Blu Excel

Introduction

I’m SARAVANALINGAM S (Reg No: C3E12208), studying M.Sc.

Chemistry Second Year at R. V. S. Kumaran Arts and Science College,

Ayyalur - 624801, Dindgul District. I completed the 10 days internship

at Blu Excel Company (Palaniyappa Soap Company) for Quality

Analyst Role.

Company Overview:

 Company Name: Blu Excel Company (Palaniyappa Soap

Company)

 Industry: Soap and Detergent

 Location: Erunasamuthiram, Eriodu

The process of creating cleaning agents like soap and

detergents involves a fascinating interplay of chemistry and practical

skills. This report covers the preparation methods, key ingredients,

chemical reactions, and equations involved in making these essential

soap products from last 12 years.

 Soap
Ingredients:

 Fats and Oils: Such as coconut oil, olive oil, or palm oil.

 Lye (Sodium Hydroxide, NaOH)

 Water

 Essential Oils: Optional, for fragrance.

 Colorants: Optional, for adding color.

Steps:

1. Preparation of Lye Solution: Carefully mix NaOH with water in

a well-ventilated area. The dissolution of NaOH in water is highly

exothermic and should be handled with care.

2. Melting Oils: Heat the selected fats and oils until they are fully

melted.
3. Combining Lye Solution and Oils: Slowly pour the lye solution

into the melted oils, ensuring constant stirring.

4. Saponification Process: This is the chemical reaction where

triglycerides (fats/oils) react with sodium hydroxide to produce

glycerol and soap.

For example, using coconut oil (primarily lauric acid

triglycerides):
 5. Blending to Trace: Use a stick blender to mix until the mixture

thickens, achieving "trace."

6. Adding Fragrance and Color: Mix in any essential oils or

colorants.

7. Pouring into Molds: Pour the mixture into soap molds and allow

it to set.

8. Curing: Let the soap cure for 4-6 weeks to harden and complete

the saponification process.

Chemical Explanation:

 The triglycerides in oils undergo hydrolysis in the presence of

sodium hydroxide, leading to the formation of glycerol and fatty

acid salts (soap).

 Solid Detergent
Ingredients:

 Sodium Carbonate (Washing Soda, Na₂CO₃)

 Sodium Bicarbonate (Baking Soda, NaHCO₃)

 Sodium Borate (Borax, Na₂B₄O₇·10H₂O)

 Soap Flakes: Grated bar soap or soap powder.

Steps:

1. Mixing the Powders: Combine equal parts of sodium carbonate,

sodium bicarbonate, and sodium borate in a large bowl.

2. Adding Soap Flakes: Gradually add grated soap flakes to the

powder mixture and mix thoroughly.

3. Storing the Detergent: Store the solid detergent in an airtight

container. Use 1-2 tablespoons per laundry load.

Chemical Reactions:

 Cleaning Action: When dissolved in water, the detergent forms a

basic solution. The soap molecules emulsify grease and oils,

allowing them to be washed away.

 The sodium carbonate and bicarbonate help to soften water by

precipitating calcium and magnesium ions:

Chemical Explanation:

 The soap anions surround grease and oil particles, enabling them to

be suspended in water and rinsed away.

 Sodium carbonate and bicarbonate help in the removal of hard

water ions, preventing them from interfering with the cleaning

process.
 Floor Cleaner Liquid
Ingredients:

 Water

 Soap Flakes: Grated bar soap or soap powder.

 Washing Soda (Na₂CO₃)

 Borax (Na₂B₄O₇·10H₂O)

 Essential Oils: Optional, for fragrance.

Steps:

1. Boiling Water: Bring a large pot of water to a boil.

2. Adding Soap Flakes: Gradually add soap flakes to the boiling

water, stirring until dissolved.

3. Mixing in Powders: Add washing soda and borax, stirring until

fully dissolved.
 4. Cooling and Diluting: Allow the mixture to cool, then add more

water to achieve the desired consistency.

5. Adding Fragrance: Mix in essential oils if desired.

6. Storing the Detergent: Pour the liquid detergent into bottles for

storage. Shake well before each use.

Chemical Reactions:

 The soap dissolves in water to form soap anions and sodium

cations.

 The washing soda acts to soften the water and assist in cleaning.

 Borax helps to enhance the cleaning power and also acts as a

buffer.

Chemical Explanation:

 Soap molecules interact with grease, allowing them to be

emulsified and washed away.

 Washing soda assists in the removal of hard water ions.

 Borax acts as a bleaching agent and boosts the cleaning efficiency.

Skills Acquired on Internship:

1. Soap Production Techniques: Mastering the process of making

soap, including ingredient selection, mixing, and curing.

2. Quality Control: Ensuring that each batch of soap meets specific

standards for consistency, scent, and appearance.

3. Inventory Management: Keeping track of raw materials and

finished products to maintain efficient production.

4. Scent Blending: Creating unique and appealing fragrances by

combining different essential oils and other scent ingredients.

5. Business Acumen: Understanding the business side of soap

manufacturing, including marketing, sales, and customer service.

6. Creativity: Developing new soap designs and formulations to

meet market trends and customer preferences.

7. Safety and Compliance: Adhering to safety regulations and

industry standards to ensure safe production practices.

Conclusion

The preparation of soap and detergents involves a blend of chemical

reactions and practical steps. By understanding these processes and the

underlying chemistry, one can appreciate the science behind these

everyday cleaning products. This assignment highlights the steps

involved in creating soap, solid detergent, and liquid detergent, along

with the chemical equations that drive these reactions. This knowledge

empowers individuals to create customized, eco-friendly cleaning

solutions and provides insight into the practical applications of

chemistry.

I have been an invaluable experience, providing me with a

comprehensive understanding of the soap production process and the

operational dynamics of the industry. Throughout my time here, I have

gained hands-on experience in various aspects of soap manufacturing,

from ingredient selection and mixing to quality control and packaging.

One of the most significant takeaways from this internship is the

importance of maintaining high standards of quality and safety. I have

learned how meticulous attention to detail and adherence to industry

regulations are crucial for producing a product that meets consumer

expectations and regulatory requirements.

Additionally, I have developed a deeper appreciation for the business

side of soap manufacturing. Understanding market trends, customer

preferences, and effective marketing strategies has broadened my

perspective on how to successfully bring a product to market.

Overall, this internship has equipped me with a diverse set of skills and

knowledge that will be beneficial in my future career. I am grateful for

the opportunity to work with a team of dedicated professionals and for

the mentorship and guidance, I received throughout this experience. I

look forward to applying what I have learned in my future endeavors

and contributing to the field of soap manufacturing.