Hawasa University Chemical Engineering Department

HAWASSA UNIVERSITY

INSTITUTE OF TECHNOLOGY

CHEMICAL ENGINEERING DEPARTMENT

Final Industrial Attachment Report

Hosting company: ETAB Soap Factory

Duration: October 2019 – January 2021

Name: Hailu Haliso(I.D 0834/10)

Academic Advisor: Dr Tadesse
Company advisor: Samuel

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Declaration
I hereby, declare this final internship report is the result of my work except as cited in the
reference and compiled according to the internship report guideline given.

Name of student: Hailu Haliso

Signature:

Date:

This final internship report has been submitted for examination with my approval as University
advisor.

Advisor Name: Dr Tadesse

Signature:

Date:

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Acknowledgement
First of all I want to praise and give honor to the almighty God for his aid in every aspect of my
life. Next I would like to express my great gratitude to my family especially for my brother
Kebede Haliso who shapes me in a disciplined way and as much as possible for his provision of
every material that is vital unto me.

Then, I would like to thank my instructor Dr. Tadese (my academic advisor) for his wonder
support during my internship period. He was inspiring me to do my work and project in a well
precise manner. And also I would like to express my special thanks to Samuel (Sami) (company
advisor) and Sisay for their support in everything what I want. Finally, I desire to thank other

Company staffs for their willing to share their knowledge

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Contents pages

Declaration......................................................................................................................................II
Acknowledgement.........................................................................................................................III
Abstracts.....................................................................................................................................VIII
List of tables..................................................................................................................................IX
List of figures..................................................................................................................................X
Acronym........................................................................................................................................XI
Chapter One.....................................................................................................................................1
Background of ETAB soap factory.................................................................................................1
1.1 History of the company..........................................................................................................1
1.2 Management and organization of ESF...................................................................................3
The individual departments have their own tasks. The tasks of the general manager and each
sdepartment are described as follow....................................................................................................4
General Manager.................................................................................................................................4
Administration department..................................................................................................................5
Quality control.....................................................................................................................................5
Marketing department..........................................................................................................................5
1.3 Annual production plan of ETAB soap factory.........................................................................6
1.4 Objectives...............................................................................................................................7
1.4.1 General objective........................................................................................................................7
1.4.2 Specific objective........................................................................................................................7
CHAPTER TWO.............................................................................................................................8
Literature review of soap factory.....................................................................................................8
2.1 introduction............................................................................................................................8
2.2 Soap Manufacturing Process..................................................................................................8
Chapter Three................................................................................................................................13
Description of ETAB soap factory Production process.................................................................13
ETAB soap factory use so many unit operation for production of final quality soap product, so the
process description of each unit operation are the following;............................................................13
3.1 Utility preparation for production process...........................................................................13

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The main utilities of ETAB soap factory are water and steam. Hence before performing the main
production we have to make ready these utilities...............................................................................13
3.1.1 Water treatment process............................................................................................................13
3.1.2 Boiler........................................................................................................................................15
3.1.3 Chiller.......................................................................................................................................17
3.2 Raw material preparation.....................................................................................................19
3.2.1 Receiving and storage of raw materials....................................................................................19
3.2.2 Sodium silicate melting............................................................................................................22
3.2.3 Raw tallow melting...................................................................................................................24
3.2.4 Bleacher....................................................................................................................................25
3.2.5 Blender.....................................................................................................................................26
3.3 Saponification room (crutcher)............................................................................................28
 to make the soap formable and shiny (sodium silicate).............................................................28
Using the saponification values of the oils and their weights in gram, the required quantity of caustic
soda to be used can be obtained. Since caustic is in the form of powder first it should be dissolved in
water. So 1200 liter water is added to the crutcher and calculated amount of caustic soda was
weighed (17 sacks each containing 25 kg) and added to it.................................................................28
The caustic soda was stirred well using a stirrer until it blends with the water. The solution was
heated and stirred until concentration of the solution matches its required value. Then oil is pumped
and added to it. It was warmed in order to hasten the reaction between the caustic soda and the fat.
...........................................................................................................................................................29
When saponification occur sodium silicate was added to increase foaming capacity of soap and
giving the soap sticking behavior. The occurrence of saponification is known by visual sight of the
solution. Animal fats and plant oils contain compounds known as fatty acids. These fatty acids are
bound to glycerol to form triglycerides. In the presence of a strong base such as sodium hydroxide
the triglycerides breakdown to form the metal salt of the fatty acid. This reaction which is shown
below is called saponification which literally means the soap making. Saponification is an
exothermic and an auto catalytic reaction and is normally described as consisting of 3 stages;........29
3.4 Preparation and Packaging of products in to bar soaps.......................................................30
3.4.1 Temporary storage (feeding tank).............................................................................................30
3.4.2 Neat Soap Dryer (Atomizer with Cyclone and Condenser)......................................................31
3.5 Finishing processes..............................................................................................................34
3.5.1 Mixers.......................................................................................................................................34
3.5.2 Millers......................................................................................................................................36
3.5.4 Soap Moulds and Press (stamper).............................................................................................37

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3.5.5 Cutter........................................................................................................................................37
3.6 Packaging of products..........................................................................................................38
Chapter 4........................................................................................................................................39
Quality and assurance processes for ETAB soap factory..............................................................39
Chapter Five...................................................................................................................................48
Material and Energy Balance.........................................................................................................48
5.1 Material balance...................................................................................................................48
5.1.1 Mass balance on tallow melter..................................................................................................48
5.1.2 Mass balance on bleacher.........................................................................................................49
5.1.3 Mass balance batch formation & Blender.................................................................................50
5.1.4 Mass balance on saponification room.......................................................................................51
5.1.5 Mass balance on atomizer (vacuum dryer)................................................................................52
5.1.6 Mass balance on mixer.............................................................................................................55
5.1.7 Mass balance on vacuum plodder.............................................................................................56
5.2 Energy balance.....................................................................................................................58
5.2.1 Energy balance on Refiner........................................................................................................58
5.2.2 Energy balance on bleacher......................................................................................................60
5.2.3 Energy balance on batch formation...........................................................................................61
5.2.4 Energy balance on blender........................................................................................................63
5.2.5 Energy balance on saponification kettle (creature)...................................................................64
5.2.6 Energy balance on temporary storage.......................................................................................68
5.2.7 Energy balance on vacuum dryer..............................................................................................69
5.2.8 Energy balance on sodium silicate dissociation tank................................................................70
5.2.9 Energy balance on boiler..........................................................................................................71
Chapter Six....................................................................................................................................73
Social And Environmental Analysis..............................................................................................73
6.1 Social analysis......................................................................................................................73
6.2 Environmental analysis........................................................................................................74
Chapter Seven................................................................................................................................75
Case Study.....................................................................................................................................75
7.1 Challenges and problems of the company...........................................................................75

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7.2 ..............................................................................................................................................75
7.2.1 Background...............................................................................................................................75
7.2.2 Hypothesis................................................................................................................................76
7.2.3 Statement of the problem..........................................................................................................76
7.2.4 Objective...................................................................................................................................77
7.2.4.1 General objective...............................................................................................................77
7.2.4.2 Specific objectives.............................................................................................................77
7.2.5 Literature review.......................................................................................................................77
7.2.5.1 Benefits of Soybean oil for soap........................................................................................77
7.2.5.2 Soybean oil Extraction.......................................................................................................77
7.3 Economic Analysis of My Project.......................................................................................80
Chapter Eight.................................................................................................................................82
Problems and Recommendations of the Company........................................................................82
8.1 Problems and Challenges.....................................................................................................82
8.2 Conclusion and Recommendation.......................................................................................84
Chapter Nine..................................................................................................................................88
Overall benefits gained from the internship..................................................................................88
9.1 Practical skills......................................................................................................................89
9.2 Theoretical skill....................................................................................................................89
9.3 Interpersonal communication skills.....................................................................................89
9.4 Team playing skill................................................................................................................90
9.5 Leadership skills..................................................................................................................90
Work ethics related issues..........................................................................................................90
9.6 Entrepreneurship skills.........................................................................................................91
References......................................................................................................................................92
Appendices....................................................................................................................................93

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Executive Summary
ETAB soap factory produces a variety of soaps for local (country) markets. I have spent four
month by working on this company. I categorize this final internship report in to nine basic
topics to clearly show what I have understood from my internship program in ETAB.

On this Literature Introduction, organizational establishment, material and energy balance,

Environmental and socioeconomic analysis as well as the whole Process from raw material
preparation to Finishing discussed with great depth. In addition i tried to harmonize my report
byincluding overall benefits of the internship program and recommendation for the problem of
the company, further more I do my own project to enhance the profitability of ETAB plant

ABSTRACT Soaps are the sodium salts or potassium salts of stearic acids or any other fatty acids. They
are prepared by the saponification process, which is, reacting the oil which contain triglycerides with
caustic soda (NaOH) to give the soap. However different oils have different composition of fatty acids
which are responsible for different properties of soaps made out of them. In the present work 5
different types of oils are taken. They are blended in various ratios to prepare 14 different samples of
soap. Different properties of these samples were analyzed to see which soap is the best one. The
cleansing and lathering properties of all samples were compared. The blend of coconut oil and castor oil
at 3:1 ratio is found out to be the best with 76.8% of TFM and 89.46% of yield. The best blend is
analyzed for various properties and they were compared with that given in the literature. The
saponification values, iodine values of coconut oil and castor oil were found out and these values were
also found for the blend. It was found that the blend was having SAP value of 230.4 and iodine value of
40 which are higher than the individual values. Thus soap prepared using blend of both these oils has
better properties than the soaps prepared by individual oils.

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Biodiesel is obtained through the transesterification reaction of vegetable or animal

oil, with ethanol or methanol and in the presence of a catalyst, with better ignition
properties, pour point and flow properties (viscosity and specified density). Besides
the transesterification, which is the best know method and used in large-scale for
production of biodiesel, there are three other: dilution, micro-emulsification and
pyrolysis (Ferrari, Oliveira, & Scabio, 2005; Knothe, Gerpen, Krahl, & Ramos, 2006)

III. Advantages of our gas oil fired steam boiler

1).Adopt the latest international technology of big volume combustion design and deploy world
famous burner, making the boiler has more fully burning, higher efficiency and lower failure rate.
2).Adopt the advanced structure of corrugated furnace. On one hand, it increases the heat-
transfer area. On the other hand, it can bear the free expansion of furnace after heating. 
3).Adopt thread smoke tube, which can enhance heat-transfer and eliminate welding stress. 
4).Adopt double seal structure with the back of inner seal surrounded by water, which makes
the boiler more reliable and maintenance costs lower.
5). double door design, it is very convenient for checking and maintainace.
6). All kinds of protective functions, such as over-temperature, over-pressure, water shortage,
leak checking, flame-out and so on,ensuring safe and reliable operation of boiler

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Acknowledgements It is no exaggeration to state that without insisting the Almighty God, Jesus Christ,
would not have been in a position to finalize successfully accomplished of this thesis paper. So, glory to
him and his mam. I would like to express heartfelt appreciation and gratitude to my advisors, Zemenu
Aynadis (Ass. Prof.) for his valuable advice and technical support in strengthening the work to be
completed. In fact, this thesis would not have come in its present form had it not been complemented
by their proper follow up in reshaping and organizing. I am greatly indebted to my wife w/o
Askalemaryam ayisheshim as well friends Tilahun Nebiyu and Abeba who shared my burdens
throughout the course of the study. I also extended my special thanks to biny , girum and Mohamed.

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