WASHING POWDER AND WASHING SOAP
[CODE NO.4073]
Synthetic detergents occupy a vital place in the present age particularly when the modern society is constantly looking for quick, effective and economic cleaning agents. Synthetic detergents emerged as a regular industry after Second World War only. The development of this industry is closely linked with Petro-chemical industry which forms the basis for its raw materials.
Detergents when dissolved in water, acquire better cleaning properties and hence facilitates easy removal of dirt & dust and grease etc.
Apart from their use in clothes washing, detergents also have applications in the following industries.
1. In industry, in laundry and dry cleaning.
2. In textile processing, grain milling, metal plating and foods canning.
3. In dairy foods and beverages processing and in restaurants.
4. In plant maintenance and industrial house-keeping.
The principal types of synthetic detergents are an ionic, non-ionic and employtics. Sodium dodecyle benzene sulphonate is an example of the ionic type while nylon phenol, nylone oxide obtained from ethylene oxide is the non-ionic type. The amploytic detergents like the alkyl amino propionates behave as cations in acidic solutions and like anions in alkaline solution.
Among the numerous detergent powders are available today in the market e.g. Hipoline, T.Series, Areal, Rin, Ghari, Surf, Sunlight, Nirma, Wheel detergent powder is most popular.
The synthetic detergent industry is one of the largest chemical process industries. The most recent estimates indicate an annual U.S production of synthetic detergents of about 3 million tones with an approximate annual value of 2 billion. The industry differs from many other chemical process industries, however, in that the bulk of its production is sold directly to individuals for house hold consumption primarily as branded products, rather than to industrial or institutional users.
The detergents are highly popular replacing the soap because of their favourable characteristics. Almost all the detergent, despite their difference in origin and methods of manufacture, have two points in common. One part the long hydrocarbon chain that is oil soluble (linophilic) and the other portion, a water soluble (hydrophilic) group. The latter property may render the whole molecule as soluble in water as to impart some or all of the characteristics mentioned.
The oil soluble portion may be derived from a natural fat or from petroleuum, or aromatic hydrocarbon, such as benzene etc. with an alkyl side chain. The water soluble portion may be derived from material acids, alklylene oxides, polyhydric alcohols and polyamides.
The detergents are further divided into several classes e.g.
a. Anionic
b. Cationic
c. Non-ionic
d. Amphoteric.
Each type acts differently in aqueous solutions.
When detergent is mentioned, the cake, bar or powder usually comes to mind. For small manufacturers, the best advice on making liquid detergents is to purchase from primary producers an intermediate dodecyl benzene sulphonic acid (DDBSA) better known as acid slurry. They themselves, can neutrilize the doecyl compound in a variety of ways. They may use ammonia amines, soda or potash to yield liquid detergents.
Generally, there are two types of liquid detergents.
1. Light duty liquid detergent.
2. Heavy duty liquid detergent.
Light duty detergents are in general use, although heavy duty liquid detergents are also being made but this has not captured the market to any serious extent. Liquids detergents, which actually proceeded powders, are used mainly for fine wash and dish washing. It can undoubtly be said that liquid detergents are an important part of today cleanser markets of developed countries. In India, liquid detergents are under development stage, except that is used in large quantities in textile mills for wet processing for textile goods. In certain parts of the world, pastes which are purely sodium dodecyl benzene sulphonate in a fairly concentrative from are used for dish washing. Previously, powder detergents well widely used but the trend is not towards liquid detergents.
Hand washing Detergent powder occupy a vital place in the present age particularly when the modern society is constantly looking for quick effective and economic cleaning agent.
Synthetic detergent emerged as a regular industry and is closely linked with petrochemicals industry which provides the basis for its raw materials.
Among the numerous detergent powder are available in the markets are Ariel, Surf Excel, Nirma, Wheel Ghari are the popular Brand available in the market.
COST ESTIMATION
Plant Capacity 15 Ton/Day
Land & Building (3000 sq.mt.) Rs. 1.81 Cr
Plant & Machinery Rs. 1.27 Cr
Working Capital for 1 Month Rs. 3.45 Cr
Total Capital Investment Rs. 6.71 Cr
Rate of Return 66%
Break Even Point 33%
INTRODUCTION
PROPERTIES OF DETERGENTS AND USES
PROPERTIES OF WASHING SOAP AND WASHING POWDER
USES AND APPLICATION
MARKET OVERVIEW OF WASHING POWDER AND WASHING SOAP
B.I.S. SPECIFICATION
MANUFACTURERS/SUPPLIERS/ EXPORTERS OF SOAPS AND DETERGENTS
FORMULATION AND ITS MANUFACTURE OF WASHING SOAP
INGREDIENT DOSING
SLURRY PREPARATION
COOLING AND REFINING
EXTRUSION
CUTTING OR
CONDITIONING OR
STAMPING
PACKING
FUNCTION OF VARIOUS COMPONENTS OF THE DETERGENT CAKE
1. ACTIVE ORGANIC COMPOUND
2. CARBOXY METHYL CELLULOSE
3. PHOSPHATE BUILDERS
4. SODIUM PERBORATE
5. OPTICAL WHITENING AGENT
6. FOAM BOOSTER
RAW MATERIAL REQUIREMENT
MANUFACTURE OF DETERGENT CAKE
PROCESS - I
(BASIS: -1 TON OF DETERGENT CAKE PER DAY)
PROCESS - 2
1. FORMULATION: FOR 500 KG BATCH.
PROCESS OF MANUFACTURE FOR FORMULA I.
1. CONCENTRATION OF SLURRY
2. MAKING OF CAKE/BAR
3. PACKING OF DETERGENT CAKE/BAR
4. DESPATCHING OF DETERGENT CAKE/BAR
FLOW SHEET OF DETERGENT BAR PROCESSING
VARIOUS OTHER FORUMULATIONS
MANUFACTURING PROCESS OF DETERGENT POWDER
THE COMPOSITION OF A GOOD QUALITY DETERGENT CAN BE WRITTEN
AS UNDER:-
THERE ARE THREE PROCESSES WHICH CAN BE USED FOR
MANUFACTURE OF DETERGENT POWDER.
FORMULATION OF DETERGENT POWDER (LOW COST)
FORMULATION OF DETERGENT POWDER (MEDIUM COST)
FORMULATION OF DETERGENT POWDER (HIGH COST)
SOME OTHER FORMULATION OF DETERGENT POWDER
(BASIS: -1 TON OF DETERGENT POWDER PER DAY)
PROCESS - 2
FORMULATION
1. FORMULATION: FOR 500 KG BATCH.
2. FORMULA: FOR 100 KG. BATCH
PROCESS OF MANUFACTURE FOR FORMULA I.
FORMULATION
MANUFACTURING PROCESS OF HAND WASHING DETERGENT POWDER
FORMULATION
PROCESS
PROCESS DETAILS
FORMULATION OF WASHING DETERGENT POWDER
DETRGENT POWDER BY SPRAY DRYING
SPRAY DRYING TOWER PROCESS
PROCESS OF MANUFACTURE OF WASHING DETERGENT POWDER
SURF EXCEL TYPE DETERGENT POWDER
FORMULATION - 1
PROCESS
PROCESS OF MANUFACTURE OF WASHING DETERGENT POWDER
(WHEEL TYPE)
HIGHER GRADE/QUALITY ARIEL TYPE DETERGENT POWDER
FORMULATION - 1
PROCESS
FORMULATION OF DETERGENT POWDER
FORMULATION OF DETERGENT POWDER, SURF EXCEL TYPE
FORMULATION OF DETERGENT POWDER, WHEEL TYPE
OTHERS FORMULATION AND PROCESS OF GOOD QUALITY
DETERGENT POWDER
METHOD OF PERFORMANCE OF TEST FOR SURFACE ACTIVE AGENTS
PART-I RELATIVE DESPERSING POWDER
SURFACE ACTIVE AGENTS
OUTLINE OF METHOD
APPARTUS
WHITE OIL-
PREPARATION OF SOLUTIONS
PROCEDURE
CALCULATION AND REPORTING
CALCULATION
PART - II RELATIVE EMULSIFYING POWER
OUTLINE OF METHOD
REAGENTS
LIQUID PARAFFIN
APPARATUS
PREPARATION OF STOCK SOLUTION
PROCEDURE
CALCULATION AND REPORTING
PART - V WETTING POWER
OUTLINE OF THE METHOD
APPARATUS
PROCEDURE
COMPLETE PLANT AND MACHINERY SUPPLIERS FOR SOAP, DETERGENT
CAKE AND POWDER
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF MAKING & PACKAGING
SUPPLIERS OF PULVERISER
SUPPLIERS OF MIXERS
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF DG SETS
SUPPLIERS OF RAW MATERIALS FOR DETERGENTS
SUPPLIERS OF ACID SLURRY
SUPPLIERS OF SODA ASH
SUPPLIERS OF CARBOXY METHYL CELLULOSE
SUPPLIERS OF OPTICAL WHITENING AGENTS
SUPPLIERS OF ENZYMES
SUPPLIERS OF SODIUM TRIPOLY PHOSPHATE
SUPPLIERS OF SODIUM SULPHATE
SUPPLIERS OF SODIUM SILICATE
SUPPLIERS OF PERFUME
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)
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