ADDIS ABABA INSTITUTE OF TECHNOLOGY

SCHOOL OF CHEMICAL AND BIO-ENGINEERING

Chemical Engineering Design

Project
Title: PRODUCTION OF RBD TALLOW AS A RAW
MATERIAL FOR BAR SOAP

Done By:
Hibreselam Dereje
Melaku Daniel
Yemisrach Yared
Outline
Introduction
Problem Statement
Objectives
Significance of the Study
Materials and Methodology
Process Technology & Mass and Energy Balance
Economic Evaluation of Plant
Recommendation

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 Introduction

Tallow is a rendered form of beef or mutton fat, primarily made up of triglycerides. It

is primarily derived from rendered beef tissue but can contain other animal fats as well.
In terms of total volume and economic value, tallow is one of the most important
animal fats.

The predominant source of tallow comes from cattle and is a by-product of the meat
industry.

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 Introduction

As a saturated animal fat, tallow almost looks like a hybrid of coconut oil and butter, but with a
dry, waxy texture. It’s generally made from cattle fat, but can come from any animal, except
pork, pork tallow is called lard.

It is used as an inexpensive and readily available

domestic raw material for the production of soap
due to its chemical similarity to oils.

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 Problem Statement
The manufacturing of soap requires a lot of
expensive synthetic ingredients and essential oils
of which most are imported.

Due to the above reason, there exists a need for

possible alternatives that are locally available.
One alternative is is RBD Tallow.

This study plans to address the problem stated

above by producing RBD Tallow to serve as raw
material for the production of soap.
 Objectives
General Objective
The general objective of this study will be the production RBD Tallow.

Specific Objectives
• To render animal fat into tallow.

• To bleach tallow.

• To deodorize tallow.

• To characterize physicochemical properties of the RBD Tallow.

• To study the economical feasibility of RBD Tallow production.

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 Significance of the Study
• Producing RBD Tallow would help to reduce environmental pollution.
• It has the potential to decrease foreign currency dependency for the soap
industry.
• It will bring in an additional income for the industries involved in processing
meat.
• It will be helpful to create job opportunity.

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 Materials and Methodology
Material and Equipment to be Used in the Lab

Raw Materials Equipment

Electronic mass balance
Animal Fat
Thermometer
Sodium Hydroxide
pH meter
Deionized Water
Oven
Ethyl Alcohol
Water Bath
Hydrochloric Acid
Magnetic Stirrer
Nitric Acid
Burette
Chloroform
Beakers
Phenolphthalein
Filter Cloth
Containers

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 Materials and Methodology
RBD Tallow Preparation

i. Collection of Animal Fat

ii. Rendering of Animal Fat into Tallow
iii. Bleaching of Tallow
iv. Deodorization of Tallow
v. Storing RBD Tallow

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 Materials and Methodology
Characterization of RBD Tallow

• Free Fatty Acid Content: Free fatty acid is expressed as percentage of free oleic acid of total
sample weight. Generally, the FFA content should not be more than 2%.
• Iodine Number: It indicates the degree of unsaturation i.e., the number of double bonds
present in the length of the chain. Tallow typically has an iodine number ranging between 40
to 53.
• Peroxide Test: This test will be used to determine the rancidity of tallow. Fresh fats have a
peroxide value of 1 to 2, whereas rancid fats have a peroxide value of 15 to 20.
• Smoke Point: It is the temperature to which the fat may be heated before it begins to smoke.
It has direct relationship with FFA. Tallow with FFA of 0.2%, 1.0% and 5.0% have smoke
points of 225 degrees Celsius, 145 degrees Celsius and 120 degrees Celsius respectively.
• Saponification Value: It represents the number of milligrams of potassium hydroxide or
sodium hydroxide required to saponify 1g of fat. Tallow typically has a saponification value
ranging between 190 to 202 mg KOH/ g of fat.

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 Materials and Methodology
Characterization of RBD Tallow

• Refractive index: It indicates the purity and identity of substance. Tallow typically has a
refractive index ranging between 1.448 to 1.460.
• Melting point: The melting point of a solid is the temperature at which it changes state from
solid to liquid. Tallow typically has a melting point ranging between 35 to 40 decrees
Celsius.
• Moisture, Impurities and Unsaponifiable (MIU): Pure fat is virtually free of moisture.
Water in tallow is undesirable as it acts a medium for the growth of fat-splitting bacteria and
the action of fat- splitting enzymes. A moisture content of around 0.2% is desirable.
Unsaponifiable matter is the material in tallow that cannot be converted into soap by the use
of an alkali. Tallow has a typical unsaponifiable matter content of 12 g/kg.

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Process Technology

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 Mass and Energy Balance
Mass Balance on the Renderer
Assumptions: 100 𝑘𝑔 of feed
Input mass = Output mass
Accumulation = 0 kg;
𝑊1 = Initial Animal Fat = 100 𝑘𝑔
𝑊2 = Rendered Animal Fat = 100 𝑘𝑔
𝑋2 = Cracklings and Volatile Compounds Content = 0.1
𝑋1 = Rendered Tallow Content = 0.9
𝑊1 = (𝑊2 ∗ 𝑋1) + (𝑊2 ∗ 𝑋2)
100 𝑘𝑔 = (100 ∗ 0.9) + (100 ∗ 0.1)
Mass Balance on the Bleacher
Similar Assumptions;
During bleaching, there is loss of 1% of the input mass due
to the absorption of impurities by the bleaching agent used.
𝑋1 = Rendered Tallow Content = 0.89
𝑋2 = Calcium Sulphate = 0.11
𝑊1 = Initial Animal Fat = 90 𝑘𝑔
𝑊2 = Calcium Sulphate = 10 𝑘𝑔
𝑊1+𝑊3= (𝑊2∗𝑋1)+(𝑊2∗𝑋2)
90 𝑘𝑔 + 10 𝑘𝑔 = (100 ∗ 0.89) + (100 ∗ 0.11) 13
100 𝑘𝑔 = 89 𝑘𝑔 + 11 𝑘𝑔
 Mass and Energy Balance
Mass Balance on the Deodorizer Energy Balance on the Renderer

Assumptions
The rendering process happens at 60 degrees Celsius.
Ws = 8.5 kW
∆H = Hout - Hin
∆H = [m ∫ (cpdt)out − m ∫ (cpdt)in]
Cp, tallow = 2.775 kJ/kg
M (mass flow rate) = 1000 kg/day
Working hour = 8hr/day
Similar Assumptions;
During bleaching, there is loss of 1% of the input mass due to
vaporization of odorous substances under very high temperature. ∆H = 3.348 kW
Q = ∆H + Ws
𝑊1 = Rendered and Bleached Tallow = 100 𝑘𝑔 Q = 3.348 + 8.5
𝑊2 = RBD Tallow = 99.5 𝑘𝑔 Q = 11.848 kW
𝑊3 = Volatilized Odorous Substances = 0.5 𝑘𝑔

𝑊1= 𝑊2+𝑊3
100 𝑘𝑔 = 99.5 𝑘𝑔 + 0.5 𝑘𝑔 14
 Mass and Energy Balance
Energy Balance on the Bleacher Energy Balance on the Deodorizer

Assumptions Assumptions
The bleaching process happens at 40 degrees Celsius. The deodorizing process happens at 160 degrees Celsius.
Ws = 8.5 kW Mechanical agitation is not required here. Q = ∆H
∆H = Hout - Hin ∆H = m [ ∫ 𝑐𝑝𝑑𝑡]
∆H = [m ∫ (cpdt)out − m ∫ (cpdt)in] Cp, tallow = 2.775 kJ/kg
Cp, tallow = 2.775 kJ/kg M (mass flow rate) = 1000 kg/day
M (mass flow rate) = 1000 kg/day Working hour = 8hr/day
Working hour = 8hr/day

∆H = 1.435 kW ∆H = 12.914 kW
Q = ∆H + Ws 𝑄 = ∆H = 12.914 kW
Q = 1.435 + 8.5
Q = 9.935 kW

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 Economic Evaluation of Plant

Table of Equipment
and Their Cost

Equipment Cost in
Birr = 3,839,000 ETB

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 Economic Evaluation of Plant
After considering the cost of Equipment installation, Instrumentation and
controls installation, Piping installation, Electrical installation, Building,
process and auxiliary costs, Service, facilities and yard improvement and
Land purchase cost the total direct cost is the following.

Total Direct Cost = 20,164,050 ETB

Taking Direct Cost = 75% of FCI

FCI – Direct Cost / 0.75
FCI = 26,885,400 ETB
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 Economic Evaluation of Plant

The Annual Cost of Raw Materials = 10,383,849.60 ETB

The Annual Utility Cost = 742,800 ETB
The Annual Salary and Training Cost = 2,738,000 ETB

The Total Working Capital = 13,864,649.60 ETB

Total Investment Cost = Total Fixed Investment Cost + Total Working Capital
= 26,885,400 + 13,864,649.6
= 40,750,049.60 ETB

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Economic Evaluation of Plant

The Annual Gross Profit = 13,635,350 ETB

The Annual Net Profit = 8,405,442.5 ETB
The Annual Net Return = 9,109,342.5 ETB
The Return on Investment = 20.62%
The Profitability Index = 1.14
Break Even Analysis in Production Capacity = 148.18 %
Payback Period = 4.47 years

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 Recommendation

“
Despite the technical feasibility from an economic point of view, the
construction of the plant as it is, is not recommended due to the low
profitability index a long, relatively, payback period.

If the plant is found necessary to be constructed and to start production,

it is recommended to increase the capacity of the production to about
250% to 300% and increase the price of the product by 20%, to
maximize the profit index and minimize the payback period, while still
staying in business.

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Thank you