Toilet soap making process

can be divided in mainly seven following process :

Soap Saponification (Raw soap production)

-Oils/fats are fed by pump from storage tanks and the process is started.

Soap Cooling/Drying
-solution is heated (boiled) by using steam of steam boiler.
-soap will be ready in saponification vessel which is transferred in to
cooling moulds.

Soap Mixing
-the same soap is converted in soap chips by using soap chips making
machine
-The dried chips will then go to the soap mixer machine where desired
color, perfume preservatives, additives etc. are added.
Soap Rolling
-The mixed soap is then fed to the soap roller machine where it
gets homogenized, finishing and final output soap in form of thin
ribbon.

Soap Double extrusion (Plodding)

-The same thin ribbon is fed in to the duplex plodder machine
which used for highest compression, finishing of soap and which
produced final output of soap in bar form.

Soap cutting
-cutting of soap bar in to tablet which will be with suitable size of
soap stamping process.

Soap Stamping
-The stamping dies of stamping machine are made specially
according to buyer's selected logo, design, brand name.
Chemical Reactions:
Fat splitting reaction:

Saponification reaction:
(a) Hydrolyser

The fat and catalyst are mixed together and enter the hydrolyser.

Hot water is added here

Water has 10 15% solubility in oil and fats.

Temperature is maintained at 230C - 250C and pressure at 40 45 atm

for reaction between water and organic compound.
Fatty acid stream block

(b) Flash Tank

Fatty acids from the hydrolyser enters the steam flash tank to remove
water & concentrate the fatty acids.

(c) Vacuum Still:

The concentrated fatty acids enter a high vacuum still.

Jet ejector is used to generate vacuum in the still.

Wastes are separated from the bottom.

(d) Mixer:

Fatty acid produced from vacuum still is now pumped to mixer.

Base such as NaOH or KOH is mixed in appropriate proportions and

mixed thoroughly.

After mixing a viscous mass is produced.

 (e) Blender:

The viscous mass from the mixer is sent to the blender.

Ingredients like scents, anti fungal & anti bacterial chemicals etc. is
mixed in the blender.

The blender removes the solid mass which is then sent to:

1. Chipping rolls
2. Spray dryer
3. Bar Press Stock
Glycerin stream block

(f) Ion Exchange:

15 20% glycerin along with impurities from the hydrolyser goes for
ion exchange.

Here salt and colour is removed from glycerin.

(g) Triple effect evaporator:

The product stream from ion exchanger is sent to triple effect
evaporator.

The glycerin solution is concentrated in evaporator.

(h) Vacuum still:

The glycerin obtained from vacuum still is called yellow glycerin. It is

used for industrial use.

(i) Mixer:

For removing color, yellow glycerin is treated with activated carbon

in mixer.
(j) Filter:

Activated carbon is separated from the solution.

99% white glycerin is produced. The yield is 30 35kg per ton of

soap produced.