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Chemical engineering Thesis and Dissertations
2018
production of anti dandruff shampoo

from aloe Vera plant
Birhanu, Abadi
http://hdl.handle.net/123456789/11095
Downloaded from DSpace Repository, DSpace Institution's institutional repository
[PRODUCTION OF ANTI DANDURFU SHAMPOO] 2010 E.C
BAHIR DAR INSTITUTE OF TECHNOLOGY
FACULTY OF CHEMICAL AND FOOD ENGINEERING

DEPARTMENT OF CHEMICAL ENGINEERING
Project tittle: production of anti-dandruff shampoo from aloe Vera plant
Prepared by: ID
Abadi Birhanu 0600001
Ashenafi H/Michal 0600257
Fanus Melese 0600706
ADVISOR Mr. Melkamu ,
2010 E.C
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DECLARATION
We declare that this project is based on our original work. We write this project by the
knowledge gets from the literatures. We have dually acknowledged and refereed all materials
used in this work. We understand that non-adherence to the principles of academic honesty and
integrity, misrepresentation/ fabrication of any idea/data/fact/source will constitute sufficient
ground for disciplinary action by the university and can also evoke penal action from the sources
which have not been properly cited or acknowledged thesis.
Advisor Name Signature Date
Melkamu Birile …………………… …………………
Student Name
Abadi Birhanu …………………… ………………….
Ashenafi H/Michael …………………… ………..…………
Fanus Melese ……………………. …………………..
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ACKNOWLEDGEMENT
First of all, we would like to thank God for giving us the strength to finish our project. He gave
us the courage and wisdom to pursue this original and challenging idea and contribute a basic
knowledge foundation for the production of anti-dandruff shampoo.
Next, we would like to thank the School of Chemical engineering for preparing this semester
project program. Special thanks to Mr.melkamu our advisor, who relentlessly supported and
advised us from the beginning of the project and our lab assistance.
Besides, we would like to thank the owner of” SMART DETERGENCY PRODUCTION”
enterprise for gave us different chemicals which used to produce anti-dandruff shampoo.
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ABSTRACT
Dandruff is a common disorder affecting the scalp condition caused by yeast Pityrosporum.
Dandruff can‟t be completely eliminated but can only be managed and effectively controlled.
A shampoo is detergent containing surfactant (i.e. surface active material) in a suitable form
which when used under the specified conditions will remove surface grease, dirt, and skin debris
from the hair shaft and scalp without adversely affecting the user. Various anti-fungal agents are
employed in hair care preparations for the treatment dandruff. These products show many side
effects like loss of hair, increased scaling, itching and irritation. Hence the project concerned to
formulate natural anti-dandruff shampoo which is effective in terms of safety and treating the
dandruff condition better than the chemical based anti-dandruff shampoo. Natural anti-dandruff
shampoos were formulated using natural plant based ingredients like Lemon juice and Aloe Vera
gel and other ingredients for preparing base shampoo. The formulated shampoos were subjected
to evaluation parameters like pH, viscosity, Percentage of solids contents, conditioning action,
cleansing action, Foaming ability and foam stability, anti-fungal activity test, eye and skin
irritancy and physiochemical evaluation. The production of anti-dandruff shampoo was
‟
performed in three different mixer s speed at revolution per minute (rpm) of 100, 200 and 300
with different amount of sodium chloride (10g, 15g and 20g). It was found that 300rpm and 15g
of NaCl are the desired speed and amount of salt respectively to formulate the anti-dandruff
shampoo. Based on the chemicals involved, Different formulations of anti-dandruff shampoo
(F1, F2 and F3) were made. Out of the three formulations, formulation one enhanced desired pH
value = 5.87 and viscosity = 900cp. These were subjected to safety studies on animals, such as
eye irritation test and skin sensitivity test. From these formulations, F1 exhibited good safety
without any irritation and sensitivity. Besides, formation one was found good conditioner for
hair. Stability studies for a period of one month were conducted for F1 formulation showed
negligible changes in its physicochemical properties. All formations were good for anti-fungus
activities.
Key words: Aloe Vera, Dandruff, anti-dandruff, Pityrosporum.
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Table Contents
DECLARATION ............................................................................................................................. i
ACKNOWLEDGEMENT .............................................................................................................. ii
ABSTRACT ................................................................................................................................... iii
List of Tables ............................................................................................................................... viii
List of acronyms ............................................................................................................................ ix
Chapter one ..................................................................................................................................... 1
Introduction ..................................................................................................................................... 1
1.1 Background ........................................................................................................................... 1
1.2 Statement of the problem ...................................................................................................... 4
1.3 Objective ............................................................................................................................... 4
1.3.1 General Objective ........................................................................................................... 4
1.3.2 Specific Objective........................................................................................................... 4
1.4 Scope of the study ................................................................................................................. 5
1.5 Significance of the Study ...................................................................................................... 5
Chapter two ..................................................................................................................................... 6
Literature review ............................................................................................................................. 6
2.1 Aloe vera ............................................................................................................................... 6
2.2 Anti-dandruff shampoo ......................................................................................................... 7
2.3 formulation of antidandruff shampoo ................................................................................... 8
Chapter Three................................................................................................................................ 10
Materials and methods .................................................................................................................. 10
3.1 Material and equipment ....................................................................................................... 10
3.2 Methods ............................................................................................................................... 11
3.2.1 Extraction of lemon juice ............................................................................................. 11
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3.2.2 Extraction of aloe Vera gel ........................................................................................... 12
3.2.3 Weighing ...................................................................................................................... 13
3.2.4 Mixing .......................................................................................................................... 14
3.3 Characterization of anti-dandruff shampoo......................................................................... 15
3.3.1 Determination of pH ..................................................................................................... 16
3.3.2 Viscosity ....................................................................................................................... 16
3.3.3 Foam ability and Foaming Stability ............................................................................. 17
3.3.4 Detergency and cleaning action .................................................................................... 17
3.3.5 Anti-microbial test ........................................................................................................ 18
3.3.6 Non-irritating (free eye and skin irritancy) ................................................................... 20
3.3.7 Stability Studies ............................................................................................................ 20
3.3.8 Determination of the Percentage of Solid Contents ..................................................... 20
Chapter Four ................................................................................................................................. 21
Material and Energy Balance ........................................................................................................ 21
4.1 Material balance .................................................................................................................. 21
4.2 Energy Balance ................................................................................................................... 27
4.3 Equipment selection, specification and design ................................................................... 28
4.3.1 Equipment selection and specification ......................................................................... 28
4.3.2 A basic stirred tank design............................................................................................ 30
4.3.3 Design of impeller size and power consumption.......................................................... 31
4.3.4 Impeller size design and power consumption............................................................... 32
Chapter Five .................................................................................................................................. 34
Cost Estimation and Evaluation .................................................................................................... 34
5.1 Cost Estimation ................................................................................................................... 34
5.1.1 Estimation of total capital investment (TCI) ................................................................ 34
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5.1.2 Estimation of Total product cost .................................................................................. 36
5.2 Economic evaluation ........................................................................................................... 40
5.2.1 Rate of investment ........................................................................................................ 41
Chapter Six.................................................................................................................................... 42
Result and Disscussion ................................................................................................................. 42
6.1 Effect of sodium chloride on viscosity................................................................................ 42
6.2 Effect of impeller‟s speed on viscosity ............................................................................... 43
6.3 Solid content determination ................................................................................................ 43
6.4 Physicochemical Evaluation of the Prepared Shampoo during Stability ............................ 44
6.4.1 Physical Appearance and Visual Inspection ................................................................. 44
6.5 Shampoo formulation .......................................................................................................... 44
6.5.1 Formulation one (F1) .................................................................................................... 45
6.5.2 Formulation two (F2).................................................................................................... 46
6.5.3 Formulation three (F3).................................................................................................. 46
6.6 The effect of F1, F2 and F3 on eye and skin irritancy ........................................................ 46
6.7Anti-biotic effect .................................................................................................................. 49
6.8 Conditioning action ............................................................................................................. 50
6.9 Cleansing action of anti-dandruff shampoo ........................................................................ 50
Chapter Seven ............................................................................................................................... 51
Conclusion and Recommendation ................................................................................................ 51
7.1 Conclusion........................................................................................................................... 51
7.2 Recommendation ................................................................................................................. 51
Reference ...................................................................................................................................... 53
Appendix ....................................................................................................................................... 56
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List of Figures
Figure 2.1: aloe vera plante ............................................................................................................. 7

Figure 3.1: aloe vera showing by animation ................................................................................. 12
Figure 3.2; aloe Vera sample cutting from the source .................................................................. 12
Figure 3.3 this is the animation how to cut the sample................................................................. 13
Figure 3.4: weighting the sample .................................................................................................. 14
Figure 3.5: Process flow diagram of antidandruff shampoo production ..................................... 14
Figure 3.6: the rpm and mixing..................................................................................................... 15
Figure 3.7: pH values .................................................................................................................... 16
Figure 3.8: viscosity value ............................................................................................................ 17
Figure 3.9: foam stability .............................................................................................................. 17
Figure 3.10: detergency and cleaning ........................................................................................... 18
Figure 3.11 anti-microbial tests .................................................................................................... 19
Figure 3.12: incubator ................................................................................................................... 20
Figure 4.1: material balance .......................................................................................................... 25
Figure 4.2: material balance for mixer 1 ....................................................................................... 26
Figure 6.1: the effect of NaCl on Viscosity .................................................................................. 42
Figure 6.2: the reference ............................................................................................................... 47
Figure 6.3: formation 3 ................................................................................................................. 47
Figure 6.6: effect of anti-microbial tests ....................................................................................... 49
Figure 6.7: conditioning ................................................................................................................ 50
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List of Tables
Table 1.1: key features of different shampoo ................................................................................. 2

Table 2.1 components of aloe vera and its functions ...................................................................... 6
Table 2.2 physico chemical property of anti-dandruff shampoo .................................................... 7
Table 3.1 materials with its function............................................................................................. 10
Table 3.2: equipment with its function ........................................................................................ 11
Table 4.1: statistical data of imported anti-dandruff shampoo from 2010 – 2014 ....................... 21
Table 4.2 time series analysis method to forecast the amount of Antidandruff shampoo ............ 22
Table 4.3: projection of imported anti-dandruff shampoo ............................................................ 24
Table 5.1: purchased equipment and their cost ............................................................................. 34
Table 5.2: direct costs and purchased equipment cost .................................................................. 34
Table 5.3: indirect costs and purchased equipment cost ............................................................... 35
Table 5.4: raw material cost .......................................................................................................... 36
Table 5.5: operating labor ............................................................................................................. 37
Table 6.1: physicochemical evaluation ......................................................................................... 44
Table 6.2: shampoo formulation ................................................................................................... 45
Table 6.3 standard value and the measured value......................................................................... 45
Table 6.4: shows that cleansing action of the shampoo ................................................................ 50
Table 1: shows that effect of sodium chloride and speed of mixer on viscosity .......................... 56
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List of acronyms
CAPB Cocamidopropl betain
CIP Carriage and insurance paid
d Impeller diameter
DC Direct cost
DIN Deutsches institute for norming
DV Vessel diameter
EDTA Ethylene diamine tetra acetic acid
FCI Fixed capital investment
H Height
hP Horse power
ID Indirect cost
L Length
m Meter
Ml Milliliter
N Revolution per minute of impeller shaft
NaCl Sodium chloride
NP Power consumption
NQ Flow number
NRe Reynolds number
NPV Net present value
P Power
PH Negative logarithm of the concentration of hydrogen ion
Q Volumetric pumping rate
RoR Rate of return/investment
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S Specific gravity
SDA Sabouraud dextrose agar
SLS Sodium lauryl sulfate
Tb Blending time
TbN Dimensionless blend time
TCI Total capital investment
TPC Total capital cost
V Volume
Vav Average velocity
π Pie
μ Viscosity
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Chapter one
Introduction
1.1 Background
The word shampoo in English is derived from Hindi chāmpo. The Hindi word referred to head
massage, usually with some form of hair oil. In the 1860s, the meaning of the word shifted from
the sense of massage to that of applying soap to the hair. Earlier, ordinary soap had been used for
washing hair. However, the dull film soap left on the hair made it uncomfortable, irritating, and
unhealthy looking [1].
Shampoos assumed importance as a product category with the advent of synthetic detergents.
These were developed in the 1930s, became widely used in Laundry markets by the mid- 1940s
and appeared in a shampoo format during the 1950s. Shampoos are probably the most widely
used hair products today. Based On synthetic detergents they are relatively insensitive to water
hardness, thus allowing for efficient rinsing since there are no scum residues. In the early days a
shampoo could be defined as an effective cleansing agent for hair and scalp, but today the
shampoo must do much more. It must leave the hair easy to comb, lustrous and controllable
whilst being convenient and easy to use [1]. Shampoos are typically viscous liquids, either clear or
Opaque, containing 20–40% solids, adjusted to approximately pH 5-6, Viscosities in the ratio of
700–1,300 centipoises [2-3].
The primary ingredient of a shampoo is the detergent, either from an organic soap or a synthetic;
Vegetable oil soaps, alkyl benzene sulfonates, sodium or triethanolamine alkyl sulfates, sulfated
monoglycerides, sulfated oils and nonionic are typical. The concentration used varies with the
individual detergent and the shampoo type and will vary from about 10% to 50%. Shampoos
usually include modifying agents such as opacifiers, clarifying agents, antifreezes, conditioning
and finishing agents, sequesstrants, thickening agents, proteins, foam builders, and antidandruff
agents. The use level of these modifiers is usually about 1% to 10%.
Depending on their functions, shampoos are used as cleaning agents for cosmetic purposes,
antidandruff agents, antiseborrhoeic agents and keratolytic agents [4].
Cleaning agent shampoos should be mild, effective, without causing irritation and should be used
daily or on alternate days as needed. They remove dust and excess oil from the hair.

Antidandruff agent treats dandruff due to fungi like pityriasis versicolor. Rapidly relieves scaling
and pruritus which are associated with fungal infections.
Antiseborrhoeic agents have cytostatic effect on cells of the epidermis and follicular epithelium,
thus reducing coenocyte production.
Keratolytic agents remove ointment, pastes, which are used in the treatment of psoriasis. They
also remove hard scales from the scalp.
Table 1.1 shows key features different shampoos
Table 1.1: key features of different shampoo
Type of Shampoo Key Features
Clarifying Contain heavy duty surfactants. Used to deep clean hair and
Shampoo remove the gunky buildup of conditioners, sprays, and gels.
Volumizing Add body to limp hair. Contain proteins that bond to hair and
Shampoo pump it up
Moisturizing Best choice for dry, flyaway hair; make split ends look better,
shampoo pull moisture onto hair to keep it from getting too dry.
Revitalizing Made for color treated, premed, and damaged hair. Use as a
Shampoo gentler cleanser, protect color from fading.
Dandruff Shampoo Contain medication that loosens and rinses away those annoying
flakes.
2-in 1 Shampoo With conditioner, save time.
Swimmers Remove chlorine and other minerals.

Shampoo
The visual perception of individually distinguishable flakes on the scalp, in the hair, or on the
clothing is considered an abnormal condition frequently referred to as dandruff, seborrheic
dermatitis, or multiple other names [5-6]. This condition is, however, most often referred to as

dandruff, especially in the public domain of non-technical literature and advertising. In the
medical literature, the same disorder, though often in a more severe form, is most commonly
referred to as seborrheic dermatitis. Historically, there have been multiple other descriptive
names reflecting the fungalcause of this condition, such as pityriasis simplex and pityriasiscapitis
(referring toPityrosporum) and furfuracea (referring to Malasseziafurfur). As all of these names
remain in use, we simply need to remember they represent a continuum of the same symptoms
based on the same causes and with similar treatment [5, 8]. More than 50% of adults may be
affected by these conditions, which suggests a high socioeconomic impact.
Dandruff is common condition, which is marked by itching. In some cases it can be

embarrassing and not easy to treat. Dandruff can start in early adolescence during puberty, and
lots of teens and adults live with it. Doctors don't know exactly what causes dandruff, but some
people think it happens when the oil glands and hair follicles produce too much skin oil (sebum).
Hormone levels are high during teen years, causing more oil production, which can lead to
dandruff. Dandruff is a common scalp disorder affecting almost half of the population at the
post-pubertal age and of any gender and ethnicity. It often causes itching. It has been well
established that keratinocytes play a key role in the expression and generation of immunological
reactions during dandruff formation. The severity of dandruff may fluctuate with season as it
often worsens in winter. Most cases of dandruff can be easily treated with specialized shampoos.
There is, however, no true cure. Those affected by dandruff find that it can cause social or self-
esteem problems, indicating treatment for both psychological and physiological reasons.
Anti-dandruff Shampoo is a hair care product that is used for the removal of oils, dirt, skin
particles, dandruff, environmental pollutants and other contaminant particles that gradually build
up in hair. It can carry out the duties of a regular shampoo but that also have specific active
ingredients to treat dandruff. Unfortunately, dandruff is an on-going issue that is caused by an
excess turnover of dead skin cells, which itself is caused by chronic inflammation of the scalp
through the action of the Malasseziaglobosa fungus [4-8].
Anti-dandruff shampoo formulation deals with the unique aspects of formulating for specific
body area that is on hair. Anti-dandruff shampoo formulations were classified based on the raw

material which it is made from. Those are: chemical based made anti-dandruff shampoo and
natural or herbal type of anti-dandruff shampoo.
The project focused on herbal or natural based anti-dandruff shampoo production. The project
presents diverse knowledge sets from dermatology (a branch of medicine concerned with the
diagnosis and treatment of skin or hair disorders), cosmetic chemistry, and product formulation.
It synthesizes the information into one cohesive unit for practical application by the
dermatologist, cosmetic chemist, formulator, or testing facility. Only by understanding all
aspects of anti-dandruff shampoo formulation can technology expand the hair care marketplace.
1.2 Statement of the problem
In Ethiopia the number of population increases from 66.537 to 107.534 million in 2010 to 2018
year dramatically [9]. Now days many people who suffer with dandruff are significantly
increasing as a result, the demand for anti-dandruff shampoo also increases. But it is not
sufficient for demand since it is imported from abroad in millions of dollars. Hence we initiated
to do our project to fulfill the demand and to minimize imported cost by producing the product in
our country. The most well-known use of anti-dandruff shampoo is to alleviate dandruff. In
addition to this, antidandruff shampoo can carry out the duties of a regular shampoo.
1.3 Objective
1.3.1 General Objective
Production of anti-dandruff shampoo from aloe Vera plant
1.3.2 Specific Objective
 Characterization of anti-dandruff shampoo

 To investigate the effect different parameters( speed of mixer and component proportion)
on the quality of anti-dandruff shampoo
 Performing cost estimation and evaluation to checking the profitability of our project.

1.4 Scope of the study

 Determination of the optimum mixers speed and components dosage for the desired anti-
dandruff shampoo production.
 Investigating effect of the product for human being usage
 Analysis of the project feasibility
1.5 Significance of the Study

The significance of this study project is introducing new product to the country and reducing the
foreign currency for the many anti-dandruff imported and other transportation expenses

Chapter two
Literature review
2.1 Aloe vera

It is a stem less or very short-stemmed plant growing to 80-100 cm tall, spreading by offsets and
root sprouts. The leaves are lanceolate, thick and fleshy, green to grey-green, with a serrated
margin. The flowers are produced on a spike up to 90 cm tall, each flower pendulous, with a
yellow tubular corolla 2-3 cm long. The tissue in the center of the aloe leaf contains a gel which
yields aloe gel or Aloe Vera gel.
Aloe Vera contains numerous vitamins and minerals, enzymes, amino acids, natural sugars and
Agents which may be anti-inflammatory and anti-microbial. The combination and balance of the
Plant‟s ingredients are what purportedly give it its healing properties. The part of the Aloe Vera
which is used is the leaves. The Aloe is an Emollient, Purgative and Vulnerary. It is also used for
its antibacterial, anesthetic and antiseptic properties, and is good to use as a tool for restoration of
tissue. It is most commonly used on burns and minor cuts, especially good for sunburns,
although it is being used for the treatment of skin cancer. Aloe is very useful on rashes caused by
Poison Ivy, and it may help to draw out infection. Table 2.1 shows components of aloe vera plant
and its functions.
Table 2.1 components of aloe vera and its functions
Components of Aloe vera Function

Acids antimicrobial, anti-helminitic (anti-parasitic
worms), wound healing for skin tissue and
Ulcers
Amino Acids required for repair and growth of hair
Enzymes - catalysts enabling chemical reactions to take
place
Lectin Anti-tumor effects.
Lipids principle structural components of living cells

Minerals Stimulates growing cells

Lactates and salicylates analgesic properties

Phenolics mild antiseptics and antimicrobials
Urea-Nitrogen pain killing effect
Vitamins contains 8 of the 13 recognized vitamins
Fig 2.1: aloe vera plante
2.2 Anti-dandruff shampoo

Anti-dandruff Shampoo is a hair care product that is used for the removal of oils, dirt, skin
particles, dandruff, environmental pollutants and other contaminant particles that gradually build
up in hair. Table 2.2 describes physico chemical property of anti-dandruff shampoo
Table 2.2 physico chemical property of anti-dandruff shampoo
Parameters Standard value

Viscosity (cp) 700 – 1100
pH 5–6
Density (kg/m3) 1010 – 1030
Solid content 20 – 24%
Foaming stability Good foaming
Physical appearance and visual inspection Clear and homogenous
Conditioning action Shine

Eye irritancy It does not change eye‟s color

Skin irritancy Non – harness and itching
Cleansing action Removes dirty, odor and oil…
2.3 formulation of antidandruff shampoo

Anusha et.al (2013) studied on formulation of herbal anti-dandruff shampoo which is effective
in terms of safety and treating the dandruff condition better than the chemical based anti-
dandruff shampoo. Herbal anti-dandruff shampoos were formulated using herbal based
ingredients like Lemon Grass Oil, Neem oil, Henna, Aloe Vera gel and other ingredients for
preparing base shampoo. The formulated shampoos were subjected to evaluation parameters like
visual inspection, pH, viscosity, Percentage of solids contents, Dirt dispersion, Surface tension,
Foaming ability and foam stability, anti-fungal activity test using Pityrosporum Ovale strain.
Formulation (F8) exhibited good antifungal activity i.e., maximum zone of inhibition. Hence it
was subjected to safety studies on animals, such as eye irritation test and skin sensitivity test. The
(F8) exhibited good safety without any irritation and sensitivity. Stability studies for a period of
three months were conducted for F8 formulation and showed negligible changes in their
physicochemical properties.
Ahmed M. Agiba et.al (2015) studied the Development & Optimization of Anti-Dandruff
Shampoo by Modifying its Rheological Behavior. Different formulations of 2 gm% ketoconazole
were prepared, using different percent concentrations of the rheology modifier (NaCl) as 0.8
gm%, 0.2 gm%, 0.4 gm%, 0.1 gm% at different pH values 5.5, 6.5 and 7.5. Experimental
formulations were prepared at different temperature and time intervals. The measurements of pH
and viscosity of the prepared shampoo were evaluated during stability. Stability studies were
carried out as per ICH guidelines for 18 months and monitored by validated stability indicating
HPLC method (linearity: 60-140 μg/mL; R2=0.9995; acceptable accuracy and precision %RSD
< 1.0%). The prepared ketoconazole shampoo was high stable at high pH (6.5-7.5) and at
temperature < 30 °C during the manufacturing process. Furthermore, the amount of rheology
modifier had a high significant effect on the stability of ketoconazole. Formulations containing
0.1 gm% NaCl showed better stability and exhibited ideal thixotropic rheological behavior.

M. Z. Haque * et.al (2014) conducted an experiment to evaluate the amount of dietary inclusion
of Aloe vera leaves. Many of the health benefits associated with Aloe vera have been attributed
due to the presence of protein, carbohydrate, fat etc. in the gel of the leaves. Proximate analysis
of the leaves revealed fat, 1.83%; protein, 10.50%; ash, 19.50%; carbohydrate, 56.27%;
phosphorous, 1.90 mg/g and energy, 290.08 kcal.
*Naga Padma P, Anradha K, Divya K, (2015) studied commercially available shampoos for
antifungal activity against a human dandruff isolate of M. furfu. Different plant extracts that
possess various active compounds which have antifungal activity could help to overcome the
incidence of the disease and also avoid the emergence of resistance in the pathogen. The plant
Extracts were tested in different concentrations like 1:5, 1:10, 1:20 and they were hibiscus, neem,
soap nut, etc. The inhibitory action was studied using agar well assay and disc diffusion method
and the results indicated in percentage of inhibition. The study was significant as not only
efficient known plant products with anti-dandruff activity could be compared with commercially
available shampoos but also their better efficacies at minimum concentrations could be
identified. This can help make a polyherbal mixture that could be incorporated in hair oil or
shampoos for better anti-dandruff activity.
M.Surya Prabha at el (2014) studied the development of a completely natural shampoo, in which
all the ingredients were plant derived material and were recorded anti-pityrosporum activity. In
the present investigation, physico-chemical parameters, conditioning effect, antifungal potential
against, Candida albicans, anti-bacterial effect against gram +ve and –ve bacteria, and stability
studies were evaluated. From this investigation it can be concluded that the formulation of anti-
dandruff herbal shampoo powder contain all good characters of an ideal shampoo and it was
found to be harmless, more effective and economic.

Chapter Three
Materials and methods
3.1 Material and equipment
Table 3.1 shows, the materials and there functions used in this project.
Table 3.1 materials with its function
Materials Function
Distilled water Diluents
Sodium chloride Thickener

Anti-dandruff agent, sequestering agent,
stimulate hair growth ,natural conditioner,
Aloe Vera gel or juice moisturizer, anti-microbial and ant-
inflammatory agent
Anti-bacterial &antifungal agent

natural anti-oxidant, anti-dandruff
Rosemary oil
EDTA(ethylene diamine tetra acetic acid) Preservative, chelating agent
Sodium silicate Foam stabilizer/thickener(20 surfactant) and pH

modifier
Lemon juice Natural cleanser , anti-dandruff, pH

modifier

cleansing, foam, condition, viscosity and

SLS aesthetic appeal
Table 3.2 shows that the equipment with its function for anti-dandruff shampoo production
Table 3.2: equipment with its function
Equipment Function
Beaker To hold the sample
Stirrer To mixing and make uniform
pH meter To measure pH
Viscometer To measure viscosity
Measuring cylinder To measure volume
Beam balance To measure mass
Thermometer To measure temperature
3.2 METHODS
3.2.1 Extraction of lemon juice
Getting the lemon warm and applying pressure is the two key components in maximizing juice
output. Both actions go a long way in weakening the membranes that trap the juice inside the
lemon‟s flesh. The lemon was sat out at room temperature. A room temperature lemon has a
softer texture that makes it easier to squeeze. The bowl was filled with warm water. The lemon
was warmed in a bowl of water up to 600 c. The water should be warm enough to feel the
warmth coming through the sides of the bowl, but it should not be boiling or steaming. The
lemon was placed inside the water and allowed it to put for 30 minutes. Once the skin felt
warm to the touch and before the water was cooled off, The lemon was pulled out. The lemon
was rolled before cutting. The lemon was cut lengthwise instead of crosswise. A simple, hand-
held press juicer was used to extract the juice.

3.2.2 Extraction of aloe Vera gel

Collection of Aloe vera plant: Aloe vera plant was collected from Raya. A mature and
healthy aloe plant is recognizable by its large, green leaves. It should be about 8 inches (20 cm)
long. Aloe grows from the center outward; making the outer most leaves the oldest, largest, and
richest of the leaves to use [10].
Fig 3.1: aloe vera showing by animation
Cut off some aloe Vera leaves: The outermost leaves of an aloe Vera plant Was Cut off using a
sharp knife at the base of the plant. The leaves do not grow back, but by only cutting a portion of
the plant, left it to continue to grow and produce more aloe Vera for us in the future.
Figure 3.2; aloe Vera sample cutting from the source
Clean off the cut aloe Vera: once the leaf was cut off, a yellow substance was begun to ooze
from the cut. In order to keep the plant from making a mess, the leaf was put vertically, cut end

down, into a bowl to allow the substance to continue coming out. Water was used to clean the
leaf from top to bottom [11].
The yellow ooze produced in this step was a sap called aloe latex. It is not the aloe Vera gel,
which is clear and thick in appearance, and we did not want it to be contaminated because latex
has laxative properties that may mess up our digestive track.
Remove the top sharp of the leaves: the sharp portion was cut off and discards. The previous
rinsing step was repeated for the top portion as it was also produced yellow ooze.
Fig 3.3 this is the animation how to cut the sample
Remove the spines: the hard, a spine edge on either side of each leaf was removed. The skin of
the aloe Vera leaf was sliced. That is the thin, outer green. The gel was removed and stored. The
gel was cut and washed for easier storage. The aloe Vera gel was rinsed itself 2-3 times to be
sure that it was free of any aloe latex residue. [12]. spoon was used to scrape up any excess gel
left over along the skin. Store all of the gel extracts was stored.
3.2.3 Weighing
All ingredients were weighed to ensure accuracy in the ingredients proportions.

a(mass balance) b(sample measuring)
Figure 3.4: weighting the sample
3.2.4 Mixing
Fig 3.5: Process flow diagram of antidandruff shampoo production

10 % (w/w) of sodium lauryl sulfate (SLS) was added to 40% (w/w) of deionized water with
agitation. The ingredients were mixed until it became uniform. 20% (w/w) of aloe Vera gel, 1.5%
(w/w) of lemon juice and 5% (w/w) of sodium silicate were added to the mixture of sodium
lauryl sulfate with agitation. All the ingredients were mixed (mixer one) until the solution
became uniform.
In a separate vessel (mixer 2), 1% of sodium chloride and 0.2% (w/w) of ethylene diamine tetra
acetic acid (EDTA) were slowly sifted into 21.85% (w/w) of deionized water. The ingredients
were kept at uniform solution. The solution from mixer one and mixer two was transferred into
the main mixer (mixer 3). The solution was mixed for time 40 minute with speed of the mixer
at100, 200 and 300 rpm and with amount of salt 10g, 15g and 20g. While the solution was being
mixed, 0.3% (w/w) of rosemary oil and 0.15% (w/w) of fragrances was added into the main
mixer (mixer 3). The whole solution in the main mixer was mixed until it becomes uniform. PH
and viscosity was checked and Adjusted as required.
a(rpm adjusted) b(mixing the sample)
Figure 3.6: the rpm and mixing
3.3 Characterization of anti-dandruff shampoo
It is important to design anti- dandruff shampoo with its outcome clearly in view. Desirable
qualities for a shampoo are: Lathering in hard or soft water, easily and completely removable
lather, without leaving a residue, Safe for repeated use, non-Irritating, chemically and physically
stable, and not damaging to the eyes and skin (free eye and skin irritancy), Anti-microbial.
Anti-dandruff shampoo will be characterized physically by measuring its viscosity by
viscometer, its density and pH by pH meter.
3.3.1 Determination of pH
PH was measured at 30 °C ± 2 °C, by using pH meter (Digital pH meter)
a(pH value of f3) b(pH value of f2) c(pH value of f1)
Figure 3.7: pH values
3.3.2 Viscosity
The viscosity of the prepared shampoo was determined at 30 0C ± 2 using Brookfield
Viscometer rotated at 20 rpm, using spindle 64. The temperature and sample container‟s size was
kept constants during measurements.

Figure 3.8: viscosity value
3.3.3 Foam ability and Foaming Stability

Cylinder shake method was used for determining foaming ability of the prepared shampoo. 50
ml of 1% of the prepared shampoo was placed in a hand-closed 250 ml graduated cylinder and
shaken for 10 times. The total volume of the foam content after shaking for 1 min. was recorded.
Foam stability was evaluated by shaking the volume of foam at 1 min. intervals for 4 minutes.
Figure 3.9: foam stability
3.3.4 Detergency and cleaning action

a(before washing) b(during washing)
C (after washing)
Figure 3.10: detergency and cleaning
15gm sample of soiled and oiled human hair was placed at 30°c in 500ml cylinder which
contains 50ml water and 3 gm. of shampoo. The measuring cylinder was shaken 30 times a
minute for 4 minutes. Then, it was washed with sufficient amount of water, then after, the hair
was dried and weighed. The amount of soil is removed under these condition is calculated.
3.3.5 Anti-microbial test

Twenty four hours broth culture of the test organism was used for the study. The culture in the
Sabouraud Dextrose Broth with olive oil was used for inoculation of the tubes with the test
Ingredients and incubated at 30 0C for 24 hr

a (fungus or dandruff) b(dextrose sample)
c(hydrolyzes of the material) d (measuring the sample)
Figure 3.11 anti-microbial tests

After that, a loop full of broth culture was streaked on a Sabouraud Dextrose Agar (SDA) plate
over laid with olive oil to detect the presence or absence of growth of Malassezia. 4μl of
shampoo (containing active ingredients) were weighed separately in the Petri plates and the
molten SDA was poured and mixed thoroughly. Twenty μl of culture was spread over the agar.
The plates were incubated at 30o C for 3-5 days. Experiments were done in triplicates with
suitable controls.

a(droplet of shampoo) b(incubator) c(beater dish)
Figure 3.12: incubator
3.3.6 Non-irritating (free eye and skin irritancy)

Most shampoos are formulated as either neutral or slightly acidic to minimize the damage to the
hair. The pH of shampoo helps in minimizing irritation to the eyes, prevents swelling, promotes
Tightening of the scales, enhances the qualities of hair and maintains the hair, and maintains
Ecological balance of the scalp. Rabbit was used to determine the eye and skin irritancy of the
shampoo. 4ml of shampoo was transferred to the skin of rabbit. Likewise a droplet of shampoo
was inserted into the eye of the rabbit. After 2hrs the effect was observed
3.3.7 Stability Studies

Shampoo samples were stored at 30 °C ± 2 °C for a period of 1 month. Samples were withdrawn
at regular interval 1, 2, 3 and 4 weeks for physical and chemical stability evaluation.
3.3.8 Determination of the Percentage of Solid Contents

Four grams of the prepared shampoo were placed in a dry clean previously weighted evaporating
dish. The dish and shampoo were weighed to confirm the exact weight of the shampoo. The
evaporating dish with the prepared shampoo was placed on the hot plate until the liquid portion
was totally evaporated and solids were precipitated. The percent weight of solids after drying
was calculated.

Chapter four
Material and Energy Balance
4.1 Material balance

Assume there are 26 working days per month and there are 300 working days per year excluding
holydays and maintenance. Assume total capacity of the plant using three mixing machines two
of which is used for mixing the oil phase and water phase separately, the third mixer serves as
the main mixer for making shampoo. Assume that time taken for raw material preparation plus
mixing the two phases plus making the shampoo takes an hours.30 minutes for raw material
preparation, 40 minutes for mixing the two phases and 25 minutes for the preparation of
shampoo. Take 9 hour working day including 1 hour which goes to lunch time.
Number of bath per a day is =No of working hours/time to finish single bath
= (16) hr x 60min/hr divided by 95min
= 10batch/day.
To calculate the bases which will be produced per day: bases in L/batch = (total capacity per year
projected from market analysis) divided by (number of days per year x number of batch per day).
Hence, market projection must be done.
Table: 1 Statistical data of imported anti-dandruff shampoo from 2010 – 2014 [13]. Average
density of standard shampoo =1020kg/m3 [14].
Table 4.1 shows statistical data of imported anti-dandruff shampoo from 2010 -2014.
Table 4.1: statistical data of imported anti-dandruff shampoo from 2010 – 2014
Year Net weight(kg) Volume(m3) Volume(L)
2010 11728.01 11.509 11509
2011 1527.85 1.499 1499

2012 5263.06 4.9558 4955.8
2013 1783.32 1.7500 1750
2014 1679.33 1.648 1648
Market projection of imported anti-dandruff shampoo to the present and

future
Using time series analysis method we can forecast the amount of Antidandruff shampoo. For this
analysis let 2010 be year 1 and proceeding year will continue by the same difference number
until 2020. By using this formula we can forecast the amount of antidandruff ruff shampoo.
∑ ∑ ……………………………………………..1
∑ ∑ ∑ ……………………………………2, where X =years, n =number
Of period observations m=slope a=y-intercept
Table 4.2 shows time series analysis method to forecast the amount of antidandruff shampoo.
Table 4.2 time series analysis method to forecast the amount of Antidandruff shampoo
Year (x) Actual quantity of X*ya X2

anti-dandruff
shampoo (ya)
2010=1 11728.01 11728.01 1
2011=2 1527.85 3055.7 4
2012=3 5263.06 15789.18 9
2013=4 1783.32 7133.28 16
2014=5 1679.33 8396.65 25

Σx=15 Σya=21981.57 Σx*ya=46102.82 Σx2=55
By using the above equations it becomes:
21981.57=a +m (15)……………………………..eqn.1
46102.82=a (15)+ m (55)…………………………eqn.2 That means
15m +a=21981.57……………………………….eqn.3
15a +55m=46102.82…………………………….eqn.4
From this
A =21981.57 15m…………………….substitute this in equation 4
15a +55m=46102.87
15(21981.57 15m) +55m=46102.82
329723.55 225m +55m=46102.82
283620.73/170=170m
M=1668.357 and a= -3043.788
The equation of the market projection was
Y=mx +a
Y=1668.357x - 3043.788
Calculated quantity of anti-dandruff shampoo (yc) becomes:
Yc for 2010=1668.357 (1) - 3043.788= 1375.431
Yc for2011=1668.357(2) -3043.788=292.926
Yc for 2012=1668.357 (3) - 3043.788=1961.283

Yc for 2013=1668.357 (4 ) - 3043.788=3629.64
Yc for 2014=1668.357(5) - 3043.788=5297.99
Yc for 2020=1668.357(11) -3043.788=15308.139
To get adjusted estimation of anti-dandruff shampoo in year 2020 becomes
Average of ya/yc = (11728.01/1375.431) + (1527.85/292.926) + (5263.06/1961.283)

+1783.32/3629.64+1679.33/5297.99
Avgya/yc=0.1806
Y adjusted for year 2020=average of (ya/yc) (yc for 2020)
=0.1806 *15308.139
=2764.649 kg of an antidandruff shampoo for 2020
To get the volume of antidandruff shampoo of 2020
m=2764.649 kg and density=1020kg/m3
Volume=mass/density= (2764.649kg/1020kg/m3) =2.71045m3
Table 4.3 shows Projection of imported antidandruff shampoo for year of 2020. [12]
Table 4.3: projection of imported anti-dandruff shampoo
Year Net weight (kg) Volume (m3) Volume (L)
2010 11728.01 11.509 11509
2011 1527.85 1.499 1499
2012 5263.06 5.1649 5164.9
2013 1783.32 1.7500 1750

2014 1679.33 1.648 1648
2020 2764.649 2.713 2713
Use average quantity of the imported anti-dandruff shampoo for deciding plant capacity is:
Vav = (11509+1499+5164.9+1750+1648) /5 = 4314. 18 L/year
Assuming that the market share of the plant takes 50% of imported anti-dandruff shampoo
Plant capacity =65%* 4314.18L/yr. =2804.17 L/yr. the bases which will be produced per day is:
= (2157.09L /yr) divided by (300 days/yr *10batch/yr) =0.934739L/batch. Total capacity of the
plant = (No. of days per year (No. Of batch per day) (mass of shampoo per batch) - (mass of
shampoo lost being adsorbed at the surface. Assume mass of shampoo lost being adsorbed = 1%
of shampoo Total plant capacity;
Total plant capacity = (300day/yr) * (10 batch/day) (0.934739L/batch) - (1% * 0 .934739L/batch

* 300day/batch * 10 batch/day) = 2801.4127L/yr.
Figure 4.1: material balance

Mixer 1
Fig 4.2: material balance for mixer 1
Volume of Solution = distilled water + SLS + sodium silicate (SL) + aloe Vera + lemon juice
Annual quantity of SLS = plant capacity * 0.1 =2,135.52L/yr *0.1 = 213.552L /yr
Annual quantity of SL = plant capacity * 0.05=2,135.52L /yr * 0.05 = 106.776L/yr
Annual quantity of distilled water = plant capacity * 0.4 =2,135.52L /yr *0.4 = 854.21L/yr
Annual quantity of lemon juice = Total plant capacity* 0.015 =2,135.52L /yr *0.015=
32.033L/yr
Annual quantity of aloe Vera gel = Total plant capacity * 0.2 =2,135.52L /yr * 0.2 = 427.104L/yr
Total volume of solution 1 = (213.552 + 106.776 + 854.21 + 32.033 + 427.104)L/yr
Total volume of solution 1 =1,633.675L /yr
Mixer 2

Volume of solution 2 =Volume of EDTA + Volume of NaCl + volume of D.w

Volume of EDTA = mass of EDTA/density of EDTA =0.2/0.86=0.2325
Annual quantity of EDTA = Total plant capacity % of EDTA
= 2135.52 L/yr* 0.002325= 4.965 L/yr
Volume of salt (NaCl) = mass of salt/density of salt= 1g/2.17ml= 0.461ml
Annual quantity of salt = Total plant capacity % salt= 2135.52 L/yr* 0.00461= 9.8447 L/yr
Annual quantity of distilled water =2135.52 L/yr * 0.2185 =466.6 L/yr
Volume of solution 2= (4.965 + 9.8447 + 466.6) L/yr= 481.409 L/yr
Mixer 3
Volume of shampoo =volume of solution 1+ volume of solution 2 + fragrance + rosemary oil

Annual quantity of rosemary oil = Total plant capacity % rosemary oil = 2135.52 L /yr 0.0015=
3.2 L/yr
Fragrance= Total plant capacity % Fragrance =2135.52 L/yr* 0.0015= 3.2 L/yr
Volume of shampoo = (1,633.675 + 623.433 + 3.2 + 3.2) L/yr = 2,263.5 L/yr
4.2 Energy Balance

The mixing process is at room temperature and hence exothermic reaction .heat can be provided
to facilitate the ease of mixing especially if there are raw materials that need melting in order to
be mixed thoroughly. But we didn‟t use any raw material that needs melting and therefore there
is no energy balance to be done.

4.3 Equipment selection, specification and design
4.3.1 Equipment selection and specification
Pumps
Pumps are used to transfer material from premix vessel to the manufacturing vessel only if the
vessel is not under vacuum. If it is under vacuum the premix is automatically transferred into the
main vessel through vacuum.
Transfer pumps are required for the following:
 Transferring surfactants to premix / main vessel.

 From main vessel to storage vessels.
 From storage vessel to filling machine
Rotary pumps
Types of rotary pumps include cam-and-piston, internal-gear, lobular, screw, and vane pumps.
Gear pumps are found in home heating systems in which the burners are fired by oil. Rotary
pumps find wide use for viscous liquids. When pumping highly viscous fluids, rotary pumps
must be operated at reduced speeds because at higher speeds the liquid cannot flow into the
casing fast enough to fill it. Unlike a centrifugal pump, the rotary design will deliver a capacity
that is not greatly affected by pressure variations on either the suction or discharge ends. In
services where large changes in pressure are anticipated, the rotary design should be considered.
Globe valves
Globe valves are normally used, though the other types can be used. Butterfly valves are often
used for the control of gas and vapor flows. Automatic control valves are basically globe valves
with special trim designs. The careful selection and design of control valves is important; good
flow control must be achieved, whilst keeping the pressure drop as low as possible. The valve
must also be sized to avoid the flashing of hot liquids and the supercritical flow of gases and
vapors.
Pipeline

Interconnecting pipeline is provided for the plant as per the layout of the clients‟ room size. All
pipelines are electro polished from inside and outside. All joints are DIN standards quick open
able types. Pipelines are used for transferring the surfactants from storage tank to premix vessels,
from premix vessels to manufacturing vessels and from manufacturing vessels to storage vessel
and from storage to filling line. The capital cost of a pipe run increases with diameter, whereas
the pumping costs decrease with increasing diameter. The most economic pipe diameter will be
the one which gives the lowest annual operating cost.
Main shampoo manufacturing vessel
Manufacturing vessel is cylindrical vessels with dished bottom vessels. Top of the vessel is also
dished end welded. Agitator assembly in the manufacturing vessel, slow speed pitch blade
agitator is provided in the manufacturing vessel. However for best results contra rotating or semi
contra rotating agitators are normally preferred by most of the manufacturers for excellent
quality of the shampoo produced. CIP turbo disk is provided at the top of the vessel for cleaning.
Suitable nozzles, manholes, valves etc are provided on the vessel.
Premixing vessel
Premixing vessel is cylindrical vessels with dished bottom vessels. Top of the vessel is also
dished end welded or can be provided with loose lid too. Agitator assembly in the premix vessel
is high speed cowl/ saw cutter type agitator. In some cases high speed homogenizer are also
provided. CIP turbo disk is provided at the top of the vessel for cleaning. Suitable nozzles,
manholes, valves etc are provided on the vessel.
There is no need for any vacuum in this vessel. Normally the capacity of this vessel is 60 % the
capacity of the main manufacturing vessel. Premix vessels can be 1 no or 2 no‟s as per the
clients requirements and formulae of the shampoo.
Storage vessel
Storage vessel is simple vessel used to store shampoos. It is cylindrical type of vessel with
dished bottom, loose top lid. Bottom valve is provided with din fittings to facilitate the pipeline
connection. Its capacity is the same as the manufacturing vessel. Normally storage tanks are

more in number so that different types of shampoos can be manufactured and stored. Filling is
then done as per the requirement & market demands.
4.3.2 A basic stirred tank design
Design considerations
Cost: in terms of cost the designs can be ranked, from cheapest to most expensive,
As: simple, no baffles
• Agitation nozzles
• Spiral baffle
Pressure: as a rough guide, the pressure rating of the designs can be taken as: up to 1 atm.
Select conventional type of vertical cylindrical vessel. One of the advantages of cylindrical
vessel is less crack and suitable for holding liquid than other. Calculate Vessel (tank) diameter
First, calculate the V of tank
V tank = V shampoo +15% shampoo
15% is given as an allowance for the mixture to swing.
= (1.15) (v of shampoo)
= πd2L/3
Material selection – stainless steel18 Cr/8Ni (316) Mo2.5%
Design temperature – 100 0C
Tensile strength -520 N/mm2
Design stress – 150 N/mm2
Corrosion allowance – 2mm
For volume calculation of shampoo
Volume of shampoo per batch=0.934739 L
Therefore Volume of tank=v of shampoo+0.15 v of shampoo
=0.934739 L+0.15* 0.934739 L
=1.0749L
Volume of cylinder = Πd2 H/4
H/D =2
V = 2d3 H/4
Diameter of vessel (Dv) = (4V/2 Π)1/3

= 0.88147m
Height of vessel = 2(Dv)
= 2(0.8814) m
= 1.763m
4.3.3 Design of impeller size and power consumption
Design considerations
The vessel, when a single optimum, with the impeller located at the center for an all-liquid
system. Economic and manufacturing considerations, however, is to be used, a liquid level equal
to the diameter is impeller often dictate higher ratios of depth to diameter. A baffle width one-
twelfth the tank diameter w = D /12; a length extending from one half the impeller diameter, d/2,
from the tangent line at the bottom to the liquid level. A draft tube is a cylindrical housing
around and slightly larger in diameter than the impeller. For the popular turbine impeller, the
ratio of diameters of impeller and vessel falls in the range, d/D, = 0.3-0.6, the lower values at
high rpm, in gas dispersion, for example, Impeller speed; With commercially available motors
and speed reducers, standard speeds are 37, 45, 56, 68, 84, 100, 125, 155,190, and320rpm.
Impeller location
As a first approximation, the impeller can be placed at l/6 the liquid level off the bottom. In
Some cases there are provisions for changing the position of the impeller on the shaft. For off
bottom suspension of solids, an impeller location of l/3 the impeller diameter off the bottom may
be satisfactory. Criteria developed by Dickey (1984) are based on the viscosity of the liquid and
the ratio of the liquid depth to the tank diameter, h/D,.
Types of impellers
Power input and other factors are interrelated in terms of certain dimensionless groups.
N Re = 10.75Nd2S/ μ, Reynolds number
Np = 1.523 (1013) P/N3d5S, Power number
NQ = l.037 (10s) Q/Nd3, Flow number
Tb N, Dimensionless blend time

NFr = 7.454(10p4) N2d, Froude number,

Where,
d= impeller diameter (in.),
D = vessel diameter (in.),
N = rpm of impeller shaft,
P = horsepower input,
Q = volumetric pumping rate (cuft/sec),
S = specific gravity,
tb = blend time (min)
μ= viscosity (cP)
4.3.4 Impeller size design and power consumption
From vessel design

Take volume of vessel=1.0749L
Specific gravity = density of shampoo/density of water =1020kg/m3/1000kg/m3 =1.02
Viscosity (μ) = 800cp
For blending operation, take Horse power per 1000gal to be in a range of 0.2-0.5.
Take an average 0.35Hp/1000gal
Vessel volume in gallon= 0.44788 gal
Power P = (Hp) (V)
= (0.35) (0.44788)
= 0.1567hp
The ratio of diameter impeller and vessel falls in the range d/Dv is 0.3-0.6
Take 0.4 for liquid dispersion
d = (0.4) (Dv) = 0.4 *0.88147 =0.3553m
Select impeller speed N = 300rpm
N Re = 10.75Nd2S/ μ
=10.75*0. 162* 300* 1.02/800cp
= 0.666
NQ = Q/Nd3 = 0.3 this value is taken from figure 10.7 of chemical process equipment selection
and design Book (Stanley walas)

Q =Volumetric pumping rate

Q = NQNd3=0.3 (300/60sec) (0.3553)3
=0.0672m3/sec
V = Q/Av = (0.0.0672m3 /sec)/ (π) (0.88147m)2 /4)= 0.11m/s
To calculate power consumption of impeller
Np = power consumption
Np = 1.523(1013) P/N3d5S
= 1.523(1013) (0.1567hp)/(27*106 * 5.66 *10-3 *1.02) * 103 = 1.55hp

Chapter Five
Cost Estimation and Evaluation
5.1 Cost Estimation
5.1.1 Estimation of total capital investment (TCI)
Direct Cost
Calculate purchased equipment cost as follows:-
Table 5.1 shows purchased equipment cost and their cost
Table 5.1: purchased equipment and their cost
Purchased equipment Cost in birr

1 Shampoo packaging machine 10000
2 Shampoo filling machine 500200

3 Three cylindrical vessel with 1000000
stirrer
4 Three globe valves 8750
5 Three rotary pumps 25497
Total purchased equipment 1,544,447
cost
All direct costs can be calculated as a function of purchased equipment cost.
Table 5.2 shows direct costs and purchased equipment cost
Table 5.2: direct costs and purchased equipment cost
Direct costs Fluid-fluid processing plant % % PEC

Price (birr)
Purchased equipment – 100 1,544,447

delivered
Purchased equipment 47 725890.09
installation
Instrumentation and control( 18 278000.46
installed)
Piping(installed) 66 1019335.02
Electrical (installed) 11 169,889.17
Building (including 18 278,000.46
services)
Yard improvements 10 154444.7
Service facilities (installed) 70 1081112.9
Land 6 92666.82
Total direct cost (DC) 346 5,343,787
Indirect cost
Table 5.3 shows indirect costs and purchased equipment cost
Table 5.3: indirect costs and purchased equipment cost
Indirect costs Fluid-fluid processing plant % PEC

% Price (birr)
Engineering and 33 509,667.51
supervision
Construction expenses 41 633,223.27
Total indirect cost (ID) 74 1,142,890.78
Total direct and indirect 420 6,486,677.4
costs (D+I)
Other costs
Contractor‟s fee 5 %( D + 21 324,333.87
ID )
Contingency 10% (D+ID) 42 648,667.74

Total other costs 63 973,001.6

Fixed capital investment 126 1,946,003.22
(FCI)
= D + ID + OC
Working capital 86 990,552.8
Total capital investment 632 2936556.032
(TCI) =
5.1.2 Estimation of Total product cost
Total product cost=manufacturing cost + general expense

Manufacturing cost=direct production costs + Fixed charges + plant overhead cost
Direct Production Costs
Raw Material Cost
Table 5.4 shows the raw material cost
Table 5.4: raw material cost
Raw material cost Unit price of raw (Component %) Price in

materials (capacity) (birr/year)
(birr/L) (L/year)
SLS 19.8 213.552 4228.33
CAPB 173 106.776 18472.148
Lemon juice 40 32.033 1281.32
Aloe Vera gel 102.4 427.104 43735.45
Rosemary essential 600 3.2 1920
oil
Distilled water 6 1320.81 7924.86
Fragrance 200 3.2 640
(birr/kg) Kg/yr
EDTA 20 4.2699 85.399

NaCl 5(birr/kg) 21.368 106.84

Total raw material Cost = 52,394.35(birr/year)
Operating Labor
Table 5.5 shows the operating labor
Table 5.5: operating labor
Operating labor Number of Salary per month Salary per year

Labor
General manager 1 3500 42000
Product manager 1 2800 33600
Technical manager 1 2800 33600
Quality controlling 1 2000 24000
supervisor
Daily laborers 2 1500 18000
Casher and 1 1200 14000
secretary
Purchaser and 1 1200 14000
driver
Cleaners 2 1400 16800
Security 2 1400 16800
Total 14 17800 112800 birr/yr
Direct supervisory and clerical labor
Operating supervisor 10-25% of operating labor

Take average value 10% (112800) = 11280 birr/yr
Utilities
Assume the number of people working in the factory = 25

Assume each person use 20 liter
Water consumption per day = 500liter/day

Water consumption per year = 150000liter/yr

Total water consumption = water consumption of sanitary
=1500000liter/yr
Cost of water = volume of water price, 1m3 = 3.80 birr
= 150000liter * 3.8 * 10-3
= 570birr/yr
Total power consumption
Total power consumption of machineries and lighting is taken from the bill by considering
Monthly production consumption to production rate of a specific month and by considering
Power cost is fixed for all ranges of production to be 0.578 cent/KWh
From the analysis taken 150.64 KWh is consumed for monthly production which worth
87.07 birr for 28 batches including lighting, charging and production. For one batch yields 3.11
birr/ batch.
Total power consumption= (No. of batches/year) (price) = (1500batch/year) (3.11birr/batch)
= 4665birr/yr
Total utilities cost = total water consumption cost + total cost of power consumption
= (570 + 4665) birr/yr
= 5235 birr/yr
Maintenance and repairs: (2-10) % fixed capital investment (FCI)
Take an average = 2% FCI
= 2%* 1,946,003.22birr/yr
= 38,920.06birr/year
Operating supplies: (0.5-1) % FCI
Take an average = 0.5%FCI
= 0.5% *1,946,003.22 birr/yr
=9730birr/year
Laboratory charges: (10-20) % of operating labor (OL)
Take an average = 10% (OL)
= 10% 112800birr/yr
= 11280birr/year

Fixed charges
Local tax: 2.5% FCI = 48,650.08 birr/year

Insurance: 0.7% FCI = 13622.022birr/year
Rent: 9% (building) = 25020birr/year
Building = 18% PEC = 278000 birr/yr
Fixed charge =365,292.1birr/yr
Plant overhead cost (OC)
OC = 60% (cost of operating labor + cost of supervision + cost of maintenance)

= 474,672birr/year
General expenses
General expenses = administrative costs (AD) + distribution and selling

Costs (DSC) + research and development (RD)
Administrative cost = 15 %( operating labor cost + supervision cost + maintenance cost)
= 71,200.8 birr/year
• Distributing and selling cost = 11% TPC = 169,889.17
Research and development = 5% TPC= 77,222.35
• Financing (interest) = 3.5% TCI
= 341,631.676birr/year
Total product cost = manufacturing cost + general expense
Manufacturing cost = direct production costs + fixed charges + plant overhead costs
Direct production cost = 243,847 birr/year
Fixed charges =365,292.1 birr/year
Plant overhead cost = 474672 birr/year
General expenses = 365,779.3 + 0.16TPC
Manufacturing cost = DC + FC + POC
= 243,847 + 365292.1 + 474,672
= 1,083,811birr/yr
Total product cost = manufacturing cost + general expense
= 1,449,590.4 + 0.16TPC

TPC =1,725,702.86birr/yr
Take each shampoo packages contain 0.20 L of the product.
Unit price of one package = 200birr/package
Unit price for one liter = 1000 birr/liter
5.2 Economic evaluation
Total Sales = (Total capacity) (Unit price)

= 2804.17L * 1000birr/L
= 2,804,170 birr
Gross Profit
Gross profit = Total sales – Total product cost

= (2,804,170 –1725702.86) birr
= 1,078,467.2birr
Take that the plant will be fully depreciated over 5 years and the plant will operate for 15 years
With full capacity
Federal Income Tax = 35%
Depreciation = fixed capital/years of depreciation = 1946003.22/5 = 389,200.644 birr
Gross profit before depreciation = Gross profit = 1078,467.2 birr
Income tax for year from (1-5)
Income tax before depreciation = % federal income tax (Gross profit -dp)
= 0.35*(1078,467.2-389200.64)
= 241,243.296 birr
Net profit
Net profit for year (1-5)
Net profit = GP-DP-Ix
=1,078,467.2-241243.296-389200.644
= 448023.26 birr
Income tax after depreciation year (6-15)
Income tax = % federal income( gross profit)
= 0.35*1,078,467.2

=377,463.52
Net profit = Gross profit - income tax
= 701,003.68 birr
5.2.1 Rate of investment
ROR= ((NPav (1-5) after tax + NPav (6-15) after tax) year)/TCI
= ((5*448023.26) + (10*701,003)/15)/2,936,556.031746
= 21%
5.2.2 Payback period
Payback period = total capital investment/ (annual average net profit )

= 2936,556.031 /616,676.42
= 5 years
5.2.3 Net present value
Let take r = 10%

Where CFn = cash flow in year n, where, n = number of period
n=15
CFn =2,936,556.031birr
Cash flow (1-5) =448023.26 birr/yr
Cash flow (6-15) = 701003 birr/yr
NPV = -2,936,556.031 +448023.26 *3.79085 + 701003 *3.7855
= 1,415,472.9
Since NPV is positive so the plant is acceptable

Chapter Six
Result and Discussion
6.1 Effect of sodium chloride on viscosity
Viscosity Vs Amount of NaCl

1400
1200
1000
Viscosity 800
rpm 100
(cp) 600
400
rpm 200
200 rpm 300
0
0 5 10 15 20 25
Amout of NaCl
Figure 6.1: the effect of NaCl on Viscosity
Since the anti- dandruff shampoos were typically made from anionic surfactants the outer surface
has a specific charge density. This would affect the way that the micelles can pack together. A
higher charge density will cause the micelles to repel and result in a thinner solution. The sodium
ions from the salt lower the charge density of the micelle surface. This makes them more able to
pack closer together and creates a thicker solution. This is why salt thickening is really only
affective with anionic-based shampoos.
The way salt reduces the charge density is that it pushes the dissociation equilibrium of the
surfactant to the left. As an example, consider this dissociation equation for Sodium Lauryl
Sulfate.
C12SO4Na = C12SO4- + Na+
More sodium ions push the equilibrium to the associated state.
This drops the micelle charge density and the size increases. This in turn causes more micelle
agglomeration which can ultimately lead to lamellar structures which can form a gel. As the
amount of salt increased from 10g to 15g and to 20g, the number of salt ions also increased. This
dropped the micelle charge density and the size increased. This in turn caused more micelle

agglomeration which can lead to lamellar structures which can form viscous liquid. But too
much salt reduced the solubility of the surfactant so much (again the equilibrium is forced to the
left) that it comes out of solution and precipitates.
6.2 Effect of impeller’s speed on viscosity
Revolution per minute Vs Viscosity

1400
1200
1000
800
Viscosity NaCl 15
(CP) 600
NaCl 20
400
NaCl 10
200
0
0 100 200 300 400
Revolution Per Minute
Figure 6.2 the effect of impeller speed on viscosity.
As the speed of the mixer increased from 100 to 200 and to 300 rpm, the viscosity of the solution
also increased. This is due to the fast contact between salt ions and surfactants which leads to
complete reaction of ions. Increasing the speed leads to the formation of more salt ions. The
sodium ions from the salt lower the charge density of the micelle surface. This makes them more
able to pack closer together and creates a thicker solution.
6.3 Solid content determination

Mass of shampoo before heating, M1 = 4.132g
Mass of shampoo after heating, M2 = 3.173g
Solid content = M1-M2/m1 *100 =23.2%

In fact, if the shampoo has too many solid contents; it will not be easy to be applied and wash out
from the hair. Good shampoos usually have 20 to 30% of solid contents (15). If it has low
percent of solid contents; it will be too watery and wash away quickly. In turn, if it has too
Many solids; it will be hard to wash out. The percent of solid contents of the prepared shampoo
was from 22.4–23.8%.
6.4 Physicochemical Evaluation of the Prepared Shampoo during Stability

Table 6.1 shows physicochemical evaluation of the prepared shampoo during stability
Table 6.1: physicochemical evaluation
Parameters 0week 2 week 4 week

Physical Clear, Homogenous, Clear, Homogenous, Clear, Homogenous,
Appearance
and Visual
Inspection
PH 5.83 5.86 5.68
Solid Contents (%) 23.2 23.0 22.96
Foam ability and Good Foaming Good Foaming Good Foaming
Foam Stability (ml) Foam Volume: 86 ml Foam Volume 86 ml Foam Volume 88 ml
Viscosity(cP) 900 900 900
6.4.1 Physical Appearance and Visual Inspection

The prepared shampoo was evaluated in terms of clarity, homogeneity, foaming producing
ability, fluidity, and stability. Our prepared shampoo was clear, transparent, homogenous, semi-
viscous aqueous solution and had characteristic odor. No significance changes were observed in
physical evaluation during stability, indicating the high stability index of the prepared shampoo.
This is due to the presence of preservative and sequesterants (EDTA) which contain the loose
metal ions and maintain the systems integrity. Besides, the product consist of lemon juice, aloe
Vera jell and rosemary oil which are anti-oxidants and biotic.
6.5 Shampoo formulation

Table 6.2 shows the shampoo formulation

Table 6.2: shampoo formulation
Components F1 F2 F3
Sodium lauryl sulfate 100g 100g 100g
Distilled water 400g 400g 400g
Aloe Vera gel 200g 200g 200g
Lemon juice 15g 15g 15g
Sodium chloride 10g 10g 10g
Ethylene diamine 2g 2g 2g
tetra acetic acid(
EDTA)
Distilled water 218.5g 218.5g 218.5g
Rosemary oil 3g 3g -
Fragrance 1.5g 1.5g 1.5g
Sodium silicate 50g - -
Table 6.3 shows the standard value and the measured value
Table 6.3 standard value and the measured value
Standard Measured
F1 F2 F3
Viscosity(cp) 700-1100 900 1000 1000
pH 5-6 5.83 3.77 3.21
1010 -1030 1018 1020 1020
Density(kg/m3)
6.5.1 Formulation one (F1)

Out of 3 formulations, F1 showed good PH value (5.83), which is near to the skin pH. It is
important for improving and enhancing the qualities of hair, minimizing irritation to the eyes and

stabilizing the ecological balance of the scalp. Formulation one is the best formulation of the
others due to the presence of second surfactant which is sodium silicate. Although sodium lauryl
sulfate which is primary surfactant and lemon juice are acidic, the pH value of the formulation
one was raised by addition of second surfactant (sodium silicate) which is basic media. The
viscosity and density of formation one is slightly less than the two other formulations. This is
due to the addition of sodium silicate which is liquid in phase. But still F1 enhanced better
characteristics of anti-dandruff shampoo than the other formulations.
6.5.2 Formulation two (F2)

Formulation two showed pH problem. As it is shown in table 6.4, the pH value 3.77 which is
acidic. This pH is not safe for human skin and eye. Since sodium lauryl sulfate lemon juice are
acidic, formulation two became acidic media. The viscosity and density of F1 are slightly larger
than formulation one. This is due to the reaction took place only between primary surfactant
(sodium lauryl sulfate) and salt ions. The presence of rosemary oil made formulation two slightly
less harmful than formulation three.
6.5.3 Formulation three (F3)

Formulation three enhanced the most acidic media of the other formulations (F1 and F2). The
absence of second surfactant and rosemary oil made formulation three more acidic than the rest
formulations. But it did not show viscosity problem because surfactants and salt have great role
for thickening of the solution.
6.6 The effect of F1, F2 and F3 on eye and skin irritancy

F3 and F2 has slightly effect on eye due to the Sodium Lauryl Sulfate, known as SLS, is a
surfactant that is very aggressive and it can overstep its duties of attaching to oils and dirt and
irritate skin and eyes. The harshness of the surfactants alone is not the sole determination of
shampoo irritation potential. The irritation potential is based on the concentration of the
surfactants plus the harshness of the surfactants as well as the contact time. But this can be
alleviated by addition of second surfactant such as sodium silicate (F1). A major disadvantage of
anionic surfactants is that they can be harsh and irritating to the scalp.

a(skin reference) b(eye reference)
Figure 6.2: the reference
a(eye test of f3) b(skin test of f3)
Figure 6.3: formation 3

Since anionic surfactants are acidic, Formulation3 (PH = 3.21) has diverse effect on eye
irritancy. But it did not cause series effect on skin irritancy since human skin resists chemical up
to pH= 3.3. Rather, it could cause skin harness.
a(skin test of f2) b(eye test of f2)
a(eye test of f1) b(skin test of f1)

6.7Anti-biotic effect
F1 and F2 formulation showed that diverse effect on the bacteria growth due to Rosemary oil has
anti-microbial and anti-inflammatory activity. Its anti-microbial activity is because of
compounds in Rosemary such as camphor (18.9%), verbenone (11.3%), α-pinene (9.6%), β-
myrcene (8.6%), 1, 8-cineole (8.0%), and beta-caryophyllene (5.1%) (29-32). The gel from aloe
Vera comes from the leaves. Since aloe Vera is a succulent, the leaves are thick and contain a
great deal of water along with a number of nutrients. These nutrients include powerful
antioxidants known as polyphenols.
Figure 6.6: effect of anti-microbial tests

6.8 Conditioning action

Conditioning action is a difficult property to assess. This is because it is basically dependent on
subjective appraisal. Hence, the conditioning action was speculated by visual inspection for the
different shampoo formulation.
a(conditioning test of f2 and f3) b(conditioning test of f1)
Figure 6.7: conditioning
Most of the surfactants used for human hair are slightly acidic. To offset the effects of
surfactants, most shampoo recipes include conditioners to help smooth, soften and reduce
brittleness. Formulation 1 is the most effective conditioning action than the other formulations
duet the presence of rosemary oil.
6.9 Cleansing action of anti-dandruff shampoo

All anti-dandruff shampoos contain Surfactants. These Surfactant molecules have two parts:
Hydrophilic head (water loving) and hydrophobic tail (water hating) in nature. At high
concentration they form Micelle. When Shampooing, Anionic surfactants containing
hydrophobic tail gets adsorbed to grease or dirt of hair. Thus, this dirt‟s are removed by further
rinsing. Table 6.4 shows cleansing action of the shampoo.
Table 6.4: shows that cleansing action of the shampoo
Weight of hair before Weight of hair after washing Weight of hair after washing
washing(g) by standard shampoo by produced shampoo
8.262 7.982 7.984

Chapter Seven
Conclusion and Recommendation
7.1 Conclusion
From the above experimental set up and analysis, 15g of sodium chloride and 300 revolutions
per minutes are the best salt concentration and mixer‟s speed for the desired anti-dandruff
shampoo production respectively. But too much salt (above 15g) reduces the solubility of the
surfactant so much (again the equilibrium is forced to the left) that it comes out of solution and
precipitates. As the speed of the mixer increased, the viscosity of the solution also increased.
That is due to the fast contact between salt ions and surfactants which leads to complete reaction
of salt ions.
Out of the three shampoo formulation, F1 is the best formulation of the others. Formulation 1
consists of all components which are used for anti-dandruff shampoo production. These
components have not any type of effect on human eye and skin. But all the above formulations
have diverse effect on fungus because it all consists of aloe Vera gel which is anti-biotic. The
same is true, formulation 1 enhanced good conditioner shampoo, cleansing action, desired pH
value of 5.87. In addition, formulation (F1) has shown good physical and chemical
characteristics during long-term stability studies.
From the economic feasibility analysis of the project, since net present value is greater than
(positive) it is acceptable to continuo with the business plan.
7.2 Recommendation
Further study of this project should be undergoing on the measurements of surface tension
which is an indication of the amount of surfactant required to reduce the surface tension of the
shampoo. Analytical method for chemical stability evaluation by the HPLC is the other issue to
will be seen for the characterization of anti-dandruff shampoo.
Since Ethiopia is one of developing country factories should show openness for those trust
worthy of knowledge people working in this sector lack willingness for knowledge transfer so as

to generate new ideas. The laboratory facilities and set ups should be in a position each
encourage motivation by upgrading the capacity with number of people in charge.

Reference
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221-224.
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Dictionary, 3rd ed., Washington, D.C., Cosmetic, Toiletry, and Fragrance Association, c1982;
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keratosis and melanocytic naevus, Scripta medica (BRNO) 73 (2000) 273–282.
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Appendix
Effect of sodium chloride and speed of mixer on viscosity
Table 1: shows that effect of sodium chloride and speed of mixer on viscosity
At mixing time =40 minutes and rpm =100

NaCl(mg) Viscosity(cp)
10 200
15 200
20 300
At rpm =200 and mixing time = 40 minutes
10 300
15 400
20 500
At rpm =300 and mixing time =40minutes
10 600
15 800
20 1300

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production of anti dandruff shampoo

BAHIR DAR INSTITUTE OF TECHNOLOGY

FACULTY OF CHEMICAL AND FOOD ENGINEERING

Project tittle: production of anti-dandruff shampoo from aloe Vera plant

Abadi Birhanu 0600001

Ashenafi H/Michal 0600257

Fanus Melese 0600706

ADVISOR Mr. Melkamu ,

[BIT FACULIT OF CHEMICAL AND FOOD ENGINEERING] Page 1

Advisor Name Signature Date

Melkamu Birile …………………… …………………

Abadi Birhanu …………………… ………………….

Ashenafi H/Michael …………………… ………..…………

Fanus Melese ……………………. …………………..

[BIT FACULIT OF CHEMICAL AND FOOD ENGINEERING] Page i

[BIT FACULIT OF CHEMICAL AND FOOD ENGINEERING] Page ii

[BIT FACULIT OF CHEMICAL AND FOOD ENGINEERING] Page iii

ABSTRACT ................................................................................................................................... iii

List of Tables ............................................................................................................................... viii

List of acronyms ............................................................................................................................ ix

Chapter one ..................................................................................................................................... 1

1.1 Background ........................................................................................................................... 1

1.2 Statement of the problem ...................................................................................................... 4

1.3 Objective ............................................................................................................................... 4

1.3.1 General Objective ........................................................................................................... 4

1.3.2 Specific Objective........................................................................................................... 4

1.4 Scope of the study ................................................................................................................. 5

1.5 Significance of the Study ...................................................................................................... 5

Chapter two ..................................................................................................................................... 6

Literature review ............................................................................................................................. 6

2.1 Aloe vera ............................................................................................................................... 6

2.2 Anti-dandruff shampoo ......................................................................................................... 7

2.3 formulation of antidandruff shampoo ................................................................................... 8

Materials and methods .................................................................................................................. 10

3.1 Material and equipment ....................................................................................................... 10

3.2 Methods ............................................................................................................................... 11

3.2.1 Extraction of lemon juice ............................................................................................. 11

[BIT FACULIT OF CHEMICAL AND FOOD ENGINEERING] Page iv

3.2.2 Extraction of aloe Vera gel ........................................................................................... 12

3.2.3 Weighing ...................................................................................................................... 13

3.2.4 Mixing .......................................................................................................................... 14

3.3 Characterization of anti-dandruff shampoo......................................................................... 15

3.3.1 Determination of pH ..................................................................................................... 16

3.3.2 Viscosity ....................................................................................................................... 16

3.3.3 Foam ability and Foaming Stability ............................................................................. 17

3.3.4 Detergency and cleaning action .................................................................................... 17

3.3.5 Anti-microbial test ........................................................................................................ 18

3.3.6 Non-irritating (free eye and skin irritancy) ................................................................... 20

3.3.7 Stability Studies ............................................................................................................ 20

3.3.8 Determination of the Percentage of Solid Contents ..................................................... 20

Chapter Four ................................................................................................................................. 21

Material and Energy Balance ........................................................................................................ 21

4.1 Material balance .................................................................................................................. 21

4.2 Energy Balance ................................................................................................................... 27

4.3 Equipment selection, specification and design ................................................................... 28

4.3.1 Equipment selection and specification ......................................................................... 28

4.3.2 A basic stirred tank design............................................................................................ 30

4.3.3 Design of impeller size and power consumption.......................................................... 31

4.3.4 Impeller size design and power consumption............................................................... 32

Chapter Five .................................................................................................................................. 34