WASHING POWDER, LIQUID DETERGENTS,

LOTION AND SHAMPOO

[EIRI/EDPR/3510] J.C.: 1597INR,1598US$

INTRODUCTION

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.

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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 detergent 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
so 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.

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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 is 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.

Modern shampoos are based on sulphated fatty alcohols and sulphonated fatty
alcohol ethers. Triethanolamine lauryl sulphte is a brown transparent viscous
liquid and is the most widely accepted cleaning agent used in shampoos.
Sodium lauryl sulphate is powder highly soluble in water and is a good
emulsifier, it may also be obtained as a paste. Mono ethanolamine lauryl suphate
is similar to triethanolamine lauryl sulphate and its viscosity can be increased
by adding sodium chloride. Turky red oil or sulphated castor oil is a viscous
water-miscible liquid having good detergent and emulsifying properties.

To get a good shampoo it is necessary to add certain additives to basic

detergents to impart certain good properties. These additives are described here.
Opacifiers like spermaceti, common salt, magnesium stearte and magnesium
silicate etc. Are used. Some people prefer clear shampoos and for this clarifiers
like butyl alcohol, isopropyl alcohol, ethyl alcohol, terpinol, pine oil, diethylene
glycol, STPP and TSP are used. Lanolin and its derivatives, isopropyl myristate,
and CMC are good finishing agents; they give shine to the hair. Glycerol,
proylene glycol, sorbitol and urea help retain moisture thus keeping the hair soft
thus conditioning the hair.

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Thickening agents increase the visosity of the shampoo thus increasing the
consumer appeal who thinks that more viscous shampoo means more powerful
product. CMC, tragacanth and acacia gums, methyl cellulose, PVA and PVP are good
thickeners but tend to leave a film on the hair. Newer thickners are diethanolamides
of lauric acid and the glycol or glycerol stearates. They do not leave any films. Foam
builder are also incorporated in shampoos to give better and stable foam,
preservatives are added to shampoos to protect them from deterioration by bacterial
or mould action. Formaldehyde, methyl-and prophyl-hydroxybenzoate are the usual
preservatives. Newer preservatives used are chloro salicylanilides and thiuram
disulphides. To finish the bacteria of the scalp certain antibacterials like
chlorosalicylanilide, thymol, bacitracin and hexachlorophene are added. In some
cases antidandruff compounds are also incorporated.

Shampoos are used to wash and clean hair. During old days, very rough soaps and
other materialsware used to wash hair. The rough type of soaps contained major
proportion of caustic soda among their constituents. No doubt these soaps had
good cleaning power due to caustic content in the shape of saponified materials
yet they spoilt the human skin by their drastic action. This actually produced
irritation and in some it ended in the production of some skin diseases like
irritation, skin itching and also in some cases gave rise to demodectic scabies.

With the introduction of shampoos all the above muiscance was removed as they
replaced the soaps at a very high speed. These shampoos are available as solid,
paste or liquid varieties.

The demand for shampoos especially the liquid type has never been greater than it is
today. For several reasons these have superseded the ordinary shampoo powders
owing to the abundance of soft lather produced and it is possible that the use of
liquid shampoos does not entail so much trouble. Liquid shampoos are virtually
solutions of soft soap in water with just sufficient spirit to aid through
saponification. At one time more spirit was used to prevent a slight gelati nation.
The popular demand in bulk shampoos being for those with a high viscosity, this
can be obtained by leaving the shampoo exposed to air for a week, or a fornight liquid
variety but the demand for coconut preparation is probably not so great as it was.
The reasons are the difficulty in covering the odour of the oil and the fact that
some coconut shampoos have the hair in a slightly greasy condition.

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The number of types of shampoos are available like coconut which are described
below:-

1. Liquid clear shampoo

2. Liquid cream shampoos or cream lotion shampoos.
3. Cream paste shampoos.
4. Egg shampoos.
5. Herbal shampoos.
6. Dry shampoos.
7. Liquid dry shampoos.

The formulation, process conditions etc. are different for different type of
shampoos but all types of shampoos can be manufactured in the similar plant
without change of set of machineries.

A lotion is a low-viscosity topical preparation intended for application to unbroken

skin. By contrast, creams and gels have higher viscosity.

Lotions are applied to external skin with bare hands, a brush, a clean cloth,
cotton wool, or gauze. While lotion may be used as a medicine delivery system,
many lotions, especially hand lotions and body lotions are meant instead to
simply smooth, moisturize and soften the skin. These may be used in anti-aging
lotions, which can also be classified as a cosmetic in many cases, and may
contain fragrances. The Food and Drug Administration voiced concern about
lotions not classified as drugs that advertise anti-aging or anti-wrinkle properties.

Most lotions are oil-in-water emulsions using a substance such as cetearyl alcohol
to keep the emulsion together, but water-in-oil lotions are also formulated. The
key components of a skin care lotion, cream or gel emulsion (that is mixtures of oil
and water) are the aqueous and oily phases, an emulgent to prevent separation of
these two phases, and, if used, the drug substance or substances. A wide variety
of other ingredients such as fragrances, glycerol, petroleum jelly, dyes,
preservatives, proteins and stabilizing agents are commonly added to lotions.

Since thickness and consistency are key factors in lotions and creams, it is
important to understand the manufacturing process that determines viscosity.

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 CONTENTS

INTRODUCTION
GENERALLY, THERE ARE TWO TYPES OF LIQUID DETERGENTS.
PROPERTIES OF WASHING SOAP AND WASHING POWDER
USES AND APPLICATION
PROPERTIES OF SHAMPOO
USE AND APPLICATION OF SHAMPOO
B.I.S. SPECIFICATIONS
SKIN LOTION INGREDIENTS
MOISTURIZING INGREDIENTS
OTHER INGREDIENTS
MARKET SURVEY
CAPITALISING ON REGIONAL DEMAND
THE SOAPS AND DETERGENTS AND COSMETICS INDUSTRIES IN ZAMBIA
AND SOUTH AFRICA
THE COSMETICS MARKET IN SOUTH AFRICA AND ZAMBIA
MAPPING THE COSMETICS AND SOAPS AND DETERGENTS VALUE
CHAIN INDUSTRIES
SOURCING UPSTREAM INPUTS
FACTORS AFFECTING FIRM COMPETITIVENESS
SCALE
PACKAGING
STANDARDS AND REGULATIONS
GROWTH CONSTRAINTS
BARRIERS TO ACCESSING SUPERMARKETS AND EXPORT MARKETS
ZAMBIA
COMPETITION FROM IMPORTS
OTHER CONSTRAINTS
GROWTH OPPORTUNITIES
NATURAL AND ETHNIC PRODUCTS
CONTRACT MANUFACTURING
GETTING THE GOODS TO MARKETS
RIDING ON THE SPREAD OF SUPERMARKETS
TAPPING INTO ALTERNATIVE ROUTES TO MARKETS
SALONS AND SPAS
DIRECT MARKETING
HOTELS
CLEANING SERVICES
MANUFACTURERS/SUPPLIERS
MANUFACTURING PROCESS OF DETERGENT POWDER (SPRAY DRYING METHOD)
DETERGENT POWDER MANUFACTURE
STEP 1 - SLURRY MAKING

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STEP 2 - SPRAY DRYING
STEP 3 - POST DOSING
TABLE 2 - THE INGREDIENTS OF DETERGENT BASE POWDER
ENVIRONMENTAL IMPLICATIONS
SYNTHETIC DETERGENT BIODEGRADABILITY
DETERGENT POWDER
ROLE OF THE LABORATORY
STANDARD DETERGENT POWDER MANUFACTURING PLANT CONSISTS
OF MIXING, DRYING AFTER DRYING PACKAGING AND ANTIPOLLUTION
UNITS.
MANUFACTURING OF DETERGENT POWDER
PROCESS - I
PROCESS - 2
PROCESS OF MANUFACTURE OF WASHING DETERGENT POWDER
SURF EXCEL TYPE DETERGENT POWDER
PROCESS OF MANUFACTURE OF WASHING DETERGENT POWDER
HIGHER GRADE/QUALITY DETERGENT POWDER
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
THE FOLLOWING FORMULATIONS ARE FOR MANUFACTURE OF DETERGENT
POWDER:-
THE GRINDING MACHINE
RAW MATERIALS
METHODS FOR PERFORMANCE TESTS FOR SURFACE ACTIVE AGENTS
PART-I RELATIVE DESPERSING POWDER
SURFACE ACTIVE AGENTS
OUTLINE OF METHOD
APPARATUS
WHITE OIL-
PREPARATION OF SOLUTIONS
PROCEDURE
CALCULATION AND REPORTING
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

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FORMULATION OF DETERGENT POWDER
SURF EXCEL TYPE DETERGENT POWDER
FORMULATION OF LIQUID LAUNDRY DETERGENT
MANUFACTURING PROCESS OF LIQUID DETERGENT
MANUFACTURING PROCESS OF LIQUID DETERGENT IN DETAILS
FORMULATIONS FOR LIQUID DETERGENT FOR WOOL,
COLD WATER WOOL DETERGENTS
OTHER FORMULATIONS FOR LIQUID DETERGENTS
FORMULA 1:
FORMULA NO.2
FORMULA NO.3
MANUFACTURING PROCESS
FOR LIQUID DETERGENT FOR WOOL
PROCESS FLOW DIAGRAM
GENERAL PROCESS OF MANUFACTURE OF LIQUID DETERGENT
THUS THE BATCH REQUIRES:
DETAILS OF RAW MATERIALS FOR SHAMPOOS
1. OPACIFYING AGENTS
OPACITY OR PEARLESCENCE EFFECT IS PROVIDED BY:-
2. CARIFYING AGENTS
TRANSPARENCY EFFECT:-
3. FINISHING AGENTS
4. SEQUESTERING AGENTS
5. CONDITIONING AGENT
6. THICKENING AGENTS
7. FOAM BUILDERS
8. PRESERVATIVES
9. ANTIDANDRUFF COMPOUNDS
COLOURS:-
PRESERVATIVES:-
PERFUMES:-
WATER:-
VARIOUS FORMULATIONS
1. LIQUID SHAMPOOS:
FORMULA NO.1
FORMULATION NO.2
2. VEGETABLE OIL SHAMPOO
FORMULA OIL SHAMPOO
FORMULA NO. 2
3. EGG SHAMPOO:
ALMOND SHAMPOO
TONIC SHAMPOO
TRANSPARENT CLEAR LIQUID SHAMPOO:-
FORMULATION - 1
FORMULATION -2
FORMULATION - 3

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FORMULATIONS
1. SHAMPOOS:-
2. COCONUT OIL SHAMPOO:
3. TRIETHANOLAMINE SHAMPOO
MANUFACTURING PROCESS (SHAMPOO)
THE FORMULATION BEING DEALT WITH IS AS DESCRIBED BELOW:
PROCESS FLOW SHEET DIAGRAM (SHAMPOO)
MANUFACTURING PROCESS FOR COCONUT OIL SHAMPOO
1. COLD PROCESS
2. HOT PROCESS
ANALYSIS OF SHAMPOOS
GENERAL ANALYSIS:-
NET CONTENTS:-
DESCRIPTION OF SHAMPOO:-
PH OF SHAMPOO:-
ASH AT 600OC:-
EXAMINATION OF ASH:-
NON-VOLATILE MATTER AT 105OC:-
TEST FOR AMMONIA:-
TEST FOR BASIC NITROGEN COMPOUNDS INCLUDING AMMONIA:-
DETERMINATION OF WATER BY TOLUENE DISTILATION:-
ETHYLENEDIAMINETETRAACETIC ACID:-
LANOLIN AND/OR STEROLS:-
WATER-SOLUBLE GUMS:-
FORMULATIONS OF BODY LOTION
FORMULATION OF BODY LOATION
FORMULATION OF BODY LOATION
GENERAL STAPS FOR MANUFACTURE LOTION
MANUFACTURING LOTIONS AND CREAMS CAN BE COMPLETED IN TWO CYCLES
A TYPICAL OIL-IN-WATER MANUFACTURING PROCESS MIGHT GO LIKE THIS
THE PROCESS OF LOTION MAKING
THE PROBLEMS OF TRADITIONAL LOTION MIXER
THE SOLUTION OF LOTION MANUFACTURING
SUPPLIERS OF RAW MATERIALS IN AFRICA
SUPPLIER OF LINEAR ALKYL BENZENE SULFONATE IN AFRICA
SUPPLIER OF CARBOXY METHYL CELLULOSE IN AFRICA
SUPPLIERS OF RAW MATERIALS
LINEAR ALKYL BENZENE (LAB)
CARBOXY METHYL CELLULOSE (CMC)
SODIUM SILICATE
SODIUM SULPHATE
DETERGEN FRAGRANCES/PERFUMES
DETERGENT ENZYMES
SUPPLIERS OF DETERGENTS MACHINES IN AFRICA
SUPPLIERS OF PLANT AND MACHINERY
STORAGE VESSEL

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PACKAGING MACHINE
INSTRUMENTATION AND PROCESS CONTROL EQUIPMENTS
MATERIAL HANDLING EQUIPMENTS
LABORATORY EQUIPMENTS
D.G. SETS

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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 COST ESTIMATION

Plant Capacity
Washing Powder: 1000 Kg./hr. or 8000 Kg./Day
Liquid Detergent: 1000 Ltr./hr. or 8000 Ltr./Day
Lotion: 100 Kg/hr. or 800 Kg./Day
Shampoo: 100 Kg/hr. or 800 Kg./Day
Land & Building (6000 sq.mt.) Rented
Plant & Machinery Rs. 2.30 Cr
Working Capital for 2 Months Rs. 6.85 Cr
Total Capital Investment Rs. 9.35 Cr
Rate of Return 43%
Break Even Point 41%

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