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Soap is one of the oldest chemical created over two thousand years
ago by soaponification animal fats with the ashes from plants.
Although soap are generally used as surfactant for washing,
Bathing cleaning, but they are also being used in textile spinning
and as important component of lubricating fat. Now soap and
detergent have become essential part of our society. There has
been continuous development Soap production technology starting
with batch kettle making process in cottage industry and to present
continuous present soap making process using either fat
soaponification or by fatty acid neutralization utilizing a wide
variety of natural and synthetic feed stock [Zhu et al., 2004]. Soaps
are also key components of most lubricating grease which are
usually mixture of, calcium, sodium, lithium soaps and mineral
oil.( من ملفlec1 على ديسكتوب... )في كراجويشن
From a chemical standpoint, is a salt (or a mixture of salts) of fatty
acids. As with all salts, soap contains a positive ion, usually Na+ or
K+, and a negative ion, usually the anions of long-chained
carboxylic acids obtained by the hydrolysis of animal or vegetable
fats. These fatty acids, of which there are about 20 naturally
happening members, are carboxylic acids containing 14, 16, or 18
carbon atoms in an unbranched chain. The even numbered chains
result from the fact that fats are synthesized in cells by the
polymerization of a 2-carbon acetate unit.(9-soap-down)
a soap factory is an industrial and marketable project, and even if
modest in range and on the scale of a cottage industry, it has a
responsibility to be viable and capable of ensuring its survival,
profitability and growth. This being the case, the marketable aspect
is very important and needs to be studied in depth. The soap
market is in fact a user goods market on which there is generally
fierce competition between soap formed locally and soap imported
at low prices.
O
NaOH ||
fats glycerol + R-C-O-Na+
The origin of personal purity dates back to very old times. Since
water is essential for life, the first people lived near water and
learnt on its purification properties. Soap got its name, according
to an ancient Roman legend, from increase Soap, where animals
were sacrificed to appease the gods. The mixture of decayed
animal fat and wood ash that ran down to the clayey soil close to
the river was found to make washing simple for women inhabiting
the area. According to the medical document Papyrus, soap-
making dates back to about 1500 BC, and that a mixture of animal
30 and vegetable oil with alkaline salts was used to form a soap-
like material.1 In ancient India too, people used soap preparations
made from plant or animal fats. Soap was made by boiling tallow
(or other hard animal fat) or vegetable or fish oil in an alkaline
solution. new technology has led to the evolution of synthetic
detergents that have gradually replaced soaps. Earlier, detergents
were used chiefly for hand dishwashing and fine fabric laundering.
This was followed by the development of all purpose detergents
for laundry introduced in the United States of America in 1946.
Soaps are the sodium or potassium salts of certain fatty acids
obtained from the hydrolysis of triglycerides. The potassium salts
form the "soft soaps" that have become popular recently. The fats
used in soap manufacture come from diverse natural sources.
Animal tallows and coconut oil are the favored sources of the
triglycerides, and quite often mixtures from different sources are
used to vary hardness, water solubility, and cleansing action of the
final product. Palm, olive, cottonseed, castor, and tall oil are other
sources. The side chains are usually Cn-Ci8 in length.
Manufacturing processes are both batch and continuous.
Sometimes the triglyceride is steam-hydrolyzed to the fatty acid
without strong caustic and then in a separate step it is converted
into the sodium salt. Either way gives a similar result. Soaps have
some disadvantages compared to synthetic detergents: they are
more expensive, they compete with food uses for fats and oils, and
their calcium and magnesium salts formed in hard water are very
insoluble and precipitate onto the clothing being washed.
Figure 24.3 U.S. consumption of soaps vs. total synthetic detergents. (Source:
Chemical Economics Handbook)
Raw material:
lauric oils hard fats soft oils
2)Glycerine:
18) Milled soaps : these are the most commonly used, mass
produced soaps. Milling refers to the combination of color,
smell and soap flakes.
Sales
Asia
Western Europe
Latin America&caribbean
North America
Middle East
East &Central Europe
Africa
Australia&Pacific Rim
The US market continues to dominate in the world, although the
Japanese market has grown significantly during the period under
review. Sales of soaps have received a strong impetus in China due
to its recent economic development. The Indian market has
also grown significantly, largely due to the reduction in rates of
excise duty on soap and detergents in 1995. Effectively, that year
witnessed a 100% jump in production and sales.
The global market for soaps is dominated by a small number of
multinational companies with strong brand identity and
enormous advertising budgets. There is cut-throat competition
between these multinationals. The top global players include
Unilever, Procter and Gamble, Colgate Palmolive and Johnson &
Johnson. Important regional players include Beiersdorf in Europe,
the Kao Corporation in AsiaPacific, Paterson Zochonis in Africa and
Nirma and Godrej in South Asia.( [Fats and oils in main commercial use for soap-
making]. Chemical Business, February 2000)
50.00%
40.00%
30.00%
10.00%
0.00%
Higher Upper Middle Lower lower
Middle Middle Middle
The highest income group (more than US $ 2250 per annum)
showed an increase of between 10-20% in the decade 1990-2000.
This was the group which consumed the most expensive or
premium soaps. The premium soap products were well received by
the top 20% (Middle-middle, Upper-middle and High income
segments), while the less expensive products were used by the
majority of 80% of people (30% by lower middle and 50% by low
income groups).
1) Latin America
There had been a 20% growth in the sales of soaps and detergents
in the last five years. There was heavy investment in the
development of new product, their launching and advertising.
Greater competition led to fall in prices and increasing
consumption as soap became more affordable. The major
multinationals in Latin America are Unilever, Colgate Palmolive,
Avon, Procter & Gamble.
2) Asia
With the majority of the population living under the poverty line,
low cost items such as the bar soap, form the dominant sector of
the market. In terms of population size, there is a huge market
potential. As income increases, consumers go for more expensive
types of soap. Unilever is the dominant player in the region.
Procter &Gamble, Colgate Palmolive and Johnson & Johnson are
also active in this region.
3) Africa and the Middle East
Unilever dominates the market in Africa. In West Africa, market
penetration of soap is estimated at 98%, due to strong hygiene
habits and a large raw material base. Production tends to be
localized for economic reasons. Manufacturing soap locally is
strong in rural areas, with 10 to 15% of soap manufactured through
local enterprises rather than multinationals.
Table 2.2
The top 20 global players in the soaps and toileteries market
1. Wear Rate
Wear rate describes the lasting power of the soap bar under use
conditions. It is influenced by the solubility of the base, which is
determined by the titer of the fats and oils, the type of alkali used,
and the amount of water.
3. Wash down
The feel of a bar during use can be determined by a wash down
test. This is usually performed at a relatively low temperature, such
as 85-90”F, in order to determine if there is any grit, drag, or
sandiness in the bar. Synthetic and combo systems are prone to this
problem, as well as formulas containing sodium cocoyl isethionate.
4. Lathering
Although lathering and detergency are not necessarily related, and
foam may actually be just a visual aid allowing the user to see
where the product has been applied, consumers associate quick,
copious foam with quality and cleaning.
5. Color
Soap bases tend to yellow, so that the color of the final bar
formulations will also change. This, coupled with additive and
fragrance instability, can produce color variations over a short
period of time. Accelerated stability testing in oven, sunlight,
and/or fluorescent light can help predict the stability of the system.
6. Odor
Olfactory evaluation of soap bases and finished soap products is as
important as any other measurements of physical characteristics.
Consumers tend to view fragrance perceptions as being at least as
important as any other product characteristic. 'Therefore it is
important that fragrances be formulated for soap to ensure as much
stability as possible. Odor stability can be evaluated under similar
conditions as color stability. Trained technicians and odor
evaluation panels usually review the results of olfactory tests.
Dahlgren, RM.; M.E Lukacovic; S.E. Michaels; M.O. Visscher. Effects of Bar Soap Constituents on Product Mildness.
In Second World Congress on Detergents, Baldwin, A.R, Ed.; Amercian Oil Chemists' Society: Champaign, IL,
1987.