The document provides information about the soap industry and the process of soap making. It discusses the history of soap making dating back to 2800 BC among early civilizations. It also outlines the key raw materials used such as alkali, fats, and oils. The document then describes the soap making process which involves preparation of raw materials, saponification (chemical reaction), glycerin removal, finishing, and packaging. It notes some advantages of soap including being eco-friendly and biodegradable but also disadvantages like being less effective in hard water.

1. PREPARED BY:
SYED ASIM ALI SHAH
D-14-CH-16
Dawood University Of Engineering
& Technology Karachi.
CONDUCTED BY:
Sir Hanif Memon

2. SOAP INDUSTRY

3. • 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 theTiber
River. Women found that this clay mixture (soap) made
their wash cleaner with much less effort.

4. History of Soap Making
The soap making can be dated back to 2800 B.C., with the
evidence of Babylonians mastering in the art of soap making.
They made soap from fats boiled with ashes. Soap was used in
cleaning wool and cotton used in textile manufacture and was
used medicinally for at least 5000 years.
The soap making can be dated back to 2800 B.C., with the
evidence Ancient Egyptians mixed animal and vegetable oils
with alkaline salts to produce a soap-like substance.
The Phoenicians used goat’s tallow and wood ashes to create
soap in 600BC.

5. Early Romans made soaps in the first century A.D.
It wasn't until the 17th century that cleanliness and bathing started to
come back into fashion in much of Europe.
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.
History of Soap Making

6.  Soap is a cleansing agent created by the chemical reaction of a
fatty acid with an alkali metal hydroxide.
 Raw materials mostly obtained from animal kingdom (fat) and
plant kingdom (oils).
 Soap is of natural origin, so it is biodegradable and eco friendly.
Raw Materials:
Traditionally, soap has been manufactured from alkali (lye) and
animal fats (tallow),
Although vegetable products such as palm oil, coconut oil,
almonds oil are used nowadays.
What is SOAP?

7. AlKali Material
(50%of fats)
Fat
(Tallow with 20% Grease)
Oil
(Coconut 15%)
Composition Of Soap

8. Alkali Material:
Fat orTallow :
 Tallow is obtained from suet and used in making soap.
 Tallow is the fat obtained by rendering beef or mutton.
 Tallow is the harder and less fusible fat in animals and vegetables.
 Tallow is the white (nearly tasteless) solid rendered fat of cattle and sheep
used for making candles, soap, and pet foods.
 The Alkali most commonly used today is NaOH.
 KOH can also be used. Potassium based soap creates a more water soluble
product than sodium based soap, and so it is called “Soft soap”. Soft soap,
alone or in combination with sodium based soap in commonly used in
Shaving products.

9. Oil:
 Almond Oil , extracted from the seeds of sweet almonds is used as an
emollient in high quality soap.
 Almond oil prevents dehydration of skin.
 Palm oil, coconut oil, produced by processing of palm fruit and coconut can
be used in soap.
 Soap from coconut frim and lather well ,
 Coconut reduce hardness to increase solubility
 Coconut contain large proportion of lauric and myristic acid as well as small
quantity of oleic, stearic, palmitic etc .
 Fish oil can also be used and better in processing of soap

10. • Sodium stearate (Chemical formula: C17H35COO-Na+)
• Sodium palmitate (Chemical formula: C15H31COO-Na+)
• Sodium oleate (Chemical formula: C17H33COO-Na+)
EXAMPLES OF SOAPS

11. TYPES OF SOAP
Laundry Soap
Toilet Soap

12. Laundry soaps, or washing soaps are made from cheaper materials
such as expired materials, residue from edible oil refineries and
caustic soda.
Used only for washing of clothes.
 Can not be used for bathing due to excess of alkali.
 It is cheaper in rate.
LAUNDRY SOAP

13. Laundry Soap Available in market

14.  Made from best quality animal or vegetable fats.
 The higher the fatty material in soap, the better the cleansing
ability.
 Toilet soaps contains more fatty material than laundry soap (i.e 60-
80% )
 Mostly KOH is used in toilet soaps.
 Some colors , additives and perfumes are used in toilet soaps.
 Do not harm the skin.
 Most of the toilet soaps present in the market (Lux, Liril, Lifebuoy,
Dettol, Margo etc.
TOILET SOAP

15. TOILET SOAPS AVAILABLE IN
MARKET

16. MICELLES – SOAP MOLECULES
 A soap molecule has two
ends with different
properties:
1. A long hydrocarbon part
which is hydrophobic (i.e. it
dissolves in hydrocarbon).
2. A short ionic part containing
COO-Na+ which is
hydrophilic (i.e. it dissolves in
water).

17. Soap molecule is made up of two very different ends.
One end love the water called hydrophilic
 Other end hate the water called hydrophobic .
 Hydrophobic end attached to the dust, dirt, oils or the materials which
we want to remove, detaching takes place, get suspended in water and
can be easily removed.
 while hydrophilic end remains in water.
CLEANING ACTION

18. MECHANISM OF SOAP

19. SOAP
MANUFACTURING
PROCESS

20. 1) Preparation of raw materials
2) Saponification
3) Glycerin removal and soap purification
4) Finishing
Batch process

21. The calculated amount of raw materials is selected in
order to get desired product.
Exact amount of raw materials is determined by
determining the saponification value.
Saponification value is the number of milligrams of
alkalis required to completely saponify the one gram of
specific fat.
Preparation of raw material

22. Imported tallow contains mixed glycerides has low melting point and solidify at
room temperature so the ships and storage tanks have heating system in which
steam is circulating in pipes.
Liquid tallow fed to settling tank and then filter press where unwanted materials
are settled down and removed.
Solid alkalis are diluted by adding water according to required concentration.
(40-50%).
After that pure tallow and alkali fed to the soap kettle.

23.  In soap kettle triglycerides in fats/oil react with aqueous NaOH/KOH and converted into
soap and glycerol.
 Reaction is exothermic and heat is controlled by gradual addition of NaOH/KOH.
 Helical pipe agitator is used in soap kettle which is circular pipe having perforations and
steam is used for mixing.
 Rosins are added inorder to create transparency
Saponification

24.  Free Fatty acid react with Alkali metal to produce soap and Glycerin.
 Glycerin is a by product of soap making .
 Chemical Reaction
 Metallic salt of fatty acid, is a chemical name of soap.
 Laundry Soap HarshAlkali NaOH is used .
 Toilet Soap used KOH.

25. Glycerin is more valuable than soap so it must be
removed from soap and some of glycerin is left in soap to
help make it soft and to avoid the shrinkage of skin.
Salt is added to the wet soap causing it to separate out
into soap and spent lye and to avoid bunch formation.
The product is washed with water inorder to remove all
unwanted materials.
Spent lye and solid soap are withdrawn from soap kettle.
Glycerin removal and soap purification:

27. The solid soap from the pan is blended with builders and
additives in a special machine called crutcher.
Sodium silicate is added in laundry soap which acts as a
inhibitor which is then shaped into bars and cutting is carried
out.
Soap still contains little quantity of water which is evaporated
by dry air.
After drying, specific perfumes and colors are used for toilet
soap and after that final packing is carried out.
Finishing :

28. FINISHING PROCESS

29. Soaps are eco friendly and biodegradable because are of
natural origins.
Soaps are not effective in hard water because when it reacts
with the magnesium or calcium salts which makes water hard
to produce insoluble precipitate called scum.
When we use soap and hard water , the amount of lather
produced is very small.
They have weak cleaning properties than detergents because
no specific additives and builders are used in soap.
Advantages and Disadvantages