Soap Production
AIM:
The aim of this assignment is to identify a particular product that can be produced by a company and explain the process of production and the plant machine used. Therefore, effort is made to explain in details the manufacturing process of soap.
INTRODUCTION
Soaps and detergents belong to the same group of chemical products called surface-active agents or surfactants. This group of products are, amongst other properties, well-known for their detergency which is due to a reduction in water surface tension which removes the dirt by wetting, emulsification, lathering and removal.
Soap production can be regarded as one area of business that is lucrative and needs only little capital to start with, and considering the vast available resources in Nigeria there is need to design and develop strategy on war footing in order to explore and utilize full benefits of these raw materials using the available indigenous technology.
The manufacturing of soaps and detergents is a complex process that involves different activities and processes. The size and complexity of these processes and activities may range from small manufacturing plants that employ a small number of people to those with hundreds and thousands of workers.
PRODUCTION PROCESS OF SOAP/DETERGENT
The first phase in the manufacturing of soaps and detergents is the selection of raw materials. Raw materials are selected on the basis of various factors, including – cost, human and environmental safety, compatibility with other ingredients, and the performance characteristics and appearance of the final product. While the actual production process may vary from company to company and manufacturer to manufacturer, there are some steps, which are common to all types of cleaning products.
The industrial soap making involves four basis steps –
- Saponification
- Glycerin Removal
- Soap Purification
- Finishing
These different steps involve various processing steps and operations in their own. A brief description of these different steps is given below –
- Saponification: The saponification process involves the mixing of tallow (animal fat) and coconut oil with sodium hydroxide and the application of heat. The process results in formation of soap, which is a salt of long chain carboxylic acid
- Glycerin Removal: Glycerin is more valuable than soap, and hence most of it is removed for its uses in more expensive cosmetic products. Some of the glycerin is left in the soap to make it soft and smooth. Soap is generally not very soluble in salt water, while glycerin is, hence the salt is added to the wet soap thereby causing it to separate out into glycerin and soap in salty water.
- Soap Purification: In the soap purification stage, any remaining sodium hydroxide is neutralized with a weak acid, like citric acid and two thirds of the remaining water is removed to obtain pure soap.
- Finishing: The final stage of industrial soap manufacturing process, finishing stage involves mixing of additives, such as colors, preservatives, and perfume into soap, which is then shaped into bars for sale.
PACKAGING
The final stage of the detergents and soap manufacturing process is the packaging. In this stage, the finished product is packed for final supply to consumer. During the packaging stage, bar soaps are either wrapped or cartooned in single packs or multipacks. Detergents, including household cleaners, dishwashing cleansers and laundry cleansers are packaged in cartons, bottles, pouches, bags or cans.
SOAP PACKAGING BENEFITS
Packaging is one of most important steps in soaps and detergents manufacturing and hence should be given prime consideration by soap and detergents manufacturers. Some of the important benefits of soap packaging include –
- Enhances the marketability of product
- Improves the appearance and attractiveness of product
- Increases the shelf appeal of product
- Increases the shelf life of product
- Reduces the waste during production
- Makes the product easy and convenient to use
- The product can be packed in different sizes to meet the varying demands of consumers
PLANTS AND MACHINE USED IN SOAP MANUFACTURING
Machines / plants used in soap making as shown in the flow chart above are:
- Soap mixer
- Soap Roller
- Soap duplex Plodder
- Soap Sircular Bar Cutting machine
- Soap Cutting machine for soap cakes
- Soap Stamping machine
CONSTRAINTS IN THE PRODUCTION OF SOAP IN NIGERIA
1. Access to capital & credit. Lack of financial capital is the single most significant challenge when it comes to doing business in Nigeria. Even with the conceptualization and implementation of financial programs meant to support businesses, the government has always been in a struggling position to ensure that financial capital is easily made accessible to entrepreneurs. In most cases, entrepreneurs have to turn to personal savings, business loans, families and friends, or government grants to get financial capital for business.
2. Electricity / Power Supply: Getting access to constant electricity and a power supply is a major concern for business in Nigeria. an average household in Nigeria can only have access to 6 hours uninterrupted power supply out of the 24 hours that exist in a given day. This is why the use of generators as an alternative power source is so common in Nigeria.
3. Government regulations: The government plays a major role in the decision of how business gets done in Nigeria. No government or economic system leaves all decisions about doing business to the market. These regulations are meant to keep businesses in-check and ensure that follow a common rule. The law that guides doing business is known as Companies & Allied Matters Act (CAMA).
4. Corruption & Bribery. While Nigeria is among the world’s leading investment destinations and is formally a well-functioning business environment, corruption and bribery are still serious obstacles. The federal structure of the political system means there is a wide range of regulatory agencies, which can lead to demands for bribes from public officials.
5. Market developments: There is also market risk around the fact that there is global uncertainty around economic growth. When you are unsure of the direction that the entire economy is going to take, it makes business planning and strategy development a great deal more difficult and risky.