Industrial technology for the production of soap. Making soap at home. What raw materials are required for the production of soap

Soap production is one of the promising ideas that allow you to set up a profitable business both on an industrial scale and in the “hand-made” mode in your own apartment.

A successful business project for the production of soap products includes several main stages:

1. Acquisition of equipment and inventory for the production process.
2. Procurement of quality raw materials and additional ingredients.
3. Establishment of an efficient and safe technology for soap production, its packaging and storage.
4. Organization of sales of products.

Industrial soap production

To organize a soap shop, an entrepreneur needs to equip the premises with special equipment. At the initial stage of production, it is enough to have a plate, molds and several large metal containers. After the enterprise "gets on its feet" and there is a need to modernize production, it is necessary to purchase a specialized production line. Such equipment includes refrigerator, mixers, stamping machine, grinding, cutting and shaping machines. Innovations will help reduce the share of manual labor, increase the profitability of the process and the profitability of production.
To obtain industrial soap, they mainly use inexpensive available types of raw materials - coconut, palm oils, fatty acids produced from petroleum products and artificial flavors.

Technology of industrial soap making

The soap making process on an industrial scale can be divided into two stages:

Chemical stage of soap production. It consists in the treatment of fatty acids with aqueous solutions of sodium (potassium) and alkalis. The semi-finished product (“glue soap”) obtained during the chemical reaction is purified by electrolytes, stratifying into “soap cream” and waste (water, glycerin).

Mechanical stage of soap production. It consists in cooling the resulting "sound" soap, drying it and mixing it with various ingredients (perfumes, aromatic oils, dyes, etc.). Then the processes of cutting, pressing and shaping the finished product follow.

For the correct calculation of the soap production business plan, all costs of the activity should be predicted. These include:

• rent of workshop premises and utility costs;
• cost of equipment;
• the cost of purchasing raw materials (to promote products on the market, it is better to launch the production of several varieties of soap at once);
• the cost of wages of employees (for the initial stage, 3-4 workers are enough);
• expenses for product promotion and packaging production (do not forget that branded packaging is the “face” of the enterprise!).

Soap sales can be established both through retail outlets, and through pharmacies and online commerce. With proper planning, organization of sales and optimal pricing policy, you can see the economic effect in a month of the enterprise's operation.

Soap "exclusive" at home

For the manufacture of homemade soap, only high-quality natural vegetable and animal fats, flavors and essential oils are used. The result of the work of a craftsman-private trader is a hypoallergenic natural soap, which has an original appearance and high cost.

To organize the production of handmade soap, you will need large stainless steel pots, a refrigerator, measuring containers, various shapes and scales. The components are mixed according to the recipe, saponified with an alkali solution. Further, hot or cold technologies are used to process the resulting semi-finished product.

Hot way (more cost effective) consists in heating the mass with all the additives in a water bath with stirring. After 3-4 hours (without allowing the product to cool), the product is poured into molds. The frozen soap is taken out, cut (if necessary) and defended for 2 weeks.

Cold process soap making at home consists in pouring the prepared mass into molds and "ripening" of the soap for 3-4 days. After removal from the molds, the product is kept until ready for another 1-12 months (depending on the composition of the soap).

The calculation of a business plan for home production is similar to an industrial estimate, taking into account the small scale of the technological process. When creating a natural high-quality product, the organization of the sale of goods comes to the fore. Expensive soap-making "masterpieces" are great gifts for various holidays and the best choice for people who prefer environmentally friendly products. When selling such soap, cooperation with pharmacies and cosmetic boutiques is necessary, as well as distribution of goods via the Internet.

Video about industrial and homemade soap making

It would seem that the need to make soap at home has disappeared thanks to the huge selection of this cosmetic product in stores. But soap making is gaining more and more popularity. Soap makers show off their own masterpieces to one another, invent new recipes, conduct master classes, and even earn good money from their hobby. There are also special departments and shops for soap making, which once again proves the growing need for soap making. Is it easy to make soap with your own hands?

Why is homemade soap better than store bought?

Soap, which is sold in ordinary household chemical stores and supermarkets, does not contain natural ingredients. In fact, it is difficult to call it soap, since soap is saponified vegetable fats, and not processed petroleum products. A store-bought product often dries the skin and can cause allergic reactions.

When making at home, you can use only natural ingredients that are suitable for your skin type. And if now it's just a hobby, then later it can become a profitable business.

Handmade soap can be of different colors, with beautiful streaks and splashes of scrubbing elements

What ingredients are used

You can make soap from scratch, or from a ready-made purchased base. As the latter, you can also use natural, fragrance-free baby soap. And for the thrifty, there are ways to digest remnants and turn "waste" into fragrant soap.

It is much easier to work with a ready-made base. It is transparent and white. Also commercially available are organic bases for making natural soaps. You can buy them at soap shops. Working with the base is not difficult, but some skills will still be required. As for making soap from scratch, in this case you will also need knowledge in the field of chemistry, since you will have to work with alkali. Before you start making soap, be sure to familiarize yourself with the safety precautions when working with alkali.

The amount of ingredients will depend on how the soap is made and the recipe. Consider the list of necessary components for each case.

Soap base ingredients

All the main ingredients can be bought in a specialized store, and additional ones in a regular supermarket. Some are sure to be in your home. You will need:

• finished base;
• base vegetable oils;
• dyes;
• flavors;
• essential oils;
• herbs, petals, honey, ground coffee - optional;
• medical alcohol.

Bases from different manufacturers differ in price, hardness, hardening speed and other characteristics. There are organic bases that are used to make all-natural soaps.

A transparent soap is made from a transparent base.

Base oils are used to enrich the soap, they give it such beneficial properties as moisturizing, nourishing and softening. Without them, the product dries the skin, and also quickly “dries out”, cracks and exfoliates. For the same purpose, you can add body cream or milk, cream or pasteurized milk.

Important! Do not overdo it with moisturizers and oils. If you decide to add full fat milk, reduce the amount. Soaps that are oversaturated with fats don't lather well.

Dyes come in liquid and dry form. It is most convenient to use liquid ones, since it is very easy to measure the right number of drops. Dry dyes are pre-mixed with oils or liquids and only then introduced into the finished mass. Try not to overdo it with dyes, because because of this, the lather will also be colored when lathering. To get started, it will be enough to purchase three basic colors: red, yellow and blue. By mixing them, you can achieve almost any shade.

In addition to purchased artificial dyes, natural dyes can also be used. These can be spices (turmeric, curry), the same base oils (sea buckthorn, pumpkin), different fillers (colored clays, ground coffee, cocoa, strong decoctions of herbs). Of course, with their help it will not be possible to achieve bright, saturated colors, but the soap will be as environmentally friendly and natural as possible.

For decoration, you can also use mother-of-pearl pigments, sparkles and various decors.

With the help of special dyes, you can give the soap any shade

Fragrances are responsible for the beautiful aroma. You can use confectionery fragrances, or you can look for special flavors for home cosmetics. Instead of artificial fragrances, essential oils, honey, chocolate, coffee, dried zest, herbs, flowers and petals are used. The disadvantage of essential oils is that they fade faster. They are usually added at the very end.

Alcohol is also used in soap making. It eliminates air bubbles from the surface of the soap and connects the layers in a multilayer colored soap. To do this, alcohol is poured into a fine spray and sprayed onto the surface of the product.

You can add a decoction of medicinal herbs, dried chamomile flowers and natural essential oils to homemade soap.

In order for soap to acquire such properties as scrubbing, anti-cellulite effect, smoothing wrinkles, etc., various fillers are added to it. These are ground coffee, nutshell powder, clay, oatmeal, crushed sea salt and much more. All these are additional caring elements that will give the soap the desired beneficial properties.

Do not use fresh fruits, berries, cucumbers, ginger root and similar ingredients. They will rot and quickly render your enriched soap unusable. Instead, use dry herbs and leaves, petals and small dried flowers, ginger powder, dried fruits.

Tools and devices

You will also need:

• pan enameled or stainless steel;
• any other saucepan for a water bath;
• plastic or glass microwave container;
• a spoon;
• whisk;
• measuring cup;
• kitchen electronic scales;
• spray for alcohol;
• soap molds.

Forms can be bought in the same specialized stores or you can use confectionery silicone molds. Also suitable are children's plastic molds for playing with sand, containers for yogurt or sour cream, and other small containers made of flexible plastic. Purchased molds are made of plastic or silicone. For beginners, it is best to use the latter, since they are the easiest to get ready-made soap from.

Soap molds are available in plastic and silicone.

As for dishes, you can not use aluminum pans, cast iron dishes. For these purposes, stainless steel containers with enamel coating, as well as heat-resistant glass and plastic containers for use in a microwave oven, are suitable. For the exact amount of ingredients, you will need a measuring cup and scales.

What ingredients are used to make soap from scratch?

The soap base is prepared independently, using only three components:

• alkali;
• oils for saponification;
• liquid - distilled water, herbal decoction, milk.

To make hard soap, you need caustic soda (NaOH). It is sold in the form of flakes or small crystals. Alkali is needed for saponification of fats, namely base oils.

Caustic soda is also called caustic soda.

In the preparation of soap from scratch, the so-called overfat is of great importance. Since fats cease to be useful after reacting with alkali, it is recommended to add more oils at the end of cooking. This will be overkill. As a rule, valuable and expensive oils are used for it.

Vegetable oils use any. Rarely add pork fat. The liquid is needed in order to pre-dissolve the alkali and prepare it for combination with fats. Using decoctions of medicinal herbs, you will give the soap useful properties, as well as a natural aroma and shade.

To improve the soap, its coloring and aromatization, the following components are used:

• plasticizers - sugar, sorbitol, fructose, honey;
• acids - lactic, succinic, stearic, citric;
• lanolin;
• glycerol;
• oils for enrichment (overfat);
• dyes;
• flavors;
• various useful supplements.

Dyes, flavors and fillers use the same ones. Plasticizers are needed in order to make soap more plastic, as well as improve foaming. The acids will harden the soap and give it bactericidal properties. Lanolin will have a softening effect on too dry and rough skin.

With the help of different base oils, you can give soap caring, beneficial properties.

Auxiliary tools

You will need:

• two pans (one can be made of heat-resistant glass);
• hand blender;
• measuring cup;
• a glass stirring rod or a regular spoon;
• container for working with alkali;
• forms.

Important! Tools that were used to make soap should never be used for cooking!

When working with alkali, great attention is paid to safety measures.

Ingredients for different types of soap: for face, hands and body

To give the soap of different qualities, you will need the appropriate components. Some of them have emollient properties, others are moisturizing and nourishing, and others are bactericidal and drying. It is worth noting that it is better to use the appropriate soap for each part of the body. Washing your face with body or hand soap is not recommended. Also, not all components are suitable for every skin type.

Table: Recommended Soap Ingredients Based on Use

Components	Arms	Face: skin types				Body
		Normal	Dry	Oily	problematic
base oils	olive cocoa Palm jojoba shea (shea) walnut	olive almond cocoa avocado	castor evening primrose shea (shea) wheat germ wild rose almond avocado	sweet almond apricot kernels peach pits hazelnut	olive sea ​​buckthorn	olive cocoa coconut shi (karite) almond sesame and etc.
	any	ylang-ylang lavender geranium jasmine chamomile	lavender palmarosa neroli ylang-ylang jasmine mint	lemon cypress geranium rosemary	juniper fir sandalwood tea tree eucalyptus	orange grapefruit eucalyptus tea tree and etc.
fillers, including scrubbing	lanolin glycerol beeswax	cosmetic clay ground coffee crushed herbs milk	cosmetic clay powdered milk glycerol decoctions of herbs chamomile extract, mint, coltsfoot, lime blossom	cosmetic clay Activated carbon camphor alcohol infusions and decoctions calendula and chamomile propolis tincture	cosmetic clay Activated carbon eucalyptus leaves herbal infusions and decoctions	clay loofah honey sea ​​salt ground coffee eucalyptus leaves tar seaweed

For aging skin, geranium oil is recommended because it helps to smooth out wrinkles. Mint will save you from dryness, and juniper will saturate the skin with useful substances. For rough, overdried skin, it is recommended to use lanolin. Orange oil, algae, loofah and ground coffee have an anti-cellulite effect and make the skin supple.

Essential oils give a beautiful aroma, and also “enrich” the soap with useful properties.

Making solid soap at home

First, the base is melted in a water bath or in a microwave oven. With the first method, the base melts longer, but a uniformly melted mass is obtained. In addition, you will be able to independently control the entire melting process. When heated in an oven, there is a risk of the base boiling. Therefore, set the power to the very minimum and heat for 1 minute, checking the condition of the base every 5-10 seconds.

Soap base

Having prepared all the necessary ingredients and appliances, do the following:

This is the standard algorithm of actions. The amount of ingredients and fillers mainly depend on the recipe.

• base oils - 1/3 tsp;
• essential oils - 3-7 drops;
• flavor - 3-4 drops;
• liquid dye - 1–7 drops;
• dry pigment - 1/3 tsp.

Other additives (herbs, clay, scrub components) can be added at will, as well as in accordance with the recipe.

Important! Esters are added at the very end to a warm, but not hot, “soapy” mass. They are quite volatile, evaporate quickly, and their properties are lost.

Video: How to make soap from a finished soap base

Cold and hot manufacturing from scratch

This is the real soap making. You can only prepare the base and use it in the future as a ready-made purchase.

Soap making from scratch is not the safest activity. You have to work with alkali, and, as you know, it is capable of leaving burns on the body. Therefore, much attention is paid to the means of protection and familiarization with the properties of alkali, its reaction with water, as well as the chemical reactions that occur during the saponification of fats and their transformation into the same soap.

Alkali, reacting with water, emits a pungent odor and is very harmful to the mucous membranes. Contact with alkali on the skin causes severe burns, so be extremely careful when working with this substance.

Safety rules for working with alkali

• Be sure to use protective equipment: goggles, a respirator, rubber gloves.
• Clothing and shoes should be as closed as possible.
• Utensils and tools that are used for making soap are not used for cooking.
• It is best to work with lye outdoors. If this is not possible, open the windows and turn on the hood.
• Food should not be prepared in the kitchen. Children and animals should also not be present.
• Reacting with water, the alkali heats up very much, as a violent reaction occurs. Make sure that the water is as chilled as possible, and preferably with ice cubes.
• The container should be glass, ideally a special container for working with alkali.

This is the minimum list of requirements to keep you safe while making your soap base. Next, follow the general rules for making soap from scratch.

Another important point. An alkaline solution is poured into liquid oils and not vice versa! You also need to strain the solution to avoid getting whole soda crystals.

To make sure that the oils and lye have fully worked and that the soap is absolutely safe for the skin, we recommend using special indicator strips (litmus papers). Just dip the tip of the strip into the soap and wait for the reaction. Next, compare the color of the paper with the color chart on the package. The darker the shade, the higher the pH level. Soap with a pH level above 10 is considered immature and not ready for use.

To prepare the base, they use ready-made recipes or develop their own using a special soap calculator. The latter can be found on the Internet at many soap making sites. The trick is that you have to calculate the amount of oils and alkalis for the correct ratio. It is difficult for beginners to do this, so we recommend using ready-made recipes from the Internet.

This is how an online calculator for calculating the amount of ingredients for soap looks like

Soap base is prepared in two ways:

• Cold way. More simple, but it takes a long time for the "ripening" of soap.
• Hot way. More difficult at first, but the soap is ready for use within a day.

Let's consider each of them.

cold way

1. Measure the correct amount of alkali.
2. Pour ice water into a special container.
3. Slowly pour the lye into the water and stir immediately.

   

   Alkali is added to the liquid gradually, gently stirring

4. While the mixture is cooling, proceed to the oils.
5. Melt solid oils in a water bath or in a microwave.

   

   Solid oils are heated in a water bath until they are completely melted.

6. Blend all oils until smooth.
7. Measure the temperature of the alkali and oils - one should be approximately the same and be 37-38 ° C (use an electronic thermometer).
8. Add the alkaline solution to the oils while straining it through a strainer.
9. Stir gently.
10. Turn on the blender and start whipping the mixture of oils and lye. Alternate beating and stirring in the off mode.

    

    The oils are whipped with an alkali solution using a hand blender.

11. When the mixture becomes viscous, you can start adding various benefits, colors and flavors.
12. At this stage, fat, essential oils, and other natural ingredients are added.

    

    When the soap base becomes viscous, you can start adding various fillers and utilities.

13. Pour the finished mixture into molds and leave to harden.
14. Remove soap after 24 hours and remove from mold.
15. Wrap in cling film and leave to ripen for at least 4 weeks.

A long maturation stage is needed in order for the soap to pass from the “trace” stage to the “gel” stage. In simple words, during this time it will become what it should be.

Video: Soap "from scratch" in a cold way

At the “trace” stage, when the mass begins to thicken, you can stop and leave everything as it is. The frozen mass will be the soap base, which can then be melted and made into fragrant homemade soap.

hot way

Up to the “trace” stage, soap is prepared in the same way as with the cold method. The most interesting begins later.

So, the viscous base is ready. Let's move on to the next step:

Video: Hot soap from scratch

As you can see, the hot method is much more complicated, but it has the advantage that soap can be used almost immediately after it is made.

Soap Recipes

There are a huge number of recipes for the preparation of different types of soap, differing in their purpose, properties, fillers and appearance. Let's consider several recipes using the base, but if desired, they can also be used in the manufacture of soap from scratch.

baby

• organic base - 250 g;
• carrot juice - 1/2 tsp;
• a decoction of string and chamomile - 1 tsp;
• almond oil - 8 drops;
• tangerine oil - 1-2 drops;
• funny baby molds made of silicone in the form of animals.

It's very simple: melt the base, mix with the rest of the ingredients, pour into molds and leave for 24 hours to harden the soap.

These cute teddy bears can be made from a soap base and other ingredients.

Tar

• transparent base - 100 g;
• calendula oil extract - 1/3 tsp;
• birch tar - 1.5 tsp (sold in a pharmacy);
• mint essential oil - 6-8 drops.

In a melted and slightly cooled base, add the ingredients in the following sequence: oil extract, tar and finally essential oil. Mix everything thoroughly and pour into molds.

Birch tar has antiseptic and antifungal properties, so this soap will be useful for problem skin.

It will look like tar soap from an opaque natural base

Two-layer colored soap with honey

According to this recipe, you can make a beautiful decorative soap from layers of different colors.

First layer:

• transparent base - 50 g;
• yellow food coloring - 3 drops;
• flavor "Honey" - 10 drops;
• natural honey - 1 tsp;
• grape seed oil - 1/3 tsp

Second layer:

• white base - 100 g;
• avocado oil - 1/2 tsp;
• pasteurized milk - 2 tsp;
• pearlescent pigment - 1/2 tsp;
• honeycomb shape.

First, prepare the first layer of a transparent base, pour it into a mold and sprinkle with alcohol. When the layer has cooled, sprinkle it again with alcohol and cover the prepared white base.

This yellow-white soap has a unique aroma of honey.

The use of remnants

Agree, sometimes it is a pity to throw away the remnants of soap or the so-called remnants. We offer a simple way to "resuscitate" remnants and make soap from them, which in the end can even surpass its "original source". From the "soap" residues, you can make both solid and liquid soap.

In addition to remnants, you will need the following ingredients and tools:

• remnants - 200 g;
• water - 5 tbsp. l.;
• glycerin - 2 tbsp. l.;
• alcohol tincture of calendula - 2 tbsp. l.;
• essential oils and fragrances for fragrance - optional;
• grater for rubbing remnants;
• containers for a water bath;
• a spoon;
• forms.

Remnants can be used in a variety of ways, except, of course, the remains of laundry soap for washing and various stain removers. Fillers and fragrances can take any. With their help, you "enrich" the soap, give it new useful properties and flavors.

From colored remnants you can make wonderful soap

Glycerin is needed to obtain a more viscous consistency, it helps the components dissolve faster and retains the desired moisture. Instead of alcohol tincture of calendula, you can use medical alcohol.

The remnants will need to be melted in a water bath. Thus, the contents will be evenly heated and melted to the desired consistency.

So, having prepared all the necessary ingredients and tools, get to work:

In the same way, soap can be made from the remains of a soap base and baby soap.

Video: How to make solid soap from remnants

How to make liquid soap

To prepare liquid soap from scratch, another type of alkali is used, namely KOH (potassium hydroxide). This type of soap is also called potassium soap. Liquid soap can be made from the same remnants, from baby soap, from the remnants of a soap base, or from any solid soap. Consider the cooking process.

From remnants

To prepare 1 liter of liquid soap you will need:

• remnants - 50 g;
• distilled water - 1 l;
• tincture of calendula or medical alcohol - 2 tbsp. l.;
• essential oil - 3 drops;
• liquid food dye - 3 drops;
• glycerin - 4 tbsp. l.

Put a pot of water on the fire and do the following:

Video: how to make liquid soap from remnants

Liquid laundry soap

It is used for washing clothes and washing dishes. You will need one bar of laundry soap (200 g), 1 liter of water, essential oils and fragrances - optional. How to cook:

1. Rub the soap on a grater - the finer the chips, the faster it will dissolve.
2. Pour the shavings into a stainless steel saucepan and add water.
3. Mix the ingredients and cook over low heat until the chips are completely dissolved.
4. At the end, strain the mass through a sieve and cool slightly.
5. Add about 20 drops of essential oil or fragrance.
6. Pour the finished liquid soap into a plastic bottle.
7. Concentrated washing gel is ready.

The finished product is stored in a closed container.

Photo gallery: beautiful handmade soap

Loofah soap has a scrubbing and anti-cellulite effect on the skin Soap brewed with a decoction of herbs is always a pleasure to use. Coniferous soap has extraordinary healing properties and a beautiful aroma. Soap in the form of a jelly dessert looks very appetizing This soap is almost indistinguishable from a natural mineral This soap not only looks beautiful, but also smells delicious. The main thing is not to confuse such soap with a real cake! Natural soap without artificial dyes and additives, the most beneficial for the skin Soap in the form of a snowflake will be a great gift for the New Year Homemade colored soap with various additives will decorate the bathroom Handmade soap can have a wide variety of shapes and colors.

Due to the great popularity of soap making, it will not be difficult to find special equipment for its production.

Main Devices:

• a container in which the raw material will be melted;
• boiler for cooking;
• mixing devices;
• two-stage screw press mixer;
• forms;
• cutting and marking machines.

You can buy inexpensive equipment that has low productivity. Or pay attention to more powerful and expensive devices.

Process of creation

Soap production is based on chemical reactions. And the equipment acts as a kind of catalyst, which accelerates them and allows you to increase the number of products. Accordingly, the larger the technological device, the larger the volume will be produced. In industrial production, the stages are distinguished:

• the main components are heated, and a chemical reaction begins;
• the required amount of raw materials is placed, and soap glue is produced;
• glue is divided into liquid and solid parts;
• various additives are added to the solid part;
• the mass is pressed, after which it is cut and packaged.

There is nothing complicated in the process itself, all that is required is a clear observance of proportions.

Installation UHM 0.6

Composition: boiler, heating element, 2 control stations, 6 sludge tanks, table and template. The unit is equipped with a service platform.

The boiler is covered with thermal insulation and equipped with a lid, which is a cylinder with a conical bottom. Inside there is a tank made of boiler steel. The unit is equipped with a reliable motor, on which the mixing device is fixed.

Technology cooking is fully automated. Components enter the boiler through the loading window along with water. With the help of the control post, voltage is applied to the heating element. Its use creates a completely autonomous hot water supply system. During operation of the stirrer, a solution of caustic soda is gradually supplied to the molten mass. In the boiler, the entire process of soap making takes place in stages. When the agitator is turned off, the soap begins to settle until the core is completely separated from the soap liquor. After that, the process of polishing the soap is turned on, then it is settled, cooled and cut.

Equipment for the production of laundry soap

Laundry soap is an environmentally friendly product, since natural raw materials are involved in its manufacture. It is distinguished by the presence of additives, consistency, production method, and so on. Minimum set equipment for the production of laundry soap:

• boilers for cooking (50 and 250 l);
• a boiler for melting fat - raw;
• device for mixing with additives;
• press;
• compressor.

This line can be operated by one person.

Equipment for the production of detergents

Cleanliness is the key to health. Sales of detergents and cleaning liquid funds, powders are steadily rising up. This direction is becoming more and more popular due to its simplicity. The production technology includes: mixing, drying (for powdered) and packaging. Main equipment for the production of detergents:

• mixer - for mixing components;
• vacuum chamber;
• homogenizing plant;
• several containers;
• distribution equipment.

Equipment for the production of liquid soap

Liquid detergent is very popular among the population. And its production will be promising and profitable. Necessary liquid soap making equipment:

• dosing pumps;
• containers for products;
• filters;
• water heater and compressor;
• bottling and labeling equipment.

There are several manufacturing technologies, among which the simplest is cold. During which it is necessary to mix all the ingredients and pour into packages. It looks more difficult hot, during which it is necessary to heat the fats and saponify them with alkali and cooling.

Soap making at home

Increased attention to natural cosmetic and hygiene products contributed to the development of soap production self made like a business. Previously, this product was in the souvenir category. But now many consumers are interested in its constant use, which has a positive effect on sales growth. Organize such an enterprise at home will not be difficult even with a small start-up capital.

To start manufacturing, it is advisable to allocate a separate room, since you will have to deal with aggressive substances. You will also need additional space for storing and drying finished products. Initial set of equipment:

• stove for heating the mixture;
• containers in which products will be cooked;
• scoops with which the core will be collected;
• objects and containers with which the components will be mixed;
• large freezer;
• sawing machine
• press;
• molds for products.

If there are still funds left in the budget, then you can turn to purchase a more expensive and specialized mini equipment. It will not only speed up the process, but also make the product better.

The production of laundry soap involves 2 stages: soap making and processing of the soap mixture into a finished product. Due to the naturalness of the products used in the manufacture of laundry soap, it is environmentally friendly.

The production process may include the use of not only fats and oils of animal and vegetable origin, but also acid, synthetic and industrial fats.

Product Feature

Starting such a business is easy due to the widespread use of these products in domestic and industrial conditions. Detergent features:

• High performance;
• Use at any temperature;
• No allergic reactions to the skin;
• Low cost and sales value;
• Completeness of decomposition into biological components;
• Fire safety and non-toxic;
• Storage duration.

Hard varieties are distinguished by their purity of environmental friendliness and first-class quality, corresponding to GOST 30266-95. The soap raw material composition does not include surrogate materials and substances. Products are manufactured that have an antibacterial effect and without preservatives, using modern technologies.

Application of the soap product

Laundry soap is used for cleaning and washing heavy dirt and hands. To do this, on wet skin, a small amount of the product is rubbed and lathered to remove contamination, after which the foam is washed off with water.

This soap is recommended for washing fabrics made of pure cotton, cotton and wool blend products. In this way, you can wash and disinfect baby clothes. Dosage for hand or machine wash - for 1 kg of laundry is 20 g of the product and 6 liters of water. Fruit stains are removed by adding 12-18 g of soda ash to the indicated dosage.

As a plasticizing additive, laundry soap is used in the preparation of oil-adhesive, PVA-based and acrylic putties. For the manufacture of a plasticizer, 5-9% of the product is used for the entire weight of the putty.

This tool is preferred to clean parts in certain areas of the industry related to technology. Soap finds its application in both farming and agricultural industries.

Ensuring the safety of soap products

It is not enough to learn how to produce laundry soap, one must be able to and ensure its safety. The recommended storage temperature for the environment should be at least 0°C in the original packaging, which should not be aluminum or galvanized. The storage area must be well ventilated.

It is acceptable to stack products in stacks up to 2.6 m in height and with a distance between them of 0.6 m. The humidity level in the warehouse should not be high. The semi-finished product is stored temporarily for the period of stopping soap production.

In the absence of cooking production, soap layers of soap are transported to other regions for their further processing into finished goods.

Range

The variety of laundry soap rolls over. Traditionally, this product is classified according to the following criteria:

• Appointment;
• Consistency (solid, liquid, ointment and powder);
• The volume of acidic fats (1, 2 and 3 groups);
• Preparation method: sawn, sound or glue production;
• Color: normal or brightened;
• Fillers: aromatic, coloring, abrasive or antibacterial additives;
• Shape: rectangular or complex.

The production of laundry soap, as well as its testing and acceptance, must comply with state standards. This is a universal product that is in great demand, despite the wide selection of detergents on the market.

This product is purchased by individuals, and almost all enterprises. Such demand will not slow down the search for its consumer, which makes this business profitable.

The quantity and complexity of technical equipment depends on the range of soap produced. Therefore, the first decision is made on the type of soap being created, which will have its end users.

Equipment for the production of

In order to save money, organizing such a business does not require a large amount of equipment.

A line of 50 kg per hour is enough, consisting of: 2 digesters, a melting vessel, a mixer, a 2-stage screw press for sawing, cutting and marking equipment, stamping molds and a compressor.

To accommodate the necessary equipment, which will be serviced by one person, it will be necessary to rent a room of 16 sq. m. Initial investment - up to half a million rubles. Later the line can be completed with accessories. The profitability of such production is about 50%.

direct production

For the manufacture will require raw materials - animal and vegetable fats and oils or their mixtures and waste. The highest fatty acids are washed with caustic alkalis, obtaining solid, soft or liquid soaps.

It is possible to use fat substitutes and fillers to reduce fat consumption and make the material plasticity and foaminess.

Melting in boilers, a solution of caustic soda is added to the fat in a thin stream, continuously stirring the constantly boiling raw materials. They start with a weak solution - in 8-10%, then in 18-20% and finally 32-33%.

Adding small portions of water to the boiler will ensure the liquid state of the raw material. By adding alkali, it will become dark and uniform. The finished mass is checked for fluidity with a wooden spatula and should look like long transparent threads of soapy bone boiled glue.

Having settled, the mass is poured into molds and allowed to cool under natural conditions for 24 hours. Bars or layers are cut with a mass of 400 g and a stamp is applied to them. Packing is made in wooden boxes.

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 industrial sectors, such as mechanical engineering, watch 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 sectors (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, recently soap factories have been producing 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 expensive example of an expanded automated line with a capacity of 2500 kg/h is the manufacturer NPO Agromash, which costs 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 operation, the following capital costs will be required:

• equipment cost - 670 thousand rubles;
• delivery and installation of the line - 50 thousand rubles;
• preparation and repair of a production facility (20 sq. m) - 50 thousand rubles;
• creation of a commodity stock 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 price for the sale 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 within six months to a year.