Soap business. Toilet soap production technology

The main fatty raw materials for the production of soaps include edible and technical animal fats, tallow, coconut, palm kernel and palm oils, synthetic fatty acids, rosin, petroleum acids, yeast and other fats.

Animal fats. In the production of soap, rendered beef, mutton, pork and bone fats are most widely used. Animal fats are used in the manufacture of toilet soap in the form of crude or distilled fatty acids and undigested (neutral) fats. Melted animal fats are high-quality fatty raw materials for the production of all types and grades of soap. However, due to limited resources and high price, they are mainly used for the production of toilet soaps.

Industrial animal fats obtained from raw materials that do not meet the requirements for food products, from the waste of glue-gelatin, leather, bone meal and other industries, as a rule, have a dark color, high acid number and contain a significant amount of various impurities. They are used in the production of laundry soap, as well as after thorough cleaning in the formulations of lower grades of toilet soap.

Beef, lamb, hydrogenated pork and bone fats contain from 40 to 60% saturated fatty acids, of which about 50% palmitic and 36 to 55% oleic acid, making these fats a good and almost interchangeable raw material for soap making.

Due to their rapid oxidation and rancidity, rendered pork fat is used in soap making to a limited extent.

Fats of marine animals and fish in soap making are used mainly in a hydrogenated form, since the unsaturated fatty acids contained in them have an unpleasant fishy smell, which is transferred to the soap made from them and is retained for a long time by a washed cloth.

Vegetable oils used to make soap are divided into two main groups: solid and liquid.

Solid vegetable oils include coconut, palm kernel and palm oils. Their addition to soaps ensures the creation of the desired plasticity during mechanical processing.

The disadvantage of this group of oils as a raw material for toilet soap is the content of low molecular weight acids in them, the sodium salts of which do not have a detergent effect. This is the reason for the limited use of coconut oil in toilet soap formulations.

Palm oil in its fatty acid composition approaches animal fats and is a good raw material for toilet soap. Solid vegetable oils are obtained from imported raw materials and therefore they are used in production to a limited extent and only in the production of toilet soaps. They are usually replaced with highly purified synthetic fatty acids.

Liquid vegetable oils - sunflower and soybean - are not used to produce solid toilet soaps due to the presence of significant amounts of highly unsaturated fatty acids in them. For the same reason, they are introduced into the formulation of solid laundry soaps in an amount of no more than 15-30%. At the same time, they are suitable for cooking all types of liquid household and toilet soaps, as well as ointment-like household and industrial soaps.

Salomas. Technical tallow is used in the production of laundry and toilet soap. The raw materials for hydrogenation are vegetable oils, fats of terrestrial and marine animals, natural fatty acids obtained from fats, oils and soap stocks.

For the production of laundry soap, oils are hydrogenated to a titer of 46-500C, and for toilet soaps - 39-430C.

natural fatty acids. Most factories use fatty acids rather than fats to make all types of soap.

The method of direct saponification of fats is used only at individual enterprises that produce the highest grades of light toilet soaps. The main mass of fats and oils sent for soap making is subjected to preliminary splitting.

Decomposed fats (more specifically, fatty acids) can be used to make all types of soaps, while improving the quality of the product, since the fatty acids obtained by non-reactive splitting do not darken.

Synthetic fatty acids (FFAs). Synthetic fatty acids are obtained by oxidizing petroleum paraffin with atmospheric oxygen. This produces a mixture of acids containing from 1 to 30 carbon atoms in the molecule. This mixture is divided into different fractions. Two fractions are prepared for soap making. The first fraction includes mainly acids containing from 10 to 16 carbon atoms in the molecule. It is sometimes called the coconut fraction and is used in soap formulations instead of coconut oil. The second fraction of synthetic fatty acids contains mainly acids with 17-20 carbon atoms in the molecule, it is called the lard fraction and is used in soap formulations instead of lard. Unlike natural fatty acids, synthetic acid molecules can contain both an even and an odd number of carbon atoms. A significant disadvantage of the first FFA fraction is the presence in it in the form of impurities of 4-5% low molecular weight acids C5-C9, the sodium salts of which do not have a detergent effect. They dissolve well in water and soapy lye and are not salted out even with a saturated solution of table salt. For this reason, they are removed with the soap lye and are practically lost. The second fraction - fat oil, often contains an increased amount of unsaponifiable substances and other impurities, including those that impart an unpleasant odor to acids.

FFAs have a low viscosity compared to natural fatty acids, which contributes to the production of a soap base with good plastic characteristics. In addition, it improves the performance of the plant.

Fatty waste. In the process of obtaining and processing fats and oils, a variety of fat-containing wastes are formed - soap stocks, fuses, spent bleaching earths, trap fat and others used in soap making. In addition to fat, they contain a large number of various impurities, usually dark in color. Many of them have an unpleasant smell. Laundry soap, brewed from such waste, turns out to be dark in color with an unpleasant odor. Therefore, fat-containing waste must be cleaned - to remove impurities. Most effective method purification is the selection and subsequent distillation of the fatty acids contained in them.

Soap stock is a waste product obtained from the purification of oils and fats with alkali solutions. It contains soap, neutral fat and water. In addition, a variety of mucus, proteins, salts, coloring and other substances pass into the soap stocks from the purified fats. The composition of soap stocks is not constant, therefore, before processing the soap stock, it is necessary to have data on the substances included in it and their quantity.

Fuzes are flocculent sediment formed during storage of raw (unrefined) vegetable oils in tanks or separated on filter presses and centrifuges during primary oil purification. This sediment contains from 65 to 85% fat, the rest falls on various impurities: fragments of plant cells, phospholipids, protein, resinous and mucous substances, water, etc.

Fuzes have a dark color and an unpleasant odor, which increases during storage due to the decomposition of protein substances.

When using fats contained in fuses in soap making, they must be thoroughly cleaned and freed from impurities.

Spent bleaching earths, in addition to coloring substances, also absorb a significant amount of fats, which depends on the oil absorption of this adsorbent.

Fat, previously extracted from spent bleaching clays, is sent to soap production.

The fat from the traps and other fatty waste also goes to the soap factories. They contain varying amounts of impurities, so when using this fat to make soaps, it must be thoroughly cleaned.

Natural fat substitutes. Natural fat substitutes used in soap making include rosin, tall oil and petroleum acids. Due to limited resources, as well as due to the emergence of FFAs, the importance of natural fat substitutes has decreased. However, they are still used in the preparation of some types of laundry soap.

Rosin is a solid, resinous mass, from light yellow to dark brown. It consists of a mixture of resinous unsaturated acids, the main of which is abietic. Extraction rosin also contains 5-10% fatty acids.

Rosin as a substitute for natural fats can be used in the preparation of laundry soaps in the amount of 10-15% of the fat mixture. In the manufacture of lower grades of toilet soap, 3-5% of light grades of rosin are sometimes used.

Tall oil is a waste product from pulp production. Due to its dark color and strong unpleasant smell, crude tall oil is an undesirable ingredient in soaps. When it is distilled with water vapor under vacuum, a light yellow oily liquid is obtained - distilled tall oil, which is used in the production of liquid and solid laundry soap.

Petroleum (naphthenic) acids are contained in some petroleum products - kerosene, solar oil, etc. When these products are treated with a solution of sodium alkali, it binds petroleum acids and forms a specific product called soap naphtha. Together with petroleum soaps, a certain amount of petroleum products enters the mass, which impart a specific smell and dark color to soap oil.

Caustic alkalis, when interacting with neutral fats, saponify triglycerides and bind the fatty acids released in this case, forming the corresponding soaps.

Caustic soda (trade name caustic soda). It is used in the production of all types of solid soaps. It is produced in several grades and grades in solid and liquid form.

Solid caustic soda, depending on the variety, contains from 92 to 95% NaOH, and liquid - 42-43%. Of the impurities, it contains sodium carbonate (2-3%) and table salt (from 1 to 2.5%).

The enterprises prepare an aqueous solution of caustic soda of the desired concentration by stirring at 50-60°C, followed by filtration of the resulting solution.

Caustic potash is used in the production of liquid, ointment and some special soaps. Caustic potash is produced in solid and liquid form of several grades (from A to G). The solid product is an opaque mass. Liquid product - concentrated solution up to 55%. The content of caustic alkalis in a solid product, depending on the brand, is 93-95%, in liquid - 50-52%.

carbonic salts. Compared with caustic alkalis, carbonic salts are less reactive. They do not saponify neutral fats under normal cooking conditions. They react well and fairly quickly with fatty acids, forming the corresponding salts (soaps).

Sodium carbonate (soda carbonate, sodium carbonate), trade name - soda ash. is a white, fine crystalline powder.

Sodium carbonate is used in the production of solid soaps from split fats, fatty and petroleum acids, and rosin. It is introduced into some types of soaps to increase the hardness of the bar or the mobility of the molten soap. Sodium carbonate is produced in several types and grades. Depending on the type and brand, the commercial product contains from 91 to 99% sodium carbonate.

At soap factories, a solution of sodium carbonate with a concentration of 32-33% is prepared by dissolving in water at 80 ° C in containers with mixers.

Potassium carbonate (potassium carbonate), trade name - potash. The product is produced in the form of small granules. white color, two grades (calcined and one and a half water) and two grades. Depending on the type and variety, the commercial product contains 92.5-98% potassium carbonate. It is used to produce liquid, ointment-like and special soaps from split fats and fatty acids, as well as a technological additive to increase the mobility of molten soap.

phosphate salts. Sodium and potassium salts of phosphoric acid produce various chemical composition and, accordingly, they have different properties.

The main phosphate salts used in the soap industry are sodium tripolyphosphate and sodium hexametaphosphate. They are added to washing powders and in some types hard soap to improve cleaning performance.

Sodium tripolyphosphate (Na5P3O10) is a white powder. It is added to some varieties of solid laundry soap in the amount of 4-6%.

Sodium hexametaphosphate (NaPO3)6 is a hard, glassy, ​​slightly colored mass. It dissolves well in water, especially when heated, forming solutions with a concentration of up to 70%.

Aqueous solutions of sodium hexametaphosphate are acidic, therefore, in the soap industry, it can also be used to bind an excess of free caustic alkali, if there is more semen in the soap mass than is allowed by the technical conditions. It is also added to toilet soap in an amount of up to 5% to prevent the formation of calcium and magnesium insoluble soaps when using the product.

Salts of silicic acid (sodium silicates) are a product of variable chemical composition Na2O*nSiO2. Soap factories use sodium silicate, in which the weight ratio of SiO2 to Na2O ranges from 2.6 to 3.4.

Sodium silicate is produced in two types - soda and soda-sulfate. Soda sodium silicate has a higher quality, it has less impurities.

Sodium silicate has a significant detergency and is therefore a desirable ingredient. Also, this salt increases the hardness of the soap, reduces its stickiness, and prevents the appearance of soda crystals on its surface. The addition of sodium silicate in a small amount (0.1-0.5%) to toilet and laundry soap slows down the darkening and rancidity of the product. Sodium silicate enhances the action of antioxidants added to soap.

Laundry soap is an environmentally friendly product, since it is made mainly from natural raw materials - animal fats and vegetable oils. In addition, it also contains technical fats and synthetic fatty acids.

Due to its properties, such as high washing power at any temperature, no irritating effect on the skin, low cost, complete and natural biodegradability, antibacterial and hypoallergenic effects, safety (non-combustibility and non-toxicity), long shelf life (one year), laundry soap received a wide range of applications, both in production and in everyday life:

• as a cleaner and detergent, incl. for washing dishes and hands with heavy pollution;
• for washing cotton, semi-woolen fabrics, as well as children's underwear;
• for cleaning premises;
• as a plasticizer in the production of acrylic, oil-adhesive putties, as well as PVA-based putties;
• for washing parts in some industries such as mechanical engineering, watchmaking and aviation industry;
• for washing containers in the food industry;
• in agriculture - for washing eggs of birds;
• for cleaning fruits and vegetables in vegetable stores;
• in medicine - until now, soap is considered an effective antiseptic.

Consumers

Due to its characteristics, laundry soap is a truly universal product, which is in very stable demand both from buyers who purchase it for private needs, and from enterprises in almost all industries (manufacturing, Agriculture, industry, trade, medicine, engineering, etc.) The wide demand for laundry soap allows it to easily find its buyer, which makes the business of its production quite attractive.

Range

Laundry soap is traditionally classified according to the following criteria:

• by appointment - for washing and soaking linen made of linen and cotton fabrics, for washing various surfaces, dishes, as well as for washing heavily soiled hands;
• by consistency - lumpy solid, liquid, powder, ointment;
• according to the content of fatty acids - 72% (group 1), 70% (group 2), 65% (group 3);
• according to the manufacturing method - glued, sawn, sound;
• by color - normal or clarified;
• by the presence of additional properties - flavored, colored, abrasive, antibacterial;
• by lump mass (in grams):<150>, <200>, <250>, <300>, <350>, <400>, <500>;
• by the nature of the packaging - open (without packaging) and closed;
• in shape - a rectangular shape or a piece of complex shape;
• by name - although laundry soap does not have a special name, in Lately soap factories produce a high-quality product in polymer or paper packaging with an individual name.

It should also be noted that the quality criteria for laundry soap are regulated by GOST 30266-95 “Hard laundry soap. General technical conditions”, and the procedure for testing and acceptance of soap is described in GOST 790-89 “Hard household soap and toilet soap”.

Necessary equipment

In the case of an economical implementation of this, a significant amount of equipment is not required.

With a capacity of 50 kg / hour will include the following main equipment:

• 2 digesters - 50 and 250 liters;
• melting tank for melting raw fat;
• mixer - for mixing the soap base with various additives provided for by the soap recipe (perfume, dyes, etc.);
• two-stage auger press designed for soap sawing;
• installation for cutting and marking soap;
• pneumatic press for marking and punching soap;
• stamping matrices;
• compressor.

To place such a line, an area equal to only 16 square meters is required, and one person can handle its maintenance. The cost of this kit is approximately $ 22,000.

The production line can be equipped with the following additional equipment: conveyors, filters, drip collectors, packing machines, steam ejectors, flow dividers, vacuum systems, etc. You can also purchase a device for packaging finished products, but many manufacturers successfully do without it.

A more costly example of extended automated line with a capacity of 2500 kg / h is the manufacturer NPO "Agromash", the cost of which is about $ 100,000. Such production requires an area for its placement of 70 square meters. m.

Initial Cost Estimation

Subject to the purchase of a mini-line with a capacity of 50 kg / h, in the case of 2 shift work, the following capital expenditures will be required:

• equipment cost - 670 thousand rubles;
• delivery and installation of the line - 50 thousand rubles;
• preparation and repair production premises(20 sq. m) - 50 thousand rubles;
• creation inventory for a month - 500 thousand rubles;
• other expenses - 100 thousand rubles.

Total - 1,370,000 rubles of initial investment.

Revenue and profitability

The average wholesale selling price of laundry soap is from 30 rubles per kilogram, and the monthly revenue will be from 700 thousand rubles. Thus, the profitability of production is 40-50%. Under these conditions, the initial investment will pay off in a period of six months to a year.

To prepare solid soap, take 2 kg of caustic soda, dissolve in 8 liters of water, bring the solution to 25 ° C and pour it into melted and cooled to 50 ° C lard (lard must be unsalted and it is taken 12 kg 800 g per specified amount of water and soda). The resulting liquid mixture is thoroughly stirred until the whole mass becomes completely homogeneous, after which it is poured into wooden boxes, well wrapped in felt, and placed in a warm, dry place. After 4-5 days, the mass hardens and the soap is ready.

If you want to have a more foamy soap, then add another 400 g of purified potash to the indicated amount of water or take 2 kg less fat and add the same amount of coconut oil. To prepare liquid soap, the same amount of crude caustic potassium is dissolved in 2 kg of water, the solution is brought to 25 ° C and thoroughly mixed with 8 kg of unsalted lard, previously melted and cooled to 50 ° C. then proceed as above.

PRODUCTION OF MEDICAL SOAPS

1. Vaseline-lanolin soap. 3.5 kg of vaseline and 1.5 kg of lanolin are added to 95 kg of molten soap mass. Used as a skin softener.
2. Camphor soap. Take 10 kg of the best tallow soap, 400 g of rosemary oil and 400 g of camphor. When the soap has melted and must be put into molds, finely ground camphor mixed with 25 g or more of bitter almond oil, also rosemary oil, is added and mixed well.
3. Tar soap consists of 12-16 ordinary soap and 1-2 birch tar.
4. Vaseline-tar soap. This soap consists of 9.5 kg of coconut oil, 5 kg of lard, 8.25 kg of lye at 38° B, 3.2 kg of wood tar, 1 kg of yellow vaseline, 83 kg of water, 70 g of rosemary and 50 g of lavender oil. Soap is made at 45°C.
5. Sulfur-tar soap (5%). 1 kg of sulfur color is mixed with 4 kg of heated birch tar and added to 95 kg of soap mass.
b. Carbal soap. Ordinary white soap is mixed with 2-3% carbolic acid.
7. Sublimate soap. When preparing sublimate soap, it is necessary to use good soap with an excess of free fat, since all sublimate soaps containing free alkali in their composition are covered with black spots after a few days of manufacture. Sublimate is added to soap up to 0.1%.
8. Menthol soap (5%). 95 kg of soap powder and 5 kg of menthol are mixed and pressed. It is used to wash the head with neuralgia.
9. Thymol soap (3%). 3 kg of thymol are mixed with 97 kg of soap powder and
IRESSUYu. Thymol soap has a pleasant smell and is used as an antiseptic.
10. Formalin soap (5%). To 95 kg of soap powder add 5 kg of formalin (containing 40% formaldehyde). Formalin should not be mixed with hot soap, since if the latter is alkaline, formic acid can easily be formed.
PRODUCTION OF SOAPS FOR SHAVE
1. Hot shaving soap. Such soap is prepared from 12 kg of fat, 4 kg of lard and 250 g of rosin. All these materials are boiled down to a solid core. After boiling, the solid mass is carefully separated from the lye and placed in a special vessel. Then, in another cauldron, 3 kg of coconut oil are boiled with 2 kg of 30° potash liquor. After the end of the saponification process, they increase the fire and add, carefully stirring, the sound soap prepared in advance. If the mass should not be too thick, then add another 2 kg of water and boil until the sample taken hardens on the glass. When the soap is ready, the mass is cast into molds and 50 g of lavender oil is added to perfume the soap.
2. Cold shaving soap. Take 14 kg of lard, 2 kg of bleached palm oil, 4 kg of coconut oil, 8 kg of soda lye at 30 ° B.; for aromatization, 100 g of lavender and 80 g of timpani oil are added.
3. Shaving soap melted down. 4 kg lard and 2.5 kg of coconut oil are melted in a sand or water bath; to the melted fat, continuously stirring, add 2.75 kg of potassium liquor at 42 °. When about half of the lye is added, the mass begins to thicken, but when all the lye is added, it is so thick that it is impossible to stir.
The mixture is left at a temperature of 60-70 ° C for several hours at rest. The hardened mass is ground in a marble or porcelain mortar, gradually adding 9 g of bitter almond oil, previously dissolved in 100 g of alcohol.
4. Liquid soap for shaving.
a) Mix 60 g of olein with 125 g of hot water and add to the resulting liquid, with strong stirring, 50 g of soda lye and, finally, 120 g of white soap. The whole mixture is diluted with 75 cm3 of hot water, 25 cm3 is added. alcohol and filtered
b) Mix 1 kg of white soap, 100 g of almond oil. 500 g of alcohol, 500 g of rose water, 10 g of amber and 10 g of benzoin tincture.
5. Soap paste for shaving. Take 90 g of spermaceti, 90 g of sweet almond oil, 100 g of potassium soap and bitter almond oil for fragrance.
6. Soap powder for shaving. Mix 400 g of soap powder, 50 g of borax and 25 g of almond bran.
PRODUCTION OF ORDINARY SOAP
1. Cooking soap in a handicraft way. Take wood ash or weed ash and sift it through a sieve, then scatter it, moisten it and mix it until a uniformly moistened mass of ash is obtained. After that, it is collected in a pile, in which a recess is formed on top. In the latter, lime is put, which is quenched from the presence of moisture. Lime should be taken in half the amount of the weight of the ash taken. When the lime breaks down into a fine powder, it is covered with ash. Then pour water over and leave for 24 hours, after which the lye is drained. This is the first lye, the most concentrated. It is placed in a special vessel, and then the ashes are poured over again with water, drained and a weaker lye is obtained. When this lye is ready, the stronger one is poured into the cauldron and heated to a boil.
Next, an appropriate amount of various fatty wastes is added to the lye and boiled, adding weaker lye, until the sample taken on a glass plate solidifies into a transparent sticky mass. In this way, a liquid potash soap, commonly called soap glue, is obtained. To turn the soft mass into a solid, dense soap, salt is added to the soap glue. In this case, the so-called soap core is released, which is a solid, soda soap.
After the addition of table salt, the resulting heart soap is scooped out, as well as lye, after which the soap is placed again in the cauldron, boiled again with thicker lye, salted again, scooped out and placed in boxes lined with linen; when the excess lye adhering to the soap collects drop by drop to the bottom of the box, the latter is turned over, the soap is taken out, cut into pieces and dried in air.
For the manufacture of soap, it is better, of course, to take not ash and lime, but directly caustic soda.
2. Preparation of simple soap - solid and liquid, a) To prepare solid soap, take 2 kg of caustic soda, dissolve in 8 kg of water, bring the solution to 25 ° C and pour it into the lard melted and cooled to 50 ° C (the lard should be unsalted and take it 12 kg 800 g for the specified amount of water and soda). The resulting liquid mixture is thoroughly stirred until the whole mass becomes completely homogeneous, after which it is poured into wooden boxes, well wrapped in felt, and placed in a warm, dry place. After 4-5 days, the mass hardens and the soap is ready. If you want to have a more foamy soap, then add another 500 g of purified potash to the indicated amount of water or take 2 kg less fat and add the same amount of coconut oil instead.

PRODUCTION OF TOILET SOAPS
i. Hot way. As the bulk for toilet soaps, you can take tallow soap prepared with soda lye, or prepare it separately by using pork fat in combination with coconut oil.
Coconut oil must be of the highest quality, and lard must be exceptionally fresh and well-refined.
Purification of fat is carried out as follows: fresh fat is washed several times in cold water, cut it into pieces and put it in a bag, which is hung in a cauldron of water and boiled. When the water boils and the lard blooms, it is lightly squeezed out, with most of the fiber remaining in the bag along with the garbage. The bag is taken out, and in a mixture of fat with water, for each kilogram of fat, put 4-5 g of table salt and 1-2 g of alum in powder, with a strong boil of the liquid and constant stirring. After some time, the boil is stopped and the fat is allowed to float to the surface. The resulting scale is carefully removed, filtered through the canvas into a clean vat and allowed to harden. Thus prepared fat can be stored without change in a cool place for a very long time.
To get a good toilet soap, for every 100 g of fat, take 5-20 g of coconut oil. The latter is added not only to reduce the cost, but also in order to "pour" it with more water.
The soap itself is made in the usual way, only it is necessary to ensure that the resulting soap is neutral, that is, that there is no excess of alkalis in it. For this purpose, it is salted several times and then boiled again. After the last salting, boiling is continued until the sample taken with a glass rod on the plate is completely satisfactory, i.e., when the mass is squeezed between the fingers, solid plates are obtained that should not break.
In order to have a perfectly pure soap, it is stirred with a pole, skimmed off the foam and poured into molds until it is transparent. The soap mass remaining at the bottom of the boiler will be less transparent and pure, and therefore it must be allowed to harden separately.
2. Cold way. The preparation of toilet soaps in a cold way, by means of stirring, is distinguished by many advantages, which mainly boil down to the fact that here coloring and perfumery are carried out simultaneously, constituting, as it were, one operation, after which it remains only to cut and stamp the hardened soap mass.
To prepare soap in a cold way, coconut oil is taken, previously cleaned of random dirt, and saponified with strong soda lye at low temperature and constant stirring. In order for the resulting soap to be neutral, it is necessary to make several preliminary samples and accurately determine the quantitative ratio of fat and alkali. On average, you have to take caustic soda in solid pieces about 15% by weight of the fat part.
When the saponification process reaches such a state that the contents of the boiler turn into a homogeneous and difficult to stir mass, then dyes and perfumes are added to it, which, due to prolonged stirring, are evenly distributed throughout the mass.
3. Remelted. The preparation of toilet soaps by melting is carried out as follows: ordinary heart soap is cut into pieces and thrown into a cauldron inserted into another cauldron with boiling water (water bath). So much water must be poured into the soap so that the sample taken has a good consistency, after which the soap is poured into molds and mixed with coloring and perfumes. The amount of added water poured for remelting depends on the properties of the soap: for hard, greasy soaps, more water is needed than when other grades are used, which already contain a lot of water. Water is generally poured so much that, when cooled, a solid soap is obtained, which foams strongly in water.
If the soap taken for remelting is heavily contaminated, then it must be melted with a large amount of water (50-60%), and then salted and boiled.
4. Planing. Preparation of toilet soap by planing is carried out as follows: heart soap is turned into shavings using a special machine, collected in a wooden trough, mixed with coloring and odorous substances and then turned into a homogeneous mass using a kneading machine. The machine consists of a horizontal cylindrical drum, on the circumference of which there are 4-8 knives. Above the drum, which is driven in rotation, there is an inclined plane, on which layers of soap are placed for planing. The soap is pressed by its own weight on the drum, the knives of which continuously cut the chips from the soap layer. The knives are set at a very significant slope and therefore can cut chips as thick as writing paper.
Here are a few recipes for іyualeiny soaps, іііріуіонініх in many different ways:
5. Almond soap. To prepare it, take 4 kg of white heart soap, scrape it into small chips and add a little milk. The mass is poured into the cauldron, put on moderate heat and stirred until it thickens and begins to stretch. After cooling, artificial bitter-almond oil is added and the soap is poured into a flat wooden box, on the bottom of which a linen is laid. The soap is allowed to cool, harden, and then it is cut into pieces of the required shape.
Factories prepare almond soap from good strong liquor with twice the weight of tallow, fat, coconut or palm oil, which must be boiled down until the sample taken out, placed on a cold, smooth plate, quickly hardens.
6. Rose soap. To prepare this soap, take: 64 coconut oil, 40 greasy soap, 30 water and heat this mixture for 2-3 hours, knead and add a little eosin for touch-up. Then remove from heat and stir in artificial rose oil. Soap is cast in molds.
7= Violet soap= To prepare this soap, which gives softness to the skin, take 100 white heart soap, 10 orris root, 10 dew frankincense. The soap is kneaded with water, dyed purple and perfumed with violet essence. Then add as much starch as is necessary to impart hardness to the soap, after which the soap is put into molds.
8. Lemon soap. Mix, with gentle heating, 1 white fatty soap and 1 starch, dye in yellow and suffocate with lemon essence. From the resulting mass, it is molded in special forms in the form of a lemon and tinted on top in a yellow-lemon color, dipped in yellow paint, with the addition of wax.
E. English round soap. To prepare this soap, you need to cut into small pieces 200 good white sound soap and then grind in a heated porcelain mortar, adding 1 camphor to the mass. 100 starch is added to the resulting batter, dyed in various delicate colors and perfumed. Flat-round pieces are formed from this mass.
10. English shaving soap is prepared as follows: 100 pieces of white soap are scraped into small chips and dissolved in water to the consistency of liquid jelly. Then 10 talc and 10 powdered alum are added, dyed cream and perfumed with musk and orange oil. This soap is cast in a cylindrical mold.
11. Egg soap. The egg yolk is boiled until the water has evaporated so much that no oil will ooze out of the yellow mass when squeezed with your fingers. The latter is squeezed out, filtered and turned into soap with the help of potassium. Then the yolk is mixed with a sixteenth part of this soap, 1 starch and fragrant oil are added per 30 yolks, and when all this is properly thickened, they are put into molds.
12. Glycerin soap. 13 lard and 12 coconut oil are melted in a cauldron and filtered through a sparse cloth; a mixture of 12 lye at 39.5 ° B. and 8 alcohol at 95 ° is poured into the strained fats. The mass is stirred, then 3 glycerin is poured in and at the end the so-called honeycomb is added, consisting of 8 sugar and 5 hot water. When the sample taken on the knife shows that the soap is ready, it is poured into molds. Color and scent can be added as desired.
13. Soap cologne. 50 kg of basic soap, 60 g of lavender oil, 35 g of rosemary and 30 g of bergamot oil, 70 g of lemon oil. For coloring, take 1 g of chlorophyll dissolved in the listed oils.
14. Benzoin soap. 50 kg of basic soap, 40 g of Peruvian balsam, 1 g
fisіlkoyoїo root, 15 i іelioironina, 5 i benzoic shnkіurі. For coloring, I take brown diamond (aniline) paint.
15. Soap for children. 10 kg of basic soap, 200 g of white Vaseline, 200 g of rice flour, 30 g of geranium oil, 20 g of terpineol. White color.
16. Coloring toilet nyl. Soap can be dyed with two different ways: a) Aqueous solutions of basic and acidic dyes are poured into the hot soapy mass, with constant stirring. Fat-soluble dyes that are mixed with oil are also suitable for this coloring method. All colorants must be free of alum.
b) Dry soap is cut into small pieces (shavings) and processed on a kneading machine together with basic and acid colorants dissolved in water or ground with oil. This method allows the use of insoluble resinous colored varnishes. This is how marble soaps are made.
The dyes used to tint toilet soaps can be very different. The main conditions that they must satisfy: be strong enough, mix well with soap and not have a harmful effect on the skin. Such paints can be divided into two groups: soluble and insoluble. The former deserve preference over the latter, if only because they do not leave behind an insoluble powdery residue; in addition, soluble paints are distributed in soap more easily and more evenly than insoluble ones.
Red color. For transparent soaps: alkine, magenta, eosin. For opaque - cinnabar, minium.
Yellow. For clear soaps: turmeric extract and picric acid. For opaque - chrome yellow paint.
Orange is made up of a mixture of red and yellow dyes.
Green color. For clear soap: green aniline or a mixture of indica carmine and picric acid. For opaque - chrome green paint.
Violet is made up of methyl violet or a mixture of red dye and indigo carmine.
Brown color - from light or dark brown aniline paint or burnt
GYAUYAPYA
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Insoluble paints are applied in the form of a fine powder, which is sprinkled on chips entering the planer box. Then a new layer of chips is applied to the sprinkled chips, which are again sprinkled with paint, etc. When all the soap is thus prepared, the chips are stirred and passed through a kneader to obtain a uniformly colored mass.
17. Perfuming toilet soaps. Along with a first-class, completely neutral soap base (kernel soap), perfumery plays an especially important role in the manufacture of toilet soaps. The fact is that the fragrance should not only be pleasant, but also should retain its smell for a long time and even, if possible, improve when the soap is lying and drying.
When starting to perfume, you need to strictly distinguish which types of soap you want to perfume, and accordingly choose the necessary odorous substances. Toilet soaps are divided, as we have seen, into those that are made 1) hot
method, 2) cold method, 3) tampering, 4) churning.
Therefore, when perfumering, the first question is at what temperature the soap should be perfumed. Then, secondly, what is the effect of alkalis on the applied, odorous substances. And, finally, thirdly, whether these odorous substances are well preserved in alkalis. These three basic questions underlie the entire art of skillfully perfumed toilet soaps.
Toilet soaps, made by hot process or by melting, are, for the most part, cheap grades. It is impossible to spend a lot on their perfumes, so that these soaps do not cost too much. Therefore, for the perfume of such types of soaps, you can choose only cheap odorous substances, but nevertheless having the strongest possible smell, since it is with these types of soaps that it is often necessary to kill some unwanted foreign smell. For this purpose, mainly mirban oil, safrole, citronella oil, artificial bitter almond oil are used.
For the second category of cold-made toilet soaps, that is, for good varieties of coconut soaps, higher quality odorants can be used, and the choice among them seems to be more varied. Although coconut soaps, which also include almond soaps, have recently been pushed into the background by planed soaps, good and pure coconut soaps are very readily bought, especially in areas where the water is very calcareous, and therefore planed soaps do not lather well. Coconut soaps can be perfectly perfumed thanks to the numerous natural and artificial fragrances available. You can also greatly improve the quality of these soaps by adding lanolin to them. Even soaps made with Japanese wax are very popular, as they look exactly like planed soaps. They should not only be left in the mold for a long time, otherwise they become too hard and very difficult to press.
Of the odorous substances, one can highly recommend anise aldehyde, which has a very delicate smell, bornyl acetate, which is remarkably good in coconut soaps; citronella oil, which is especially suitable for honey soaps. Then, a good effect can be achieved with coumarin, eugenol and geranyl acetate. Nerolin can also be recommended, and in particular terpeneol. Cinnamon aldehyte is also used with brilliant success. The scent of violets can be achieved with ionone II, with the addition of terpeneol, and brilliant results are obtained from the use of artificial neroli oil.
18. Marble toilet soaps. It is produced in order to give them the appearance of spotted or sinewy marble. To do this, pour liquid soap into the form to a certain height, sprinkle or douse its surface with insoluble resinous varnishes, then pour a new layer of soap, perform the same operation, etc., until the form is filled. A wooden spatula is lowered into the soap mass, which is stirred, moving it parallel to the mold walls. If they want to get wavy marbling, then they move the spatula along curved or spiral lines. Various colors are used for motley marbling.
b) To prepare liquid soap, the same amount of crude caustic potash is dissolved in 2 kg of water, the solution is brought to 25 ° C and thoroughly mixed with 8 kg of unsalted lard, previously melted and cooled to 50 ° C. Further proceed as indicated above.

You will learn how to make soap at home. We will tell you what soap is made of, what equipment will be needed to start production and to whom to sell finished products.

Do you want to make soap and make money on it? Feel free to start your own business, but first read our article.

You will find out which technologies hand made soaps exist, and which one to prefer in the organization of production. We will tell you how to calculate profit and avoid mistakes.

Soap production as a business - make money and make the world cleaner

Speaking about the manufacture of author's soap at home, they often mean dyeing, flavoring and pouring the finished base into molds. It does not require special knowledge and is suitable for handmade at home without purchasing special equipment (packaging from milk and other products is used as forms).

Such a product from a semi-finished product (purchased base) has many advantages:

• ease of manufacture;
• the speed of the production process;
• availability of a certificate of conformity;
• visual variety (opaque, transparent) and their combination.

The biggest disadvantage of such a handmade product is its high cost. This is entirely justified. After all, people who have completed part of the work (welded the base) have already received their share of the money for the final product.

If you are engaged in soap making professionally, then the transition to another technology will lead to a significant increase in profitability. This technology is called a complete brewing cycle or production from scratch.

My neighbor Alena, who makes handmade soap, has gradually moved from buying the base to making it. This greatly increased profits, and brought manual work to another level. The article provides professional advice.

Soap making methods

To obtain a solid soap base, fats (vegetable and animal) are mixed with sodium alkali in various proportions.

There are 2 cooking options.

cold technology

A mixture of oils (fats) is filtered, heated and thoroughly mixed. Separately prepare a solution of caustic soda (alkali). After straining, it is also heated to the temperature of the mixture of fats. This will prevent premature solidification of the mass.

To connect liquids, alkali is added to oils, gradually mixing. The mass thickens to the consistency of a "trace" (liquid sour cream). Dyes, oils, fragrances are added to the resulting mixture and poured into molds.

They are wrapped in cloth and left in a warm place. To accelerate the chemical reaction, ripening in the oven at a temperature not exceeding 50% for 5 hours is used. If the stage of the gel (jelly-like state) has not passed, it is defended for another 12-48 hours.

Then the mass is taken out of the molds, allowed to dry and cut. Further ripening of finished pieces takes about 6 weeks. After that they are packaged.

The finished product retains its softness for a long time and it is easy to decorate it with inscriptions and stamps.

You can learn more about cold production technology here:

hot technology

After mixing base oils with alkali to the trace stage, it is placed in an oven or in a water bath. Saponification (chemical reaction) occurs at a temperature of 80-85°C for 3-4 hours. For the uniformity of the chemical reaction, the mass is thoroughly mixed 3-5 times during the entire heating period.

Perefat (oils for skin care), flavors, dyes are added to the resulting base, mixed and laid out in a mold.

After a day, cut into pieces. Allow to dry (about a day) and pack.

The amount of ingredients that make up the soap, with any of these methods is the same. But the cost of products obtained by hot technology is lower due to a significant shortening of the aging time.

Differences between soap making methods:

How to make soap for sale - production technology

To obtain large volumes, the “from scratch” method is used. This increases profitability and confidence in the feedstock.

Industrial output is standardized. It is produced according to a well-established algorithm.

Stage 1. Saponification of fats with alkali

To make soap, it is necessary to combine an aqueous solution of alkali with fats of vegetable or animal origin. In this case, alkaline hydrolysis will occur. Fats will turn into glycerol and fatty acids, which react with sodium hydroxide to form salts.

If you combine the ingredients without adding water, the chemical reaction will not occur. It will not work to correct the situation - by adding water later, it is impossible to avoid delamination.

Calculate the amount of constituent substances using a soap calculator.

The resulting mass is subjected to heat treatment (boiling).

The result of this stage of production is a viscous, viscous liquid. It is called "soap glue".

Stage 2. Salt soap glue

To turn "soap glue" into a full-fledged product, it is "salted". As a result, excess water and glycerin are removed from the original mass.

This process is also called salting out the kernel. It is produced by fractional addition of small portions of table salt (sodium chloride) or a solution of caustic soda. After the introduction of each portion, the resulting mass is boiled.

Gradually, the mixture becomes two-phase - it is stratified into layers. A soap core of solid grains remains in the upper one, an alkaline or saline solution with impurities in the lower one.

The purity, quality and yield of the final product depend on the quality of the salting. As the digestion speeds up, the core consists of low pH lumps and will subsequently become spongy. It does not meet the standards.

After boiling, the container is closed with a lid, heat-insulating material and defended until completely cooled. After that, the core is collected from the surface of the solution and defended again.

In the manufacture of laundry soap, the production chain ends at this stage. Toilet soap is subjected to further processing (bleaching).

Stage 3. Grinding the dried soap core

At this stage, the core is transformed into a product with desired properties. This is where strawberry soap starts to differ from citrus soap.

To obtain the highest grade of soap, the core is sawed. At the same time, fragrances, dyes, and other auxiliary substances are added to it. Repeated grinding between the rollers of the sawing machine leads to uniform mixing. Soap acquires the necessary properties: color, smell, etc.

Our expert Alena, in the manufacture of a large batch, suggests testing fragrances, dyes and moisturizers on an experimental specimen. In case of failure (turbidity, delamination, etc.), such a test piece can be easily rejected without damaging the entire batch.

Stage 4. Mass pressing

The resulting mass is not ready for use. It is loaded into presses to give the desired shape. Mechanisms are used to compact individual pieces and entire layers. They are manual, semi-automatic and automatic.

A miter box is used to cut a large pressed layer.

Stage 5. Packing

The cooled dried pieces are aesthetically packaged. The commercial success of a business idea largely depends on the beauty and attractiveness of the result obtained at this stage.

What equipment will be needed

As you already understood, a small factory is being equipped for soap making from scratch. It is advisable to find a separate room for him with good ventilation - you will have to work with aggressive liquids and odorous substances.

Additional space is needed to dry the finished product before packaging and storing products for sale.

To get started you will need:

1. Plate.
2. Containers for cooking (at least 3 pieces) with lids.
3. Large scoops for collecting the core.
4. Containers and devices for mixing additional substances.
5. Fridge with large freezer.
6. Piling machine.
7. Press.
8. Forms, stamps, cutters.
9. Miter box.
10. Tables for work.
11. Racks for drying and storage.

Alena advises to purchase at the launch stage minimum equipment. It is better to buy what you need in the production process than to spend money on unnecessary fixtures.

To whom to sell finished products

The resulting products are sold among target audience. Start the implementation with the inner circle - relatives and friends. When you increase the number of types and volume of goods, go to a wider audience.

Soap has different properties, and the need for it will be for different categories of customers:

Success in the production of natural, high-quality handmade soap is possible with the correct positioning of products. For example, baby soap"firefly" has little chance of active sales in the store souvenir products.

Novice manufacturers rarely pay attention to the design and name of the range they produce. Meanwhile, their alignment with the interests of clients increases the chances of success.

Learning how to make natural soap is not difficult - the master will master the nuances in a few days. It is much more difficult to sell a finished product.

How much can you earn

The answer to this question depends on several components:

1. Where is soap making. Renting a space increases the cost significantly.
2. How much production do you organize. For example, I will indicate the prices on the Internet for caustic soda. If you buy it in packs of 25 kg, then the price varies from 70 to 80 rubles. If purchased in small packaging, then offers start at 150 rubles.
3. How much is the sale. I didn't make a reservation. The sales process itself costs money. Even when trading through a site, you need to consider the cost of its creation and hosting.
4. How many people are involved in production.
5. What equipment is purchased. It is clear that the cost of 3 pans and a cutting board is much lower than the price of an industrial production line.
6. Additional costs such as logistics.

Consider whether soap making is beneficial:

In the manufacture of soap from scratch in a hot way, the yield of the finished product will be 5.5 kg. A piece of unpackaged soap weighing 100 g will have a cost of 50.34 rubles. About 14 rubles must be added to print labels, business cards and wrappers. That is, the total cost will be 64,34 rub.

In this article:

If for the industrial production of soap you need at least a room and equipment, then for the manufacture of soap at home you only need a stove and dishes.

Industrial production of soap. For this type of activity, animal fats, inexpensive oils (palm or coconut), rosin, naphthenic and fatty acids (they are obtained from petroleum paraffin) are used.

But an increase in the composition of natural ingredients will entail a directly proportional increase in demand for finished products. Indeed, at the moment, there are very few such offers on the country's market, many domestic manufacturers prefer to save on high-quality raw materials, thereby increasing their own profits.

In production homemade soap often use only high-quality components: refined animal and vegetable fats, so the risk of allergies or skin damage is minimal.

However, the cost of such a hundred-gram bar of soap will be higher than that of a similar "industrial brother".

Soap making equipment

Industrial soap making equipment

For production in an industrial environment, a beginner with limited financial resources will need a gas or electric stove, several large pots and molds for casting (wooden or silicone).

Subsequently, in order to increase profits and reduce the use manual labor, it is possible and necessary to take care of the modernization of production facilities. To date, there are many similar equipment, mostly made in China.

The processing line includes: mixer, mill, molding machine, stamping machine, refrigerator and soap cutting machine.

Homemade soap making equipment

To make soap at home, you will need a scale for liquids, large stainless steel pans, molds, a thermometer, a measuring spoon, a refrigerator.

Soap production technology

This production process consists of two stages: chemical and mechanical.

Chemical stage of production

At the first stage, with the help of an aqueous solution of sodium (potassium) salts, fatty acids and alkalis, the so-called glue soap is obtained, which subsequently needs to be cleaned and treated with electrolytes ( aqueous solution sodium chloride and alkali). Under the influence of these processes, the soap begins to exfoliate, and “soap cream” (concentrated soap with an abundance of fatty acids) floats to the surface.

Water, glycerin and contaminants from the feedstock remain in the bottom layer. A certain amount of glycerin is purified and added back to the mass. Soap, which is obtained in the end, is called sound or household.

The production technology of this soap is not characterized by high labor intensity, but with a high indicator of the quality of the finished product.

Mechanical stage of production

At the mechanical stage of production, cooling, drying and mixing with various additives takes place. The resulting sound soap must be rubbed on the rollers of the sawing machine (for a significant increase in fatty acids and its resistance to external adverse factors). With the help of pressing, the product acquires the desired shape.

For production toilet soap, in the resulting purified mass, it is necessary to reduce the water content from 30% to 12%. After that, various additives, perfumes, oils, dyes and vitamins are added.

Production liquid soap not much different from the production of traditional - solid soap, but this technology allows you to add large quantity fragrances, herbal extracts and essential oils. Fats are heated in a large vat along with caustic soda. As a result of their interaction, a viscous liquid is formed. In the chilled state, liquid soap is obtained. Often, in the process of its manufacture, additional dyes are not used to improve quality.

In the production of homemade handmade soap, high-quality purified animal and vegetable fats are used.

The ingredients in proportions, according to the recipe, must be mixed, an alkali solution should be added to them (for saponification of oils). Now two options are possible: cold or hot cooking.

cold technology

cold technology the production of handmade soap consists in thoroughly mixing the resulting soap mass, and adding essential oils, herbal decoctions, honey, etc. After that, you can pour this mass into molds and let it harden for 2-4 days. After the specified time, the soap is removed from the molds, cut and left to “ripen” for some more time (from 1 month to up to a year, depending on the variety).

hot technology

hot way is a more acceptable option to increase the profitability of production.

It consists in accelerating the saponification reaction by heating the soap mass in a water bath or in an oven, subject to thorough stirring. After a couple of hours, before the mass solidifies, you can safely add all kinds of additives and pour it into molds. After the soap has solidified, it must be removed, cut and left alone for only 2 weeks.

The technology for making soap at home is very monotonous, but it differs in a variety of necessary ingredients (depending on the recipe and, accordingly, on the intended type of soap).

The process of making soap on an example - a master class

Consider step by step process cooking one of its types.

We will need (Fig. 1):

• 100 g soap base
• dye
• fragrance
• base oil
• mold.

A piece of soap base must be cut into pieces (Fig. 2) and melted in a water bath (Fig. 3).

Then add a few drops of base oil (no more than a third of a teaspoon) (Fig. 4), dye (Fig. 5) and mix thoroughly.

Then you can add fragrance (5 drops) to the cooled mass (Fig. 6) and proceed to pouring the mass into molds. (Fig. 7)

If bubbles form on the surface, then with the help of alcohol we will be able to get rid of them. To speed up the hardening process, soap can be put in the refrigerator.

Only after complete hardening can it be pulled out of the mold. (Fig. 8)

soap making business plan

The main costs and expenses that must be incurred for the release of the first batch of industrial soap are as follows.

Period under review- 6 months, estimated production volume- 2500 kilograms of finished products.

Soap production costs

1. Premises for rent(at least 30 sq. m.), which will accommodate production capacity and perform warehouse functions (creating optimal conditions for the safety of finished products) - 30,760 rubles (about $ 1,000). For 6 months - 184560 rubles.
2. Communal payments: 3076 rubles / month. Total for six months - 18456 rubles.
3. Necessary equipment: stove - 3000 rubles, 3 vats (large pots) - 2000 rubles, 25-30 molds for pouring - 6000 rubles. Total: 11,000 rubles.
4. Raw material: 3000 kg. soap base will cost 565,000 rubles. (many suppliers give discounts for large volumes), additives and oils - 95,000 rubles, vitamins and fruit acids - 60,000 rubles. This item of expenditure is 720,000 rubles.
5. Wages of hired workers. For such a small volume of production, 4 people will be quite enough: a cook - 9228 rubles. (200 dollars), his assistant - 7690 rubles. ($150) and 2 soap packers - 6152 rubles each. (100 dollars). Our wage fund will be 29,222 rubles.
6. Soap packaging will play the role of not only a business card of the enterprise, but also perform a safe function. It is desirable that for each type of soap, the packaging also differs in variety. Let's assume the use of two types of packaging for the entire production volume: plastic - 100,000 rubles and cardboard - 110,000 rubles. Total: 210,000 rubles.

Consequently, the minimum financial requirements for organizing such a business are 1,162,238 rubles.

Economic effect

Now let's analyze economic effect from investment costs.

The minimum price of a 100-gram bar of soap is 100 rubles, and we have produced 25,000 packages of soap. Therefore, the profit from sales is 2.5 million rubles, and therefore the net income for six months of work is 1,337,762 rubles, which is 222,960 rubles / month.

The business plan for the production of soap at home is similar to the above, except for the costs of renting a room, paying staff and utilities. And the production itself will not be on such a large scale, therefore, the cost of purchasing raw materials will significantly decrease.

Soap marketing

To sell soap, you need to establish work with various stores and regularly supply them with your products. At first, you may have to lower the price a little to get them interested in your offer. But then, when the consumer appreciates the quality, it will be possible to gradually raise the price to a level justified by production needs.

You can also cooperate with pharmacies, but in this case, your product will have an extra charge of about 40%.

Another option is to create a branded point in the regular market. Do not be stingy with branded clothing with your own logo - this will be an excellent advertising move, which will soon compensate for all material and moral costs.

Handmade soap, created at home, can be purchased by people with incomes not lower than the average level. It is also a great gift for all kinds of holidays. It will not be profitable to lower its cost, since the proceeds in this case will not cover the costs of acquiring high-quality raw materials. Therefore, cooperation with cosmetics stores will also be relevant here, household chemicals and pharmacies.

It is acceptable to sell soap via the Internet and send products by mail to remote cities of the country.