Detailed Project Report (DPR) on quaternary ammonium salt softener (powder form)

QUATERNARY AMMONIUM SALT SOFTENER (POWDER FORM)

[CODE NO.4431] 

A fabric softener (American English) or fabric conditioner (British English) is a conditioner that is applied to laundry during the rinse cycle in a washing machine to reduce harshness in clothes that are dried in air after machine washing. In contrast to laundry detergents, fabric softeners may be regarded as a kind of after-treatment laundry aid.

A wrinkle releaser is a similar, more dilute preparation meant to be sprayed onto fabric directly.

Machine washing puts great mechanical stress on textiles, particularly natural fibers such as cotton and wool. The fibers at the fabric surface are squashed and frayed, and this condition hardens while drying the laundry in air, giving the laundry a harsh feel. Adding a liquid fabric softener to the final rinse (rinse-cycle softener) results in laundry that feels softer.

In the US and UK laundry is mostly dried in mechanical dryers, and the tumbling of the laundry in the dryer has its own softening effect. Therefore, fabric softeners in the US and UK are used rather to impart antistatic properties and a pleasant smell to the laundry. Fabric softeners are usually either in the form of a liquid, which is added to the washing machine during the rinse cycle (either by the machine itself or through use of a dispensing ball); or as a dryer sheet which is added to the moist laundry at the beginning of the dryer cycle. Liquid fabric softeners can be added manually during the rinse cycle or automatically if the machine has a dispenser designed for this purpose. Liquid fabric softeners may also be poured onto a piece of laundry to be dried, such as a wash cloth, and it will be distributed as the laundry is tumbled.

Fabric softeners coat the surface of a fabric with chemical compounds that are electrically charged, causing threads to "stand up" from the surface and thereby imparting a softer and fluffier texture. Cationic softeners bind by electrostatic attraction to the negatively charged groups on the surface of the fibers and neutralize their charge. The long aliphatic chains then line up towards the outside of the fiber, imparting lubricity.

Fabric softeners impart antistatic properties to fabrics, and thus prevent the build-up of electrostatic charges on synthetic fibers, which in turn eliminates fabric cling during handling and wearing, crackling noises, and dust attraction. Also, fabric softeners make fabrics easier to iron and help reduce wrinkles in garments. In addition, they reduce drying times so that energy is saved when softened laundry is tumble-dried. Additionally, they can also impart a pleasant fragrance to the laundry.

Cationic Fabric Softeners

Rinse-cycle softeners usually contain cationic surfactants of the quaternary ammonium type as the main active ingredient. Cationic surfactants adhere well to natural fibers (wool, cotton), but less so to synthetic fibers. Cationic softeners are incompatible with anionic surfactants in detergents because they combine with them to form a solid precipitate. This requires that the softener be added in the rinse cycle. Fabric softener reduces the absorbency of textiles, which adversely affects the function of towels and microfiber cloth.

Formerly, the active material of most softeners in Europe, the United States, and Japan, was distearyldimethylammonium chloride (DSDMAC) or related quat salts. Due to their poor biodegradability, such tallow-derived compounds were replaced by the more labile ester-quats in the 1980s and 1990s.

Conventional softeners, which contain 4–6% active material, have been partially replaced in many countries by softener concentrates having some 12–30 % active material.

Cationic Surfactants Used As Fabric Softeners

Diethyl ester dimethyl ammonium chloride (DEEDMAC)

TEAQ (triethanolamine quat)

HEQ (Hamburg esterquat)

Distearyldimethylammonium chloride (DSDMAC)

Anionic fabric softeners

Anionic softeners and antistatic agents can be, for example, salts of monoesters and diesters of phosphoric acid and the fatty alcohols. These are often used together with the conventional cationic softeners. Cationic softeners are incompatible with anionic surfactants in detergents because they combine with them to form a solid precipitate. This requires that they be added in the rinse cycle. Anionic softeners can combine with anionic surfactants directly. Other anionic softeners can be based on smectite clays. Some compounds, such as ethoxylated phosphate esters, have softening, anti-static, and surfactant properties.

COST ESTIMATION

Plant Capacity                            3 Ton/Day  

Land & Building (700 sq.mt.)    Rs. 1.97 Cr    

Plant & Machinery                      Rs. 31   Lac 

Working Capital for 2 Months  Rs. 1.94 Cr 

Total Capital Investment            Rs. 4.30 Cr 

Rate of Return                              49%

Break Even Point                          38%

• INTRODUCTION
• CATIONIC FABRIC SOFTENERS
• CATIONIC SURFACTANTS USED AS FABRIC SOFTENERS
• DIETHYL ESTER DIMETHYL AMMONIUM CHLORIDE (DEEDMAC)
• TEAQ (TRIETHANOLAMINE QUAT)
• HEQ (HAMBURG ESTERQUAT)
• DISTEARYLDIMETHYLAMMONIUM CHLORIDE (DSDMAC)
• ANIONIC FABRIC SOFTENERS
• ROLE OF SOFTENERS IN TEXTILE PROCESSING
• NON-IONIC SOFTENERS:
• ADVANTAGES
• DISADVANTAGES
• ANIONIC SOFTENERS:
• ADVANTAGES
• DISADVANTAGES
• CATIONIC SOFTENERS:
• ADVANTAGES
• DISADVANTAGES
• USES AND APPLICATION
• MARKET OVERVIEW OF SOFTENER
• KEY PLAYERS:
• GLOBAL QUATERNARY AMMONIUM MARKET
• MARKET-O-NOMICS
• DETAILS OF QUATERNARY AMMONIUM SALT SOFTENER MANUFACTURE
• TYPICAL IMIDAZOLINIUM SOFTENING COMPOUNDS INCLUDE:
• TYPICAL QUATERNARY AMMONIUM SALTS OF FORMULA (2) INCLUDE THE FOLLOWING:
• EXAMPLE 1
• FORMULATION OF QUATERNARY AMMONIUM SALT SOFTENER (POWDER FORM)
• PROCESSES AND FORMULATION OF FABRIC SOFTENER
• FABRIC SOFTENER
• EXAMPLE 1
• A FIRST EXAMPLE OF A LIQUID FABRIC SOFTENER COMPOSITION:
• EXAMPLE 2
• A SECOND, FRAGRANCE-FREE, EXAMPLE OF A LIQUID FABRIC SOFTENER COMPOSITION:
• EXAMPLE 3
• A THIRD EXAMPLE OF A LIQUID FABRIC SOFTENER COMPOSITION:
• EXAMPLE 4
• A FOURTH EXAMPLE OF A LIQUID FABRIC SOFTENER COMPOSITION:
• EXAMPLE 5
• A FIFTH EXAMPLE OF A LIQUID FABRIC SOFTENER COMPOSITION:
• PRINCIPLES OF PLANT LAYOUT
• STORAGE LAYOUT:
• EQUIPMENT LAYOUT:
• SAFETY:
• PLANT EXPANSION:
• FLOOR SPACE:
• UTILITIES SERVICING:
• BUILDING:
• MATERIAL-HANDLING EQUIPMENT:
• RAILROADS AND ROADS:
• MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
• PLANT LOCATION FACTORS
• PRIMARY FACTORS
• 1. RAW-MATERIAL SUPPLY:
• 2. MARKETS:
• 3. POWER AND FUEL SUPPLY:
• 4. WATER SUPPLY:
• 5. CLIMATE:
• SPECIFIC FACTORS
• 6. TRANSPORTATION:
• A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
• 7. WASTE DISPOSAL:
• 8. LABOR:
• 9. REGULATORY LAWS:
• 10. TAXES:
• 11. SITE CHARACTERISTICS:
• 12. COMMUNITY FACTORS:
• 13. VULNERABILITY TO WARTIME ATTACK:
• 14. FLOOD AND FIRE CONTROL:
• EXPLANATION OF TERMS USED IN THE PROJECT REPORT
• 1. DEPRECIATION:
• 2. FIXED ASSETS:
• 3. WORKING CAPITAL:
• 4. BREAK-EVEN POINT:
• 5. OTHER FIXED EXPENSES:
• 6. MARGIN MONEY:
• 7. TOTAL LOAD:
• 8. LAND AREA/MAN POWER RATIO:
• PROJECT IMPLEMENTATION SCHEDULES
• INTRODUCTION
• PROJECT HANDLING
• PROJECT SCHEDULING
• PROJECT CONSTRUCTION SCHEDULE
• TIME SCHEDULE
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF PLANT AND MACHINERY

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)