SOAP MANUFACTURING PROCESS

Retrieved from: https://www.chemistryscl.com/industrial/soap-production-manufacturing-

process-saponification/index.php

Introduction
 Soap comprises the sodium or potassium salts of various fatty acids, but chiefly of
oleic, stearic, palmitic, lauric, and myristic acids.
 For generations, its use has increased until its manufacture has become an industry
essential to the comfort and health of civilized man.
 Although soap may be classified as a detergent, a synthetic detergent in present-day
usage connotes synthetic surface-active agents derived from a wide variety of
materials, particularly petroleum.
 The basic process or soap making has remained practically unchanged for 2,000
years.
 This is by batchwise saponifying the oils and fats with an alkali and salting out the
soap
 The major changes have been in the pretreatment of the fats and oils, in actual plant
procedure, and in the processing of the finished soap.
 Hydrogenation, liquid extraction, and solvent crystallization of various fats and oils
provide newer and better raw materials.

History
 Soap itself was never actually" discovered," but instead gradually evolved from
crude mixtures of alkaline and fatty materials.
 Pliny the elder described the manufacture of both hard and soft soap in the first
century.
 Although a fully equipped soap factory was found in the ruins of Pompeii, it was not
until the thirteenth century that soap was produced in sufficient quantities to call it an
industry
 Up to the early 1800's soap was believed to be a mechanical mixture of fat and
alkali; then Chevreul, a French chemist, showed that soap formation was actually a
chemical reaction.
 Until LeBlanc's important discovery of producing lower-priced sodium carbonate
from sodium chloride, the alkali required was obtained by the crude leaching of wood
ashes or from the evaporation of the naturally occurring alkaline waters, such as
from the Nile River

Economics
 The global soap and detergent market is expected to reach USD 207.56 billion by
2025, according to a new report by Grand View Research, Inc.
 The rising disposable income and rapid urbanization in developing countries are
expected to increase the demand for soaps and detergents.
 The rising healthcare awareness coupled with government regulations to maintain
hygiene and cleanliness in food processing, product manufacturing, and hotel is
expected to drive the market growth.

Soap Manufacturing
 Saponification process for soap manufacturing involves hydrolysis of esters under
basic conditions to form an alcohol and the salt of a carboxylic acid (carboxylates).
 Fatty acids are seldom found as free molecules in nature but are most often a part of
a larger molecule called a triglyceride.
 Triglycerides consist of a three-membered carbon chain (glycerol backbone) with a
fatty acid bonded to each of the three carbon atoms in the glycerol backbone.
 The bond between the fatty acid and the glycerol backbone is referred to as an ester
linkage. In the saponification process the ester linkage is broken to form glycerol and
soap.
 Fatty acids can also be obtained from vegetable oil, soy oil, or palm kernel oil.
 Glyceryl Stearate is a monoglyceride derived from such sources of fatty acid.
 In recent years, the tendency has been to split or hydrolyze the fat and then, after

separation from the valuable glycerine, neutralize the fatty acid with caustic soda or
soda ash solution.

 The usual fats and oils of commerce are not composed of the glyceride of anyone
fatty acid, but of a mixture.
 However, some individual fatty acids of 90 per cent purity or better are available by
special processing.
 Since the solubility and hardness of the sodium salts of the various fatty acids differ
considerably, the soap maker chooses his raw material according to the properties
desired, with due consideration to the market price.
Raw Materials
Four basic raw materials are involved in the manufacture of soap:
1. Oils and fats
2. Soda lye or potash lye
3. Brine (for glycerin recovery)
4. Additives (sodium carbonate, sodium silicate, dyes, perfumes, etc.), the use of
which depends on the quality and type of soap desired.
Oils and fats
 The natural fats used for soap making are triglycerol.
 Determines the suitability of triglycerol for soap product saponification using two
main chemical parameters.
 Iodine number - It shows the presence of double links, thus the degree of
instauration of the carbonic chain. Soap made from high Iodine Number fat has
the tendency to be soft.
 Saponification value - the quantity of caustic potassium (KOH) in mg needed to
transform 1g of it in soap. An easier transformation of the fat into soap indicated
by a high Saponification value.
Soda lye or potash lye
 We need to put strongly basic solution (alkali) in the water for direct
saponification of neutral fats (triglycerols).
 Caustic soda and caustic potash are most used for this goal.
 Caustic soda | Soda lye (NaOH) - Sodium soaps are harder and less soluble
than potassium soaps, and are the most commonly used alkali for neutralizing fat
due to its ability to return air humidity. The concentrated caustic soda solutions
are harmful to the skin and can cause serious burns.
 Caustic potash | Potash lye (KOH) - It is a strong base, which like caustic soda,
allows direct saponification of neutral fats. Potassium hydroxide is a type of lye
specifically used to make liquid soap, and also, KOH is used in baby soaps
because it is more environmentally friendly, water-soluble, and gentle for babies.
Brine
 A concentrated brine solution is added to separate the glycerin from the soap.
 Soap made from fats such as copra, palm, or castor oil contain high levels of salt.
 In this case, salt can be used as a filler material.
 Also, the addition of salt to soda soaps can lead to very strong soaps.
 This method is based on the fact that saltwater is not soapy.
Additives
 Additives are used for a variety of purposes and to enhance the quality of soaps.
 Adds pigments, fragrances, preservatives, fillers, etc. as additives.

Soap Manufacturing Processes

Considering the soap manufacturing processes, there are three basic process methods
that are used industrially.
1. Cold Process (the reaction takes place substantially at room temperature)
2. Semi-Boiled Process (the reaction takes place near the boiling point)
3. Hot process/ Full Boiled Process (the reactors are boiled at least once and the
glycerol is recovered)

Cold Process
 heat is not used to make soap.
 the soap is saponified at room temperature and does not heat or wash.
 the removal of waste or the removal of glycerin produced in not included in this
process.
 This process is a relatively long process compared to the hot process.
 The mixture is kept vigorous agitation for approximately 2 hours, and the dyes,
perfumes and additives are generally added at this stage.
 As soon as most of the mixture has solidified, the crude soap is removed and
poured into cooling frames.
 The crude soap (fat content: 58%) is then removed from the frame, cut into
chunks, and sent to the finish line.
 This process is a simple, inexpensive method and is not highly mechanical.
Semi-Boiled Process
 This process differs from the cold process in that it uses a heated coil to heat the
saponification mixture to a temperature of 70-90C.
 This causes the saponification reaction to complete faster.
 This process allows the amount of baking soda to be adjusted before removing
the dirty soap.
 The process also allows for better recycling of product waste, better integration of
additives, and wider selection of raw materials.
Hot Process / Full Boiled Process
 This process is slightly different from the semi-boiled process.
 the saponification reaction usually takes place at temperatures as high as 100C.
 At this temperature, the fat ingredient allows for a wide range of uses.
  The glycerin is then separated from the soap by rinsing with alkali.
 This process allows the production of a wide range of soaps, from basic
household soaps to high-grade toilet soaps.

Procter and Gamble

 Procter & Gamble is one of the consumer good giants in the world that is
manufacturing personal care and hygiene products. It was founded as a soap
and candle company in 1873, with owners William Procter and James Gamble,
and now manufacturing a variety of trusted brands such as Downy, Oral B, Head
and Shoulders, and Tide.

Unilever
 Unilever is another one of the fast-moving consumer good companies that was
founded in 1890s by William Hesketh Lever and started with the idea of a
Sunlight Soap, which is a product popularizing cleanliness and hygiene.. At
present, the same aim was carried by the Unilever's culture and now
manufacturing products, such as Dove, that are sold in 190 countries worldwide.
QUIZ
1-3. The three processes in soap manufacturing
-cold, semi-boiled, hot process
4. This involves hydrolysis of esters under basic conditions to form an alcohol and the
salt of a carboxylic acid (carboxylates)
- saponification
5. It consists of a three-member carbon chain (glycerol backbone) with a fatty acid
bonded to each of the three carbon atoms
- Triglycerides
6. The ________ is broken down to form glycerol and soap.
- ester linkage
7. In this particular soap manufacturing process, the removal of glycerin is not included.
- cold process
8. This process uses a heated coil to heat the saponification mixture to a temperature of
70 to 90 C
- semi boiled process
9. This process allows the amount of baking soda to be adjusted before removing the
dirty soap
- semi boiled process
10. In this process, the saponification reaction usually takes place at temperatures as
high as 100 C.
- hot/full boiled process
11. This process allows the production of a wide range of soaps, from basic household
soaps to high-grade toilet soaps.
- hot/full boiled process
12. The natural fats used for making soap
- triglycerol
13. It shows the presence of double links, thus the degree of instauration of the carbonic
chain.
- Iodine number
14. Soaps that are made from high iodine number fat have a tendency to be what?
 - soft
15. This is the quantity of caustic potassium (KOH) in mg needed to transform 1g of it
into soap. An easier transformation of the fat into soap is indicated by a _________.
- high Saponification value
16. It is a strong base, which like caustic soda, allows direct saponification of neutral
fats. It is usually used in baby soaps because it is more gentle for babies.
- caustic potash / potash lye
17. This raw material is added to separate the glycerin from the soap.
- Brine solution / Brine
18. It is used for a variety of purposes which includes to enhance the quality of soaps
- Additives
19. ____ comprises the sodium or potassium salts of various fatty acids, but chiefly of
oleic, stearic, palmitic, lauric, and myristic acids.
- Soap
20. A soap manufacturing process that is inexpensive and not highly mechanical
- cold process

ESSAY:
Discuss the differences between the 3 soap manufacturing processes. (5 pts)

**BONUS QUESTION**
21. What is the full name of the professor of this course (with middle name)? (3 points)
- Dexter John Braga Taguding
22. Full names of the reporters (with middle initial) (1pt each)