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What is Soap???
.
Soap is a combination of animal fat or plant oil and caustic soda. When dissolved in water, it breaks
dirt away from surfaces.
Through the ages soap has been used to cleanse, to cure skin sores, to dye hair, and as a salve or
skin ointment.
Soaps and Detergents are cleaning products that have become an essential commodity in our daily
lives. Cleaning products play an essential role in our daily lives.
By safely and effectively removing soils, germs and other contaminants, they help us to stay
healthy, care for our homes and possessions, and make our surroundings more lively and pleasant.
History of Soap:
The exact origins of soap are unknown, though Roman sources claim it dates back to at least 600 B.C.
,when Phoenicians prepared it from goat's tallow and wood ash.
Soap was also made by the Celts, ancient inhabitants of Britain. Soap was used widely throughout the
Roman empire, primarily as a medicine. Mention of soap as a cleanser does not appear until the second
century A.D.
By the eighth century, soap was common in France, Italy, and Spain, but it was rarely used in the rest of
Europe until as late as the 17th century.
Manufacture of soap began in England around the end of the 12th century. Soap-makers had to pay a
heavy tax on all the soap they produced. So it did not come into common use in England until after the
tax was repealed in 1853.
Around 1790, French soap maker Nicolas Leblanc developed a method of extracting caustic soda (sodium
hydroxide) from common table salt (sodium chloride), replacing the wood ash element of soap.
The French chemist Eugene-Michel Chevreul put the soap-forming process (called in English
saponification) into concrete chemical terms in 1823.
Soap was made with industrial processes by the end of the 19th century, though people in rural areas,
such as the pioneers in the western United States, continued to make soap at home.
In the 19th century, soap was affordable and popular throughout Europe.
Some soap manufacture took place in Venice and Sauona in the 15th century and in Marseilles in the
17th century.
By the 18th century, manufacture was widespread throughout Europe and North America and by the
19th century the making of soap had become a major industry.
in the 1920s and 1930s, through alkyl-aryl long chain sulfonates in the 1940s, to branched chain
compounds in the 1950s and 1960s.
During the 1960s the requirement of biodegradability became important and caused the return to
linear long chains, because only the linear chains can be easily biodegraded.
Soap Manufacturing:
Saponification:
The triglycerides are most often animal fats or vegetable oils. When sodium hydroxide is used, a hard
soap is produced. Using potassium hydroxide results in a soft soap.
In the process, animal or vegetable fat is converted into soap (a fatty acid) and alcohol. The reaction
requires a solution of an alkali (e.g., sodium hydroxide or potassium hydroxide) in water and also heat.
The reaction is used commercially to make soap, lubricants, and fire extinguishers.
The basic chemical reaction in the making of soap is saponification:
The other method for making soap comprises fat splitting followed b the neutralization process with
sodium hydroxide.
Sodium hydroxide, potassium hydroxide, sodium carbonate, and tri- ethanolamine are the most
commonly used alkaline moieties in both the processes.
Recently, soap manufacture by the saponification of fatty methyl esters has been developed in Japan
and Italy. The methanolysis of triglycerides takes place in the presence of enzymes (lipase) as catalysts
to produce fatty methyl ester and glycerin.
The fatty methyl ester under- goes the saponification and forms the final product.
The chemical reaction between any fat and sodium hydroxide is a saponification reaction.
O
CH2 – O – C – (CH2)14CH3 CH2 – OH
O
CH – O – C – (CH2)14CH3 CH – OH
O O
Fatty Acid:
In chemistry, particularly in biochemistry, a fatty acid is
a carboxylic acid with a long aliphatic chain, which is
either saturated or unsaturated. Most naturally occurring fatty
acids have an unbranched chain of an even number of carbon
atoms, from 4 to 28. Fatty acids are usually not found in
organisms, but instead as three main classes of esters:
triglycerides, phospholipids, and cholesteryl esters.
In any of these forms, fatty acids are both important dietary
sources of fuel for animals and they are important structural
components for cells.
Brine:
Water:
Flowers
Honey
Milk
Clay
Beeswax
Classification:
The soap is classified or distributed in many qualities and types so we have some common types of
the soap which are in daily life use so these common described below:
Hard Soap:
Hard soap or curd soap is a kind of soap; examples are Aleppo soap, Castile
soap, and Marseille soap or Savon de Marseille.
During the preparation of the soap, common salt (sodium chloride) is added to
the liquid soap mass.
This leads to the soap mass separating from glycerin, resulting in a harder soap.
It can be made using sodium hydroxide.
This can be done by the use of some salts in the manufacturing of the salts.
Like sodium lactate, salt will help harden soap into very hard bars. Sodium
lactate is a clear liquid that comes from the natural fermentation of sugars
found in things like sugar cane and sugar beets. Used in an amount of about 1%,
or roughly four tablespoons (2.25 ounces) for this recipe, sodium lactate will
significantly harden your soap. This is especially recommended for individual
molds that have an intricate design, as they can sometimes be very tricky to un-
mold.
Reduction of water:
Lye needs to be dissolved in water in order to turn oils into soap. The amount of
water you use will make a difference in the cure time and will also affect the
outcome of the hardness of the bars.
Soap made with a fatty acid and an earthy or metallic base (iron or calcium salts of fatty acids).
By Using followings we can make Insoluble soap:
Ca/Mg-salt
Use as lubricants and dries in paint industry
Hot Process
In the hot process, the hydroxide and the fat are heated and mixed together at 80-100 °C, a little below
boiling point, until saponification is complete, which, before modern scientific equipment, the
soapmaker determined by taste (the sharp, distinctive taste of the hydroxide disappears after it is
saponified) or by eye; the experienced eye can tell when gel stage and full saponification has occurred.
An advantage of the fully boiled hot process in soap making is the exact amount of hydroxide required
need not be known with great accuracy. They originated when the purity of the alkali hydroxides were
unreliable, as these processes can use even naturally found alkalis, such as wood ashes and potash
deposits In the fully boiled process, the mix is actually boiled (100+ °C), and, after saponification has
occurred, the "neat soap" is precipitated from the solution by adding common salt, and the excess liquid
is drained off.
This excess liquid carries away with it much of the impurities and color compounds in the fat, to leave a
purer, whiter soap, and with practically all the glycerin removed. The hot, soft soap is then pumped into
a mould. The spent hydroxide
The Continuous Process:
Splitting:
the first step of the continuous process splits natural fat into fatty acids and glycerin. The
equipment used is a vertical stainless steel column with the diameter of a barrel called a
hydrolizer. It may be as tall as 80 feet (24 m). Pumps and meters attached to the column
allow precise measurements and control of the process. Molten fat is pumped into one end of
the column, while at the other end water at high temperature (266°F [130°C]) and pressure is
introduced. This splits the fat into its two components. The fatty acid and glycerin are
pumped out continuously as more fat and water enter. The fatty acids are then distilled for
purification.
Mixing:
The purified fatty acids are next mixed with a precise amount of alkali to form soap. Other
ingredients such as abrasives and fragrance are also mixed in. The hot liquid soap may be
then whipped to incorporate air.
Cooling and finishing:
3 The soap may be poured into molds and allowed to harden into a large slab. It may also
be cooled in a special freezer. The slab is cut into smaller pieces of bar size, which are then
stamped and wrapped. The entire continuous process, from splitting to finishing, can be
accomplished in several hours.
Milling:
Most toiletry soap undergoes additional processing called milling. The milled bar lathers
up better and has a finer consistency than non-milled soap. The cooled soap is fed
through several sets of heavy rollers (mills), which crush and knead it. Perfumes can best
be incorporated at this time because their volatile oils do not evaporate in the cold
mixture. After the soap emerges from the mills, it is pressed into a smooth cylinder and
extruded. The extruded soap is cut into bar size, stamped and wrapped.
Byproducts:
Glycerin is a very useful byproduct of soap manufacture. It is used to make hand lotion,
drugs, and nitroglycerin, the main component of explosives such as dynamite.
Cold Process:
In the cold soap making process, some heat is usually required; the temperature is usually raised to
a point sufficient to ensure complete melting of the fat being used.
The batch may also be kept warm for some time after mixing to ensure the alkali (hydroxide) is
completely used up. This soap is safe to use after about 12–48 hours, but is not at its peak quality
for use for several weeks.
Cold-process soap making requires exact measurements of lye and fat amounts and computing
their ratio, using saponification charts to ensure the finished product does not contain any excess
hydroxide or too much free unreacted fat.
Saponification charts should also be used in hot processes, but are not necessary for the “fully
boiled hot-process” soaping. Lye used in the cold process was made from scratch using rainwater
and ashes. Soapmakers deemed the lye solution ready for use when an egg would float in it
A cold-process soapmaker first looks up the saponification value for each unique fat on an oil
specification sheet.
Oil specification sheets contain laboratory test results for each fat, including the precise
saponification value of the fat.
The saponification value for a specific fat will vary by season and by specimen species. This value is
used to calculate the exact amount of sodium hydroxide to react with the fat to form soap. The
saponification value must be converted into an equivalent sodium hydroxide value for use in cold
process soap making.
Excess unreacted lye in the soap will result in a very high pH and can burn or irritate skin; not enough
lye leaves the soap greasy. Most soap makers formulate their recipes with a 2–5% deficit of lye, to
account for the unknown deviation of saponification value between their oil batch and laboratory
averages.
Then oils are heated, or melted if they are solid at room temperature. Once the oils are liquefied and
the lye is fully dissolved in water, they are combined.
This lye-fat mixture is mixed until the two phases (oils and water) are fully emulsified. Emulsification is
most easily identified visually when the soap exhibits some level of “trace”, which is the thickening of
the mixture.
After much stirring, the mixture turns to the consistency of a thin pudding. “Trace” corresponds roughly to
viscosity. Essential oils and fragrance oils can be added with the initial soaping oils, but solid additives such
as botanicals, herbs, oatmeal, or other additives are most commonly added at light trace, just as the
mixture starts to thicken The batch is then poured into moulds, kept warm with towels or blankets, and left
to continue saponification for 12 to 48 hours.
During this time, it is normal for the soap to go through a “gel phase”, wherein the opaque soap will turn
somewhat transparent for several hours, before once again turning opaque.
After the insulation period, the soap is firm enough to be removed from the mould and cut into bars. At this
time, it is safe to use the soap, since saponification is in essence complete.
However, cold-process soaps are typically cured and hardened on a drying rack for 2–6 weeks before use.
During this cure period, trace amounts of residual lye are consumed by saponification and excess water
evaporates.
During the curing process, some molecules in the outer layer of the solid soap react with the carbon dioxide
of the air and produce a dusty sheet of sodium carbonate.
The kettle method of making soap is still used today by small soap manufacturing companies. This
process takes from four to eleven days to complete, and the quality of each batch is inconsistent due to
the variety of oils used.
Around 1940, engineers and scientists developed a more efficient manufacturing process, called the
continuous process.
This procedure is employed by large soap manufacturing companies all around the world today. Exactly
as the name states, in the continuous process soap is produced continuously, rather than one batch at a
time.
Technicians have more control of the production in the continuous process, and the steps are much
quicker than in the kettle method—it takes only about six hours to complete a batch of soap.
Boiling
•1 Fats and alkali are melted in a kettle, which is a steel tank that can stand three stories high and hold
several thousand pounds of material. Steam coils within the kettle heat the batch and bring it to a boil.
After boiling, the mass thickens as the fat reacts with the alkali, producing soap and glycerin.
Salting:
The soap and glycerin must now be separated. The mixture is treated with salt, causing the soap
to rise to the top and the glycerin to settle to the bottom. The glycerin is extracted from the
bottom of the kettle.
Strong change:
To remove the small amounts of fat that have not saponified, a strong caustic solution is added
to the kettle. This step in the process is called "strong change." The mass is brought to a boil
again, and the last of the fat turns to soap. The batch may be given another salt treatment at
this time, or the manufacturer may proceed to the next step.
Pitching:
The next step is called "pitching." The soap in the kettle is boiled again with added water. The
mass eventually separates into two layers. The top layer is called "neat soap," which is about
70% soap and 30% water. The lower layer, called "nigre," contains most of the impurities in the
soap such as dirt and salt, as well as most of the water. The neat soap is taken off the top. The
soap is then cooled. The finishing process is the product as in continuous process.
Soap types:
Depending on their cleaning action and usage, soaps and detergents can be broadly categorized into four
main types, including –
Personal cleaning products are cleaning agents that are used to wash and clean our hands, face, body and
hair. These products may include toilet soaps, liquid cleansers, face wash, shampoos and conditioners.
Personal cleaning products help us remain clean and healthy by removing dirt, oil, and environmental
pollutants from our body. Personal cleaning products can be categorized into two main types -
Skin Cleaning products
Laundry cleaning products are detergents and surface active agents, that are manufactured to wash and
clean our laundry items. These products come in various forms, such as detergent cakes, powders and liquids
and are formulated to meet different requirements of laundry cleaning, such as stain and soil removal,
bleaching, fabric softening and conditioning and disinfectant requirements under the varying temperature,
water, and usage conditions.
Laundry Cleaning products can be categorized into five main types -
Detergent Powder
Detergent Cake
Fabric Softener
Laundry Liquid
Household Cleaning products are cleaners that we use in our homes to wash and clean different
household products, such as furniture, glass, plastic items and different types of surfaces. These products
help us keep fit and healthy be killing and removing harmful bacteria and germs from our homes and
workplaces. Household Cleaning products can be categorized into four main classes:
Floor Cleaners
Glass Cleaners
Wood Cleaners
Dishwashing products
Dishwashing products are cleaning agents that are formulated to wash and clean
dishes and other kitchen utensils. These products are available for hand wash as well as
machine wash and are made for different water, temperature and usage conditions.
Dishwashing products can be categorized into four main types -
Dishwasher Liquid
Dishwasher Powder
Dishwasher Gel
Dishwasher Tablets
Toilet Soap
Due to the increasing awareness towards health and hygiene, toilet soaps have now become a necessity for
people in modern life. Urbanization and developments in the industry has led to the increase in demand as well
as improvement in quality of products. With the advent of new technologies and sophisticated manufacturing
practices, the development processes have improved and as a result of which, the markets are flooded with a
variety of soaps that vary in both the physical as well as functional attributes. The toilet soaps can be broadly
categorized into several types of soaps, such as -
•Oily Skin Soap
•Dry Skin Soap
•Sensitive Skin Soap
•Normal Skin Soap
•Baby Soap
•Antibacterial Soap
•Glycerin Soap
•Olive Oil Soap
•Herbal Soap
Glycerin Soap:
Glycerin is a component of oil or fat. Any handmade soap
contains glycerin, a byproduct of the chemical reaction of the
soap-making process. Unlike most commercial soaps,
glycerin is being purposely removed by the manufacturer to
sold for other product making usage like cosmetic or
moisturizer.
Kitchen Soap:
Kitchen soap is a soap intended for use in the kitchen mainly
to serve the purpose of dish-washing.
Laundry Soap:
Effective in cleaning solid particles, grease and organic
compound in clothes. Can be quite convenient to wash
clothes during travels because it is easy to carry.
Medicated Soap:
Medicated soap is soap with added antiseptics and disinfectants to kill bacteria.
Beauty Soap:
Beauty Soap features fragrance and ingredients for different skin types. They can feature special oil blend or
glycerin.
Novelty Soap:
Soap that comes in various shapes colors such as fish, cake, and mustache. Novelty soap serves more than a
cleaning soap. It provides enjoyment and amusement to the children who use them.
Sensitive skin soap:
If you are suffering from sensitive skin, it means that most of the cosmetics and facial cleansers
available in the market do not work well for you. If you were experiencing rashes, itching, or
other allergic symptoms after using certain facial ingredients, it would be sensible for you to
search for sensitive skin care products.
Soap Detergent
They are metal salts of long chain higher These are sodium salts of long chain
fatty acids. hydrocarbons like alkyl sulphates or alkyl
benzene sulphonates.
These are prepared from vegetable oils They are prepared from hydrocarbons of
and animal fat. petroleum or coal.
They cannot be used effectively in hard These do not produce insoluble
water as they produce scum i.e., precipitates in hard water. They are
insoluble precipitates of Ca2+, Mg2+, effective in soft, hard or salt water.
Fe2+ etc.
Soaps are chain carboxylic acids Detergents are ammonium or
sulphonate salts of long chain carboxylic
acids.
Soaps have lesser cleansing quality Detergents have better cleansing action
compared to detergents. compared to soaps
Soaps are more biodegradable. Detergents are made from
petrochemicals
They are not suitable for hard water Detergents biodegradable.
Leather formation take place with soft They are suitable for hard water
water
Bleaching Agent:
Bleaches work by reacting with many colored organic compounds, such as natural pigments, and turning
them into colorless ones.
While most bleaches are oxidizing agents (chemicals that can remove electrons from other molecules),
some are reducing agents (that donate electrons).
Chlorine, a powerful oxidizer, is the active agent in many household bleaches. Since pure chlorine is a toxic
corrosive gas, these products usually contain hypochlorite which releases chlorine when needed. "Bleaching
powder" usually means a formulation containing calcium hypochlorite.
Oxidizing bleaching agents that do not contain chlorine are usually based on peroxides such as hydrogen
peroxide, sodium percarbonate, and sodium perborate. These bleaches are called 'non-chlorine bleach,'
'oxygen bleach' or 'color-safe bleach.
Classes of Bleaching Agent:
Most industrial and household bleaches belong to three broad classes:
Peroxide-based bleaches, whose active agent is oxygen, almost always from the
decomposition of a peroxide compound like hydrogen peroxide.
Sulfur dioxide based bleaches, whose active agent is sulfur dioxide, possibly from the
decomposition of some oxosulfur anion.
Bleaching Agents Distribution:
Additives and their Function:
Additives Material For Which Purpose It Is Added
Oatmeal Oatmeal is wonderful irritated and sensitive
skin. Oatmeal is also an exfoliate. Powder in
food processor for less exfoliation.
Dried Flowers - Lavender, Rose Buds, Exfoliation, most turn black/brown in soap
Calendula (calendula stays yellow, lavender ends up
looking like mouse poop)
Additive Material For which purpose it is added
Flower petals, leaves, and herbs Add fragrance and natural juice to soap
Most biological laundry detergents contain lipase and protease enzymes, both of
which are found in the body.
Lipases break down fats and oils, while proteases work to break down protein
chains. Their ability to break down these compounds makes them excellent for stain
removal.
Why Are Enzymes Used in Biological Washing Powder?
One of the primary reasons that enzymes are used in biological washing powders is that
the additional stain-removing help from the enzymes means that dirt can be removed
without the need for hot water. Biological detergents are effective at much lower
temperatures, helping families all across the UK to save money on their household bills,
and become more environmentally friendly.
The ability to wash in lower temperatures also means we can pop a wider variety of
materials into the washing machine – such as wool and silk which could become damaged
in high heats – and lower temperatures are also great for dyed clothing like denim jeans as
it reduces color transfer.
The use of enzymes in soap is much the same as the use of enzymes in the body. Lipases
and proteases process any remnants of protein, starches, and fats in the clothing, which
makes them great for getting rid of grass stains, pasta sauces, hamburger grease, and
more.
Once the enzymes have done their job, the broken down particles can easily be washed
away with warm water in the washing machine, so with a biological detergent like Persil
Power gems Bio, you can be sure you’re tackling stains head on.
Enzymes can accelerate reactions in several ways, all of which lower the activation energy