Janta Soap Works Project 2020
Janta Soap Works Project 2020
Janta Soap Works Project 2020
In this project work of JANTA SOAP WORKS , I have carried out all
the areas, in which chemistry is use – like Production, Quality Control, Quality
Assurance, R & D etc. One needs to keep equally balance all the departments to
run the entire company smoothly.
I have thus tried to prepare this project taking into consideration all the
areas and aspects of the company.
ACKNOWLEDGEMENT
First, I would like to thank SHRI M.P. PATEL B.ED & Science
College for providing me an opportunity to flourish my knowledge apart from
theory. I would also like to thank Principal A.P. BARASARA SIR and
Professor M.M.VADAVIYA MAM and All the Prof. of Department of
Chemistry, who has constantly guided me for the project.
2 General Information 02
3 Introduction of Soap 03
4 Starting Material 05
6 Types of Soap 06
8 Saponification 09
9 Procedure of soap 11
15 Some cases 24
16 Mission 24
17 Vision 24
18 Conclusion 25
19 References 25
20 Photos Gallery 26
COMPANY PROFILE
1
GENERAL INFORMATION
2
INTRODUCTION
Thus, vegetable fats are relatively unsaturated and liquid under the
ordinary conditions, while animal fats, being relatively more saturated, are
solid, or semi-solid, at the same temperature. For this reason, vegetable fats are
commonly refereed to as vegetable oils. (We say relatively saturated, or
unsaturated because both vegetables oils and animal fats contain saturated and
unsaturated chains).
The reason why double bonds lower the melting point of a fatty acid
chain, is that the sections of the chain attached to the double bond are attached
cis-wise to each other (probably because the double bond cis configuration
produces a bent chain which does not easily adhere to a neighboring chain by a
Van der Waals attraction hence a lower temperature (lower mobility) is required
for these molecules to adhere in order to form a solid crystal lattice.
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4
STARTING MATERIALS
CLASSES OF SALTS
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TYPES OF SOAP
Castile soap -- a mild soap originally made in Spain with pure olive oil.
Today many “castile” soaps are made with other vegetable oils. Castile is a
marvelous cleanser, producing a rich lather.
Milled soaps – these are the most commonly used, mass produced soaps.
Milling refers to the mixing of color, perfume and soap flakes.
Oatmeal soap – A rough –textured soap to which oatmeal has been added as
a mild abrasive and lather. Good for oily, dry, and normal skin.
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THE SOAP MANUFACTURING PROCESS
C R +- C R
CH2 O CH2 OH Na O
O +- O
CH O C R' + 3NaOH CH OH + Na O C R'
O O
C +- C
CH2 O R" CH2 OH Na O R"
O O
a triglceride caustic soda Glycerine metal soap
The most common fats and oils used are tallow (beef or mutton/beef
blend), coconut oil, and palm kernel oil (Table 1). Different oils produce soaps
of varying hardness, odour and lathering, so the ratios of the oils used are
closely monitored to produce a blend with the most desirable characteristics for
the most reasonable cost.
However, pure soap is hard and easily oxidised, so various additives are
added to correct this and to make a more aesthetically pleasing product. The
first such "additive" is glycerine, which is produced in the saponification
reaction. Glycerine makes the soap smoother and softer than pure soap.
However, it is also much more valuable than soap itself, so only a minimum of
glycerine is left in the soap and the remainder is extracted, purified and sold.
The glycerine is extracted from the soap with lye 2 - a brine solution that is
added to the soap at the saponification stage. Wet soap is soluble in weak
brine, but separates out as the electrolyte concentration increases. Glycerine,
on the other hand, is highly soluble in brine. Wet soap thus has quite a low
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electrolyte concentration and is about 30% water (which makes it easily
pumpable at 70oC). To remove the glycerine, more electrolyte is added,
8
SAPONIFICTION
The fats and oils most commonly used in soap preparation are lard and
tallow from animal sources, and coconut, palm and olive oils from vegetable
sources.
Tallow and lard are the fats separated from solid beef fat (suet) and hog fat,
by the process of rendering. Rendering consists of boiling the animal fat in a pot
with an equal volume of water until a layer of melted fat collects on top. (when
the animal tissue is heated, the fat in the cells melts, expands, ruptures the cell
membrane- and then flows out. Since the fat is immiscible with water, and has a
lower density, it forms a floating layer on the top of the water in the pot.) the
rendered fat is then drawn off, and allowed to solidify by cooling.
The length of the hydrocarbon chain and the number of double bonds in
the carbonylic-acid portion of the fat or oil determine the properties of the
resulting soap. For example, a salt of a saturated, long-chain acid makes a
harder, more insoluble soap. Chain length also affects solubility. Tallow is the
principal fatty material used in soap making, with coconut or palm oil blended
in, to produce a softer (more soluble) soap which will readily lather.
Soaps made with KOH (caustic potash) instead of NaOH (caustic soda) are
liquid rather than solid, at room temperature. (potassium salts have a lower
melting point than sodium salts.)
Toilet soaps are generally carefully washed free of any remaining alkali
used in the saponification procedure to avoid irritation and drying of the skin.
As much glycerine as possible is usually left in the soap, and perfumes,
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coloring, and medicinal agents are sometimes added. Also added, are
antioxidants to prevent the soap from turning rancid.
Many soaps are supperfatted , i.e. not all of the fat is hydrolysed, in order
that the final soap have some fat remaining to lubricate and smooth dry and
sensitive skin.
Besides tallow and coconut oil, there are many other natural fats and oils
which can be economically employed to make soaps of varying degrees of
quality. The less pure the raw material is, the more likely the soap will have an
off-color (generally yellow or brown), and an undesirable odor. (impure fats are
sometimes treated with bleaching agents before saponification, but this adds to
their cost.)
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PROCEDURE OF SOAP
Soaps and detergents are widely used in our society. Soaps are the
product of the reaction between a fat and sodium hydroxide:
Step 1 – 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.
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Step 4 - Finishing
1) Saturated Acids
CH3-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-COOH
CH3-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-COOH
CH3-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-
COOH
CH3-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-
CH2-CH2-COOH
2) Unsaturated acids:
CH3-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH=CH- CH2-CH2-CH2-CH2-CH2-CH2-
CH2-COOH
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CH3-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH=CH- CH2-CH2-CH2-CH2-CH2-CH2-
CH2-COOH
All fats are esters (though, not all esters are necessarily, fat!) of the
trihydroxy alcohol, glycerin, and fatty acids. Since each molecule of fat contains
three ester groups, fats are often referred to as triglycerides to distinguish them
from other materials having a fatty or greasy texture, such as waxes (mono
esters of long chain alcohols are carboxylic acids) mineral oil, and petroleum
jelly (long-chain hydrocarbons).
Note that the fatty-acid residues in a typical fat molecule are usually
different! Fats from different sources have different percentages of the common
fatty acids, and can be distinguished from one another by a quantitative analysis
of these constituents.
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TWO TYPES PROSESS FOR MAKING SOAP
Two procedures for soap making are given, a “cold” and a “hot” process.
The cold process, suitable for homemade soaps, produces soap bars which
retain the glycreine by-product, and if the amount of alkali employed in the
saponification is limited, an excess of fat (superfatted).
I. COLD PROCESS
If the liquid is being heated on a hot plate, do not the thermometer bulb to
rest on the bottom of the container, as it will then be overheated. Remove the
thermometer from the container after each reading.
Note : the thermometer supplied does not require shaking down before or
after reading. Plug in a hot plate and set to high.
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Weigh a 150 ml beaker on the trip scale and add 8g of NaOH pellets to it.
Handle NaOH with care as NaOH can burn the skin and is especially harmful to
the eyes. In the hood, add 25 ml of cold water to the beaker. Stir the mixture of
NaOH pellets and water, until a clear solution results. Caution: the beaker will
become very hot as the NaOH dissolves.
Weigh a 250ml beaker on the trip-scale and add 58g of fat (Crisco
vegetable shortening works well) to it. Then place the beaker on the hot plate
with low heat and with occasional stirring, melt the fat to melt completely.
Warm the melted fat to between 40-50 oC. Remove the fat from the hot plate
and add the lye solution to the fat with stirring. Stir the fat and NaOH mixture
continuously and until an emulsion is formed.Your mixture should look like a
thick, light yellow milk shake and should stay emulsified (should not separate
into a fat and NaOH layer). If your emulsion separates, the fat is too hot and
needs to cool.
Let the mixture cool on the bench top with occasional stirring until an
emulsion, which does not separate, is formed. You may want to add perfume or
other additives at this point. Pour the emulsion into a plastic cup and place in
your drawer for the reaction to run (it takes about 24 hours for the reaction to be
complete).
Take the soap home with you and let age for about two weeks. During
this time a powdery layer of NaCO3 (soda ash) will form on the surface, as
residual NaOH reacts with CO2 in the air while the soap is drying. This powdery
layer should be sliced off and the soap is ready to be used.
REPORT
15
Use the weight of fat taken and the reaction to find the theoretical yield (weight)
of soap bar?
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II. Hot process
Plug in a hot plate and set it on HIGH. Half fill a 400 ml beaker with hot
water from the sink and place on the hot plate. When the water begins to boil,
adjust the heat, so that the water boils gently, but continuously. While waiting
for the water to boil, weigh a 250ml Erlenmeyer flask on a triple beam balance
and add 10g of fat (Crisco, spry, or lard) to it. In a 150ml beaker prepare 100 ml
of a 50-50 solution of alcohol-water, by mixing 50 ml of water and 50 ml of
95% ethanol or methanol.
Weigh another 150 ml beaker on the triple beam balance, and add 10g of
NaOH pellets to the beaker. Handle NaOH with care as NaOH can burn the
skin and is especially harmful to the eyes. In the hood, mix the NaOH with 36
ml of the of the 50-50 alcohol-water solution to it. Stir the mixture until a
transparent solution is formed. Caution: the beaker will get very hot as the lye
dissolves.
Pour the lye solution into the Erlenmeyer flask containing the fat and mix
well using a stirring rod or by swirling with a beaker tongs. Clamp the
Erlenmeyer in the boiling-water bath and with occasional stirring, allow it to
cook for at least 30 minutes. While the mixture boils, some foam will form
(due to soap formation).
Half fill a 600 ml beaker with 300 ml of clear (filtered) saturated salt
(NaC1) solution and 50 ml of water. Pour the still hot reaction mixture
containing soap, glycerine, excess NaOH, and alcohol into the salt solution. Stir
the resulting mixture and allow to stand for 5-10 minutes. The soap will collect
as a white layer on the surface of the salt water in the beaker.
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Prepare a suction trap from the vacuum flask, which will be used later to
filter the soap preparation. Bend a long piece of glass tubing into a right angle
(instructor will demonstrate), and push one leg of the bend through a one-hole
rubber stopper fitted for the mouth of the flask. When inserted, the glass tube
should extend to about ½ inch from the bottom of the flask.
The exposed leg of the bend should be cut off at about 3 inches from the
bend, and, by means of a piece of rubber connector tubing, be attached to a 12-
inch length of glass tubing. The side-arm of the vacuum flask is now connected
to the vacuum outlet with pressure tubing. When the suction is turned on, this
device will act like a vacuum cleaner, sucking up liquid instead of dust.
Be ready to stop the suction instantly, if it appears that some of the soap
crystals are being sucked up. You can stop the suction quickly by pulling the
pressure tubing away from the outlet, then turning off the vacuum. Caution: At
no time should the vacuum flask be allowed to fill more than half-the trap, and
pour out its contents.
When most of the aqueous layer in the beaker has been drawn off, filter
the remaining mixture of soap and liquid through a Buchner funnel (with filter
paper attached ) to the suction flask. Press out any remaining moisture from the
cake of filtered crystals on the funnel with the flat end of a clean cork, or the
clean bottom of a small beaker. Allow the product to suck dry for 10-15
minutes.
Turn off the suction, detach the Buchner funnel, and with the help of a
clean spatula, transfer the soap crystals to a large sheet of smooth paper. Pick up
the sheet and slide the cystals into a clean, dry 150 ml beaker. Leave the beaker
stand, uncovered in your drawer for several days to air-dry the product.
Weight the soap powder, determine the yield, and hand it to your
instructor.
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REPORT
Use the weight of fat taken and the reaction to find the theoretical yield (weight)
of soap bar?
19
The Chemistry of Soap and Detergent Function
Firstly, this makes the surfactant molecule a wetting agent: the tails
migrate to align themselves with the solid:water interface, lowering the surface
tension at that point so that it penetrates the fabric better.
Secondly, it allows the oily dirt particles to form an emulsion with the
water: the tails of many surfactant molecules surround an oily dirt particle,
forming a micelle with a drop of oil in the centre and the ionic heads of the
surfactant molecules pointing outwards and hence keeping the micelle in the
polar solution.
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ROLE OF THE LABORATORY
When a new formula has been agreed the laboratory will lay down the
specifications that the finished soap and its intermediary stages must meet.
These could be colour, odour, moisture or electrolyte concentrations, or the
concentrations of impurities or additives. These specifications are also
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constantly being revised as the production equipment is improved, or consumer
demands change.
The laboratory lays down all the specifications for raw materials to be
purchased against. These specifications become the basis for the supplier to
quote against. The materials are constantly tested against these specifications,
either on a shipment basis or supplier's batch size. In some cases the
manufacturing plant is inspected and approved, and if the supplier can validate
their process then the need for many routine or expensive tests can be reduced
or eliminated.
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THE LEVER REXONE PROSESS
Step 2 – Saponification
The mixture of bleached oils is mixed with spent lye from the washing
stage (see below) and a caustic soda solution. The mix is heated and then left to
settle into two layers. The neutral lye (which is now rich in glycerine) is
pumped off and the mixture of soap and unreacted oils which has risen to the
top is left in the pan. More caustic liquor is added to this and the mix reheated
to saponify the remaining free oils.
Step 3 – Washing
The crude soap is then pumped to a divided pan unit (DPU) where it is
washed by a counter-current of lye. This lye is a mixture of fresh brine solution
and nigre lye (see below). The washed soap comes out the far end of the DPU
and is sent to the fitting pans, while the lye comes out the near end and is
pumped back into one of the saponification pans.
Step 4 – Fitting
Step 5 – Drying
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Moisture is flashed off under vacuum in the same manner as was
described above for the Colgate-Palmolive process.
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SOME CASES
MISSION
VISION
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CONCLUSION
At last really feel that I had receive the very best opportunity to get
practical knowledge at “janata soap works” moreover I would like to given best
wishes to the company and company may have splendid success and glorious
achievements.
REFERENCE
1) B.K.SHARMA
3) INORGANIC CHEMISRTY
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PHOTOS GALLERY
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