amount water (50-60%), then drain and boil.
Planing. The preparation of toilet soap by planing is carried out as follows: the core soap is turned into shavings using a special machine, collected in a wooden trough, mixed with coloring and odorous substances and then turned into homogeneous mass. The machine consists of a horizontal cylindrical drum, on the circumference of which there are 4-8 knives. Above the drum, which is driven into rotation, there is an inclined plane on which layers of soap are placed for planing. The soap with its own weight presses on the drum, the knives of which continuously cut shavings from the soap layer. The knives are installed at a significant slope and therefore can cut chips as thick as writing paper.
Mechanical operations with soap are very important for its quality in that all the raw components of the soap are well mixed, forming a uniform consistency and color. Due to improper mixing of the components, voids may form in the soap. The holes themselves are not dangerous (air bubbles) - the liquid collecting in them is dangerous. It can be a safe essential or liquid oil, but it can also be an alkaline solution that corrodes the skin. If this is a truly alkaline solution, then you should melt the soap and mix the soap mass well. If the liquid is essential or fatty oil, it means that the soap mass was not stirred well during preparation.
Figure 5 - Stages of making soap marketable
Grinding. After the soap making process, excess electrolyte, remaining contaminants and partly glycerin are removed from the soap core. As a result of this operation, grinding, the viscosity of the soap core decreases and its plasticity increases.
Advocacy. After grinding is completed, the soap mass should stand for some time at a temperature of 100 C.
Cooling. During the cooling process, the soap crystallizes and a fairly dense solid mass is formed. The hardness of the soap mass depends on the content of fatty acids, filler, etc.
To dry soap, continuous belt dryers are used, interlocked with cooling rollers, on which thin shavings are obtained from the soap, which are additionally dried in vacuum drying chambers.
Preliminary mechanical processing of chips. Preliminary mechanical processing of the chips is carried out on special roller equipment: they are compacted and ground.
Mixing soap with additives. Solutions of dyes, fragrances, antioxidants, superfatting agents and other useful additives are added to ground soap shavings.
Perfuming toilet soaps. Along with a first-class completely neutral soap base (core soap), perfumery plays a particularly important role in the manufacture of toilet soaps. The fact is that the fragrance should not only be very pleasant, but should also retain its smell for a long time and even, if possible, should improve when the soap lies and dries. When starting to perfume, you need to distinguish which types of soap you want to perfume, and accordingly select the necessary odorous substances. Toilet soaps are usually divided into those that are made by hot method, cold method, melting, and planing. Therefore, when perfuming, it is necessary to resolve three issues: firstly, at what temperature should the soap be perfumed. Secondly, what is the effect of alkalis on the odorous substances used. And finally, thirdly, are these odorous substances well preserved in alkalis? The entire art of perfumery for toilet soaps is based on the solution of these three cardinal issues. Toilet soaps made by hot method or by melting are mostly cheap varieties. You can’t spend a lot on perfumeing them so that these soaps don’t cost too much. Therefore, to perfume such types of soaps, you can choose only cheap odorous substances, but having, nevertheless, a possibly stronger odor, since it is with these types of soaps that it is often necessary to kill some unwanted extraneous odor. For this purpose, they mainly use mirban oil, safrole, citronella oil, and artificial bitter-almond oil.
For cold process toilet soaps, i.e. good varieties coconut soaps, you can use fragrances of higher quality and a wider choice among them. Although coconut soaps, which also include almond soaps, have recently been pushed into the background by planed soaps, good and pure coconut soaps are bought very well, especially in areas where the water is chalky, since planed soaps do not lather well. Coconut soaps can be perfectly perfumed using numerous natural and artificial fragrances. You can also significantly improve the quality of these soaps by adding lanolin or paraffin to them. Even soaps with the addition of Japanese wax are very popular, as they look exactly like planed soaps. They should not just be left in the mold for a long time, otherwise they become too hard and very difficult to press.
Among odorous substances, we can recommend anise aldehyte, which has a very delicate smell; bornyl acetate, which is good in coconut soaps; citronella oil, which is especially good for honey soaps. Then a good effect can be achieved with coumarin, eugenol and geranyl acetate. You can also recommend nerolin, and especially terpineol. Cinnamon aldehyte is also used with great success. The smell of violet can be achieved with ionone II with the addition of terpineol, and brilliant results are obtained from the use of artificial neroli oil.
Coloring toilet soaps. The dyes used to tint toilet soaps can be different. The main conditions that they must satisfy are: to be strong enough, mix well with soap and not have a harmful effect on the skin. Such paints can be divided into two groups: soluble and insoluble. The former deserve preference over the latter because they do not leave behind an insoluble powdery residue; In addition, soluble paints are distributed in soap more easily and evenly than insoluble paints.
Red color. For transparent soaps - alkanine, magenta, eosin. For opaque ones - cinnabar, red lead.
Yellow. For clear soaps - turmeric extract and picric acid. For opaque ones - chrome yellow paint.
Orange color is made up of a mixture of red and yellow dyes.
Green color. For transparent soap - green aniline or a mixture of indigo-carmine and picric acid. For opaque ones - chrome green paint.
The violet color is composed of methyl violet or a mixture of red dye and indigo carmine.
Brown color - from light or dark brown aniline dye or burnt sugar.
As for the coloring of soaps itself, it is done as follows: solutions of paints in water or alcohol are added to soap shavings, which then enter the kneading machine and are transformed into a uniformly colored mass. Insoluble paints are used in the form of a fine powder, which is sprinkled on the chips entering the planer drawer. Then a new layer of shavings is applied to the sprinkled shavings, which are again sprinkled with paint, etc. When the soap is thus prepared, the shavings are stirred and passed through a kneading machine to obtain a uniformly colored mass.
Marbling of toilet soaps. It is produced to give them the appearance of spotted or veiny marble. To do this, pour liquid soap into a mold to a known height, sprinkle the surface with coloring powder or pour over a paint solution, then pour a new layer of soap, this operation is carried out until the mold is filled. A wooden spatula is lowered into the soap mass and stirred, moving it parallel to the walls of the mold. If they want to get wavy marbling, then move the spatula along curves or spiral lines. Various paints are used for variegated marbling.
Peeling is carried out on screw (worm-type) extruders, in which soap shavings are repeatedly ground and then pressed into a dense plastic mass. The soap comes out of the extruder mouthpiece in the form of a bar.
Peeling has a great influence on the plasticity of soap, its ability to undergo plastic deformation, increases the density of soap, reduces its swelling and abrasion.
Cutting into pieces. At the exit of the extruder, the soap bar is cut into pieces using special knives.
Soap stamping. The soap bars are stamped to give them their final shape and markings. Mechanical presses of various designs with automatic feeding and ejection of a bar of soap are used. When producing soap, it is allowed to use ready-made soap base or soap shavings made by other manufacturers. (Appendix A)
General information on the raw materials from which soap is made.
Animal fats – an ancient and valuable raw material for soap-making surfaces. They contain up to 40% saturated fatty acids. Artificial, that is, synthetic, fatty acids are obtained from petroleum paraffin by catalytic oxidation with atmospheric oxygen. During oxidation, the paraffin molecule is broken in different places, and a mixture of acids is obtained, which are then separated into fractions. In the production of soap, mainly two fractions are used: C 10 -C 16 and C 17 -C 20. Synthetic acids are introduced into laundry soap in an amount of 35-40%.
Also used for soap production naphthenic acids released during the purification of petroleum products(gasoline, kerosene, etc.). for this purpose, petroleum products are treated with a solution of sodium hydroxide and an aqueous solution of sodium salts of naphthenic acids (monocarboxylic acids of the cyclopentane and cyclohexane series) is obtained. This solution is evaporated and treated with table salt, as a result of which a paste-like mass floats to the surface of the solution dark color– soap naft. To purify soap naphtha, it is treated with sulfuric acid, that is, the naphthenic acids themselves are displaced from the salts. This water-insoluble product is called asidol, or asidolmylonaft. Only liquid or soft soap can be made directly from asidol. It has an oily smell, but it has bactericidal properties.
It has long been used in soap production rosin, which is obtained by processing the resin of coniferous trees. Rosin consists of a mixture of resin acids containing about 20 carbon atoms in the carbon chain. 12-15% of rosin by weight of fatty acids is usually added to the composition of laundry soap, and no more than 10% is added to the formulation of toilet soaps. The introduction of rosin in large quantities makes the soap soft and sticky.
Of course, today it is important to use a variety of vegetable fats, there is a separate article about them in the section.
In addition to using soap as a detergent, it is used in bleaching fabrics, in the production of cosmetics, and for the manufacture of polishing compounds for water-based paints.
In everyday life, various items and objects are subjected to the washing process. Pollutants come in a wide variety of forms, but most often they are poorly soluble or insoluble in water. Such substances, as a rule, are hydrophobic, since they are not wetted by water and do not interact with water. Therefore, various detergents are needed.
Washing can be called cleaning a contaminated surface with a liquid containing a detergent or a system of detergents. Water is mainly used as a liquid in everyday life. A good cleaning system should perform a dual function: remove dirt from the surface being cleaned and transfer it into an aqueous solution. This means that the detergent must also have a dual function: the ability to interact with the pollutant and the ability to transfer it into water or an aqueous solution.
Therefore, a detergent molecule must have hydrophobic and hydrophilic parts. "Phobos" in Greek means fear. Fear. So hydrophobic means “afraid of, avoiding water.” “Phileo” in Greek means “love”, hydrophilic means loving. Water retaining.
The hydrophobic part of the detergent molecule has the ability to interact with the surface of the hydrophobic contaminant. The hydrophilic portion of the detergent interacts with the water, penetrates the water, and carries with it the contaminant particle attached to the hydrophobic end.
Detergents must have the ability to be adsorbed on the boundary surface, that is, they must have surfactants.
Salts of heavy carboxylic acids, for example CH 3 (CH 2) 14 COONa, are typical surfactants. They contain a hydrophilic part (in this case, a carboxyl group) and a hydrophobic part (hydrocarbon radical).
Properties of soaps. What is soap?
Soaps are salts of high molecular fatty acids. In technology, soaps are sodium or potassium salts of higher fatty acids, the molecules of which contain at least 8 and no more than 20 carbon atoms, as well as similar naphthenic and resin acids (rosin); aqueous solutions of such salts have surface-active and detergent properties. Salts of alkaline earth and heavy metals are conventionally called metal soaps; most of them are insoluble in water.
In the anhydrous state, sodium and potassium salts of fatty acids are crystalline solids with t o pl. 220 o -270 o. Anhydrous soaps, especially potassium soaps, are hygroscopic; Moreover, salts of unsaturated fatty acids are more hygroscopic than saturated salts.
In hot water at a temperature close to the boiling point, soaps dissolve in all respects; at average room temperatures, their solubility is limited and depends on the nature and composition of acids and alkalis.
Soaps containing large quantities salts of high molecular weight solid fatty acids, in cold water they foam poorly and have low cleaning power, whereas soaps made from liquid oils, as well as from solid low molecular weight fatty acids, such as coconut oil, wash well at room temperature. Soaps, being salts of alkali metals and weak organic acids, when dissolved in water undergo hydrolysis with the formation of free alkali and acids, as well as acid salts, which for most fatty acids are poorly soluble precipitates that impart turbidity to solutions. For salts of various fatty acids, hydrolysis increases with increasing molecular weight, decreasing soap concentration, and increasing solution temperature. Due to hydrolysis, aqueous solutions of even neutral soaps have an alkaline reaction. Alcohol inhibits the hydrolysis of soaps.
Soap in aqueous solutions are partly in a state of true solution, partly in a colloidal polydisperse state, forming a complex system consisting of molecules and micelles of neutral soap, its ions and other hydrolysis products.
With decreasing polarity of the solvent, i.e. with the transition from water to organic liquids, such as alcohol, the colloidal properties of soap solutions decrease. The solubility of soaps in methyl and ethyl alcohol is much higher than in water, and in anhydrous alcohols soap is in a state of true solution. Concentrated solutions of solid fatty acid soaps in ethyl alcohol, prepared by heating, give solid gels when cooled, which is used in technology to prepare the so-called solid alcohol.
Soaps are almost insoluble in anhydrous ether and gasoline. The solubility of acidic soaps in gasoline and other hydrocarbon liquids is much higher than neutral ones. Alkaline earth metal salts of higher fatty acids, as well as heavy metal salts, are insoluble in water. Metal soaps dissolve in fats, which is used in the production of drying oils, where these soaps act as catalysts to accelerate the drying process of fatty oils. The solubility of soaps in mineral oils is used in technology in the production of greases (solids).
The widespread use of soaps as detergents, wetting agents, emulsifiers, peptizers, lubricants and active hardness reducers, for example, when cutting metals, is explained by the specific structure of their molecules. Soaps are typical surfactants.
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Soap production technology
To prepare solid soap (toilet, laundry) take 2 kg. caustic soda, dissolve in 8 liters of water, bring the solution to 25 C and pour it into melted and cooled to 50 C lard (the lard should be unsalted and take 12 kg 800 g of it for the specified amount of water and soda). The resulting liquid mixture is thoroughly stirred until the entire mass becomes completely homogeneous, after which it is poured into molds and placed in a warm and dry place. After 4-5 days, the mass hardens and the soap is ready.
If you want to have a more foamy soap, then add another 400g of purified potash to the specified amount of water or take 2 kg of lard. less and add the same amount of coconut oil. To prepare liquid soap, dissolve in 2 kg. water the same amount of unrefined caustic potassium, bring the solution to 25 C and mix thoroughly with 8 kg. unsalted lard, previously melted and cooled to 50 C, then proceed as indicated above.
Production of toilet soaps
1.Hot method. As the main mass for toilet soaps, you can take lard soap prepared with soda lye, or prepare ossobo using pork fat combined with coconut oil.
Coconut oil should be the most highest quality, and the pork fat is exceptionally fresh and well-refined.
Fat is purified as follows: fresh fat is washed several times in cold water, cut into pieces and placed in a bag, which is suspended in a cauldron of water and boiled. When the water boils and the lard dissolves, it is lightly squeezed out, with most of the fiber remaining in the bag along with the debris. The bag is taken out and into the mixture of lard and water, for each kilogram of lard, add 4-5g of table salt and 1-2g of powdered alum, with the liquid boiling strongly and constantly stirring. After some time, the boiling is stopped and the fat is allowed to float to the surface. The resulting scale is carefully removed, filtered through a linen into a clean vat and allowed to harden. In this way, cooked fat can be stored unchanged in a cool place for a very long time.
To obtain good toilet soap, take 5-20g of coconut oil for every 100g of fat. The latter is added not only to reduce the cost, but also to “fill” it with more water.
The soap making itself is done in the usual way, you just need to make sure that the resulting soap is neutral, i.e. so that there is an excess of alkalis in it. For this purpose, it is salted several times and then boiled again. After the last salting, boiling is continued until the sample taken with a glass rod on the plate turns out to be completely satisfactory, i.e. when squeezing the mass between your fingers, you get hard plates that should not break.
In order to have completely pure soap, it is stirred with a pole, the foam is removed and poured into molds until it is transparent. The soap mass remaining at the bottom of the boiler will be less transparent and clean, and therefore it must be allowed to harden separately.
2. Cold method. The preparation of toilet soaps in the cold way, by stirring, by stirring, has many advantages, which mainly boil down to the fact that here coloring and perfumery are carried out simultaneously, constituting, as it were, one operation, after which all that remains is to cut and stamp the hardened soap mass.
To prepare soap using the cold method, take coconut oil, previously cleared of random dirt, and saponify with strong soda lye at low temperature and constant stirring. In order for the resulting soap to be neutral, it is necessary to make several preliminary tests and accurately determine the quantitative ratio of fat and alkali. On average, you have to take caustic soda in solid pieces about 15% by weight of the fat part.
When the saponification process reaches that state, the contents of the cauldron turn into a homogeneous and difficult to stir mass, then coloring and perfumery substances are added to it, which, after prolonged stirring, are evenly distributed throughout the mass.
3. Melting. The preparation of toilet soaps by melting is carried out as follows: ordinary nuclear soap is cut into pieces and thrown into a cauldron inserted into another cauldron with boiling water (water bath). So much water must be added to the soap so that the sample taken has a good consistency, after which the soap is poured into a mold and mixed with coloring and perfume substances. The amount of added water poured for remelting depends on the properties of the soap: for hard greasy soap you need to take more water than when using other varieties that already contain a lot of water. Generally, enough water is poured so that when it cools, you get a solid soap that foams strongly in the water.
If the soap taken for re-melting is heavily contaminated, then it must be melted with a large amount of water (50%-60%), and then salted and boiled.
4. Planing. The preparation of toilet soap by planing is carried out as follows: the core soap is turned into shavings using a special machine, collected in a container, mixed with coloring and odorous substances and then turned into a homogeneous mass using a kneading machine. The machine consists of a horizontal cylindrical drum, on the circumference of which there are 4-8 knives. Above the drum, which is driven into rotation, there is an inclined plane on which the layers for planing are placed. The soap is pressed by its own weight onto the drum, the knives of which continuously cut shavings from the soap layer. The knives are installed at a very significant slope and therefore can cut chips as thick as writing paper.
Here are several recipes for toilet soaps prepared in different ways:
5. Almond soap. To prepare it, take 4 kg of white soap, scrape it into small shavings and add small shavings and add a little milk. The mass is poured into the cauldron, placed on moderate heat and stirred until it thickens and begins to stretch. After cooling, add artificial bitter-almond oil and pour the soap into a flat mold. The soap is allowed to cool, harden, and then cut into pieces of the required shape.
In factories, almond soap is prepared from good strong lye with twice the weight of lard, fat, coconut or palm oil, which must be boiled until the sample taken out, placed on a cold smooth plate, quickly hardens.
6. Pink soap. To prepare this soap, take: 64 coconut oil, 40 tallow soap, 30 water and heat this mixture for 2-3 hours, knead and add a little eosin for tint. Then remove from heat and add artificial rose oil. Soap is poured into molds.
7. Violet soap. To prepare this soap, which gives softness to the skin, take 100 white kernel soap, 10 orris root, 10 dew incense. The soap is mixed with water, dyed purple and scented with violet essence. Then add as much starch as is necessary to impart hardness to the soap, after which the soap is placed in molds.
