CHEMICAL ENGINEERING DEPARTMENT

COLLEGE OF TECHNOLOGY
UNIVERSITY OF SAN
AGUSTIN
Iloilo City

PRODUCT REPORT
on

Toilet/Bath Soap
Title

By
Abbas, Jedidiah
Burgos, Andrea
Celiz, Hannah Joy
Dela Torre, Paula Jarrina
BS Chemical Engineering 4

In connection with the course

ChE 427
SOAPS AND COSMETICS

SUBMITTED TO
ENGR. CHAMAIGNE LUZ D. JAMANDRE, ASEAN Eng, FPIChE
Asst Professor

April 18, 2022

 CHEMICAL ENGINEERING DEPARTMENT
COLLEGE OF TECHNOLOGY
UNIVERSITY OF SAN
AGUSTIN
Iloilo City

Contents
1. INTRODUCTION......................................................................................................................... 2
2. RAW MATERIALS...................................................................................................................... 3
3. MANUFACTURING FLOWCHART.............................................................................................. 4
3.1 PROCESS DESCRIPTION......................................................................................................... 4
4. MANUFACTURING EQUIMENT.................................................................................................. 5
5. QUALITY STANDARDS AND ANALYSES.................................................................................6
5.1 pH Level...................................................................................................................................... 7
5.2. Product Environmental Performance.......................................................................................... 7
5.2.1. Compliance to Environmental Regulations..........................................................................7
5.2.2. Preservatives........................................................................................................................ 7
5.2.3. Builders................................................................................................................................ 7
5.2.4. Fragrance............................................................................................................................. 7
5.2.5. Coloring Agent.................................................................................................................... 8
5.2.6. UV absorbers....................................................................................................................... 8
5.2.7. pH Regulators...................................................................................................................... 8
5.2.8. Formaldehyde...................................................................................................................... 8
5.2.9. Other Harmful Substances................................................................................................... 8
6. PACKAGING................................................................................................................................... 8
7. DIFFERENT PRODUCTS IN THE MARKET..............................................................................10
 CHEMICAL ENGINEERING DEPARTMENT
COLLEGE OF TECHNOLOGY
UNIVERSITY OF SAN
AGUSTIN
Iloilo City

1. INTRODUCTION

Soap is made up of fatty acid salts. Soap is primarily used for washing, bathing, and cleaning,
but it is also found in lubricants. Cleaning soaps are made by soaking vegetable or animal oils
and fats in a highly alkaline solution. Triglycerides are fats and oils made up of three fatty acid
molecules connected to a single glycerol molecule. Saponification is a chemical reaction that
occurs when an alkaline solution, usually lye, is used. Fats are broken down (hydrolyzed) in
saponification, resulting in crude soap. Fats are converted to fatty acid salts, and glycerol is
released as a consequence, leaving glycerin as a byproduct. Most lubrication greases contain
soaps, which are mainly emulsions of calcium and lithium soaps in mineral oil. Grease based on
lithium is extensively used. Aluminum, sodium, and combinations of metal ions are among the
other metal ions employed. These soaps are sometimes referred to as thickeners since they
increase the viscosity of the oil. The addition of lime to olive oil was used to make lubricating
greases in ancient times .

There are two kinds of soap on the market: toilet soap and bath soap, both of which are made
through the 'saponification' process. Saponification is a chemical reaction that occurs when an
alkali reacts with fatty molecules to form soap and alcohol, as well as glycerin as a by-product.
Glycerin is found in soap and is responsible for the soap's moisturizing properties. Glycerin was
eliminated by most manufacturers and replaced with something else. The moisturizing and
cleaning characteristics of toilet soaps and bath soaps differ. The one for hand washing is
separate from the one for showering. The key quality determinant is total fatty matter (TFM),
which gives soaps their soapy sensation. Toilet soaps and bath soaps are mostly differentiated by
TFM and insoluble particles in the soap.

Bathing soap is a fatty acid salt with cleaning and moisturizing characteristics that is made from
calcium or potassium. Compared to toilet soaps, bath soap includes fewer chemicals. Bathing
soaps contain a variety of additions for skin softness, improved hydration, and even components
that renew and restore skin elasticity, such as vitamin E and collagen. Toilet soaps are among the
nicer types of scented soaps with emollient characteristics, and they fall into this category. The
body or base is usually a well-selected white soap, which is then washed and refined, and they
are rarely manufactured directly by the perfumer. The body should be constructed of a mixture
of olive and sweet-almond oil as the fat stock for the highest grades. The next best stock is lard
or beef tallow, with a small amount of bleached palm oil added to make palm soap.

Certain toilet soaps also contain cocoa oil and saponaceous materials from pale yellow resins.
Any well-run soap factory can provide you with these body soaps as needed. They must be
perfectly neutral, firm, free of unpleasant odor, and free of any propensity to crust in cold or
 CHEMICAL ENGINEERING DEPARTMENT
COLLEGE OF TECHNOLOGY
UNIVERSITY OF SAN
AGUSTIN
Iloilo City

sweat in damp conditions to be suitable for perfumery. They should also produce a thick lather
without wasting too much water. Soaps, in their natural state, are usually lacking in many of
these qualities, necessitating a refining process for the purposes of perfumery.

2. RAW MATERIALS
Tallow, lye, and sodium hydroxide are the raw ingredients used in this procedure. Tallow is the
primary fatty material used in soap production; the quantities needed account for almost three-
quarters of the total oils and fats and fats consumed by the soap industry. The soap business
consumes it. It is made up of mixed glycerides extracted from the solid fat of cattle through
stream rendering. When steam is used to decompose this solid fat, the tallow creates a layer
above the water that may be easily removed. In order to boost the solubility of the soap, tallow is
generally added with coconut oil in the soap kettle or hydrolyser. Greases (about 20%) are the
second most important raw element in the production of soap.
The soap maker uses a lot of chemicals, including caustic soda, salt, soda ash, and caustic potash,
as well as sodium silicate, sodium bicarbonate, and trisodium phosphate. The so-called builders
are inorganic chemicals that are added to the soap. Monsanto's Harris and colleagues established
decisively that tetrasodium pyrophosphate and sodium tripolyphosphate, in particular, were
unusually effective synergistic soap makers.

2.1 Chemical reaction for soap manufacturing

The basic chemical reaction in making of soap is making of soap is saponification. The procedure
is to split, or hydrolyze, the fat, and then, after separation from valuable glycerin, to neutralize
the fatty acids with a caustic soda solution: a caustic soda solution:

[1] 3 NaOH + (C 17H35COO)3C3H5  3C17H35COONa + C3H5(OH)5

Caustic Soda Glyceryl stearate Sodium Stearate Glycerin

[2] (C17H35COO)3C3H5 + 3 H2O  3C17H35COOH + C3H5(OH)5

Glyceryl Stearate Stearic Acid Glycerin

[3] C17H35COOH + NaOH  C17H35COONa + H2O

Stearic Acid Caustic Soda Sodium Stearate
 CHEMICAL ENGINEERING DEPARTMENT
COLLEGE OF TECHNOLOGY UNIVERSITY OF SAN AGUSTIN
Iloilo City

3. MANUFACTURING FLOWCHART
Figure 3.1 Toilet Soap Manufacturing Flowchart
 CHEMICAL ENGINEERING DEPARTMENT
COLLEGE OF TECHNOLOGY
UNIVERSITY OF SAN
AGUSTIN
Iloilo City

3.1 PROCESS DESCRIPTION

This is a continuous process which uses a plant. The process is best understood in terms of two
streams: soap flowing in the order given below against a counter-current of lye.
Step 1 - Saponification The raw materials are continually fed into a reactor in fixed proportions.
Tallow: 735.29 kg hr-1; NaOH solution: 272.33 kg hr-1 Lye: 35.22 kg hr-1 These ingredients alone
would give a low water, high glycerine soap. Soap needs to be about 30% water to be easily
pumpable, and even then needs to be held at around 70C, so excess lye is added to hydrate the soap
and dissolve out some of the glycerine. The lye added is known as "half spent lye" and is the lye
discharged from the washing column. This lye already contains some glycerine, but it is further
enriched by that formed in the saponification reaction.
Step 2 - Lye separation. The wet soap is pumped to a "static separator" - a settling vessel which does
not use any mechanical action. The soap / lye mix is pumped into the tank where it separates out on
the basis of weight. The spent lye settles to the bottom from where it is piped off to the glycerine
recovery unit, while the soap rises to the top and is piped away for further processing.
Step 3 - Soap washing. The soap still contains most of its glycerine at this stage, and this is removed
with fresh lye in a washing column. The column has rings fixed on its inside surface. The soap
solution is added near the bottom of the column and the lye near the top. As the lye flows down the
column through the centre, a series of rotating disks keeps the soap / lye mixture agitated between the
rings. This creates enough turbulence to ensure good mixing between the two solutions. The rate of
glycerine production is calculated and the rate at which fresh lye is added to the washing column then
set such that the spent lye is 25 - 35 % glycerine. Glycerine is almost infinitely soluble in brine, but
at greater than 35% glycerine the lye no longer efficiently removes glycerine from the soap. The soap
is allowed to overflow from the top of the column and the lye ("half spent lye") is pumped away from
the bottom at a controlled rate and added to the reactor.
Step 4 - Lye separation 10 The lye is added at the top of the washing column, and the soap removed
from the column as overflow. As the lye is added near the overflow pipe the washed soap is about
20% fresh lye, giving the soap unacceptably high water and caustic levels. Separating off the lye
lowers the electrolyte levels to acceptable limits. The soap and lye are separated in a centrifuge,
leaving a soap which is 0.5% NaCl and 0.3% NaOH, and about 31% water. The lye removed is used
as fresh lye.
Step 5 - Neutralisation Although the caustic levels are quite low, they are still unacceptably high for
toilet and laundry soap. The NaOH is removed by reaction with a weak acid such as coconut oil
(which contains significant levels of free fatty acids), coconut oil fatty acids, citric acid or phosphoric
acid, with the choice of acid being made largely on economic grounds. Some preservative is also
added at this stage.
 CHEMICAL ENGINEERING DEPARTMENT
COLLEGE OF TECHNOLOGY
UNIVERSITY OF SAN
AGUSTIN
Iloilo City

Step 6 - Drying Finally, the water levels must be reduced down to about 12%. This is done by
heating the soap to about 125-degree C under pressure (to prevent the water from boiling off while
the soap is still in the pipes) and then spraying it into an evacuated chamber at 40 mm Hg (5.3 kPa).
The latent heat of evaporation lost as the water boils off reduces the soap temperature down to 45oC,
at which temperature it solidifies onto the chamber walls. The soap chips are scraped off the walls
and "plodded" (i.e. squeezed together) by screws known as "plodder worms" to form soap noodles.
The soap is now known as base or neat soap chip, and can be converted into a variety of different
soaps in the finishing stages. The moisture evaporated off the wet soap is transported to a barometric
condenser, which recondenses the vapour without the system losing vacuum. The moisture can
contain soap dust (Fines) which is removed by cyclones and returned by augers to the spray chamber,
while the water is recycled.

4. MANUFACTURING EQUIPMENT
Table 4.1 Equipment List
 CHEMICAL ENGINEERING DEPARTMENT
COLLEGE OF TECHNOLOGY
UNIVERSITY OF SAN
AGUSTIN
Iloilo City

Figure 4.1 Process Flow Diagram of Toilet Soap Production

5. QUALITY STANDARDS AND ANALYSES

In order to maintain the best quality of the product it is very much necessary to manufacture this soap
under some specific standards. This mean to say that some standard specification has got to be
followed to maintain certain qualities such as pH, acid, No. total fatty matter (TFM) available and
moisture etc. Taking into account its use the product should be skin-friendly in all respects and point
of view. To manufacture this Beauty Soap a general standard for toilet soap i.e, IS : 2888-194 or
revised can be followed. Some changes in the product specification can be taken into account to
improve the quality soap to satisfy the customer’s demand and requirement.
According to Green Choice Philippines- The Ecolabelling Program of the Philippines- Here is the
standard for GCP 20080029-BATH SOAP
Standard no. Title
PNS 39:2003 Toilet Soap- Specification
N/A Asian Cosmetic Directive
 CHEMICAL ENGINEERING DEPARTMENT
COLLEGE OF TECHNOLOGY
UNIVERSITY OF SAN
AGUSTIN
Iloilo City

5.1 pH Level
The pH shall be between 5.0 and 8.0.
5.2. Product Environmental Performance
5.2.1. Compliance to Environmental Regulations
The applicant is required to comply with relevant environmental regulations and legislations. This
includes production process, transport and disposal features of the product.
5.2.2. Preservatives
The use of preservatives for purposes other than preservation is not allowed. Preservatives shall not
be bioaccumulative. The requirement is imposed in order to reduce the environmental impact
associated with the use of preservatives since they are often highly toxic to waterborne organisms.
The product shall not be formulated with the following preservatives:
• 1,2-benzisothiazolin-3-one such as proxel
• 2,4-dichlorobenzyl alcohol
• chloracetamide
• 5-chloro-2-methyl-4-isothiazolin-3-one such as kathon CG
• orthophenylphenol
• orthononylphenol
• trichlorohydroxydiphenyl ether such as irgasan, triclosan
5.2.3. Builders
The product shall not contain nitrilotriacetic acid (NTA) and diethylenetriamine pentaacetic acid
(DTPA). Ethylene diamine tetraacetic acid (EDTA) and phosphonates shall not exceed 0.1%.
5.2.4. Fragrance
The product shall not contain any substances listed in ASEAN Cosmetic Harmonization or its
equivalent. Additionally, the essence containing the following nitro-musk compounds shall not be
used because of their carcinogenicity, the following substances are:
• Musk xylene
• Musk ambrette
• Moskene
• Musk tibetine
• Musk ketone

5.2.5. Coloring Agent

All organic colorants in the product introduced either as ingredient or as raw material shall be food
grade or as listed in ASEAN Cosmetic Harmonization.
 CHEMICAL ENGINEERING DEPARTMENT
COLLEGE OF TECHNOLOGY
UNIVERSITY OF SAN
AGUSTIN
Iloilo City

5.2.6. UV absorbers
Concentration of butylhydroxytoluene (BHT) and butylated hydroxyanisole (BHA) must not exceed
0.01%. The UV absorbers shall not be formulated with benzophenone.
5.2.7. pH Regulators
The pH regulator shall not be formulated with boric acid, borates and perborates.
5.2.8. Formaldehyde
The product shall not contain more than 0.1% by weight of the product.
5.2.9. Other Harmful Substances
The product shall not be formulated or manufactured with the following ingredients and its
derivatives:
• Chlorine and chlorine compounds
• Methyl Dibromoglutaronitrile
• Opacifiers
• Quaternary ammonium salts that are not readily degradable
• Trichloroethane
• Xylene sulfonates
• 2-Butoxyethanol
• Phthalates
• Substances listed in DENR AO 2005-05 and DENR AO 2005-27
• Substances listed in ASEAN Harmonized Cosmetic Regulatory Scheme or its equivalent

6. PACKAGING
Soap manufacturers use different types of packaging products and solutions to make their products
easy and convenient to use and to maximize the performance of product.

Type of Packaging Description Picture

Small sachets for offering products in
very small quantities for
one-time use. Generally,
powder detergents and
washing gels are offered
in sachets.
 CHEMICAL ENGINEERING DEPARTMENT
COLLEGE OF TECHNOLOGY
UNIVERSITY OF SAN
AGUSTIN
Iloilo City

Cartons Soaps and detergents are

offered in cartoons for
bulk supply

Poly packs Soaps and detergents are

offered in poly packs of
different sizes to meet
the varying demands of
consumers.

Plastic bottles Generally liquid

detergents specialty
spray cleansers are
packaged in plastic
bottles to make their
usage convenient and
effective.

Tubes Tubes are most widely

used for packaging
personal care and
cosmetic products.
 CHEMICAL ENGINEERING DEPARTMENT
COLLEGE OF TECHNOLOGY
UNIVERSITY OF SAN
AGUSTIN
Iloilo City

Paper wrap Soap bars are generally

wrapped or cartooned in
single packs or multi-
packs for the
convenience of users.

7. DIFFERENT PRODUCTS IN THE MARKET

Products Example Picture

Toilet Soaps bar, liquid, paper
soap, others

Bathing Soaps shower gel, bath salts,

bubble bath, bath oils,
etc
 CHEMICAL ENGINEERING DEPARTMENT
COLLEGE OF TECHNOLOGY
UNIVERSITY OF SAN
AGUSTIN
Iloilo City

Novelty Soaps rubber ducky or the

soap-on-the-rope

Herbal Soaps Organic products

made of rare herbs
and 100 % natural
ingredients

8. REFERENCES

https://makeovermomma.com/tips/body-tips/what-is-toilet-soap/

https://pediaa.com/what-is-the-difference-between-bathing-soap-and-toilet-soap/

https://www.murtelacosmetics.com/blog/benefits-bathing-soaps/

https://consumeraffairs.nic.in/sites/default/files/file-uploads/ctocpas/Toiletsoaps.pdf

http://www.madehow.com/Volume-2/Soap.html

https://soap.club/blogs/blog/history-of-soap-making

https://pdfcoffee.com/soap-manufacturing-process-5-pdf-free.html

https://ceng.tu.edu.iq/ched/images/lectures/chem-lec/st3/c6/PROCESS%20INDUSTRY
%20LECTURE%2021%20soap%20&%20detergents%202.pdf

http://www.detergentsandsoaps.com/packaging.html