HOW TO PRODUCE POWDERED DETERGENT
A. INTRODUCTION:
Detergent like soap is used in wide range of cleaning activities. It is employed at home, office, factories, hospitals, farms etc. The major deferent between detergent and soap is that detergents have the advantage of retaining its efficiency in hard water.
Nowadays soap can also be powder or liquid as found in detergents. These liquid or powder soap are differentiate by the use of word SYNTHETIC for detergents.
B. RAW MATERIALS (ALL TYPES) FUNCTION
1. Vegetable Oil (e.g PKO)- To form soap
2. Fat - To form soap
3. Sulphonic Acid - To form soapless soap
4. Hydrogen peroxide - To help in breaking dowetergent
5. Sodium Silicate - Hardener and Bristleness
6. STPP or TSP - Water softener (optional)
7. Sodium Sulphate - Hydration (Removing water) (ptional)
8. Sodium perborate - Cleaning Material (bleach)(optional)
9. Tinapol - Brighter (Like blue dye)
10. Caustic Soda - To form soap and detergent
11. Soda Ash - Basing agent (Neutralizer) (optional)
12. Urea - To Neutralize (optional)
13. Colourant - To impact colour
14. Perfume - To impact scent
15. Sodium - Foam Booster (optional)
16. Water - To solubilize Solids
C. EQUIPMENT / TOOLS FUNCTION
1. Reactor(s) (Mixer/Heater)
(Stainless steel or Plastic) For Boiling
2. Storage Tanks (Stainless Steel
or plastic) For various purposes
3. Drying Chamber For drying (Oven, Rotary or Flash)
4. Pulveriser (Grinder) or sieve For Grindings/sieving
5. Filling machine (optional) For Filling
6. Packaging Machine (optional) For Sealing / Packaging
7. Weighing scales For Various Weighing
8. Hydrometer For Guaging of Solutions
D. PACKAGINGS:
The product is packed in a paper packets, polythene bags, plastic cans etc which in turn will be put in bigger cartons. Packaging should carry brand name, quantity, manufacturer and any other relevant instructions.
E. FORMULATIONS:
Many formulations are available for use. The producer however must consider the factors in choosing one of them adopt.
VIZ:
1. Cost of production materials
2. Availability of these materials
3. Ease of production process
4. End user requirements (Quality)
It is important to mention that a combination of soap type and synthetics detergent type formulations have been adopted when the process is cheaper. Use in made of oils, sulphonic acid and caustic soda as the basic materials.
PRATICAL PRODUCTION PROCESS:
1. Making of solution: Measure out in the container of your choice as below
(a) Caustic Soda Solutions: (N.B. Caustic Soda is corrosive)
Caustic Soda - 1 part
Water - 4 parts
Note: This means that to every one part of caustic soda pearls add 4 parts of water (e.g 1 milk cup of caustic soda plus 4 cups of water). Mix well till the colour (milk) is clear. Do not touch with bare hand or body.
(b) Soda Ash Solution: Treat as in caustic soda solution
Soda Ash light - 1 part
Water - 4 parts
Mix these two materials till Soda Ash is fully dissolved.
(c) These two solutions (a) and (b) are kept for use.
CAUTION:
Use rubber or plastic hand glove anytime you are producing to avoid direct body contact with caustic soda. Caustic soda is corrosive. Avoid body contact.
IMPORTANT NOTES:
1. The formulation given above if carefully followed and good materials are used given s a good and affordable detergent that will guarantee the investor good return on investment.
2. Do not hesitate to make further inquiries where in doubt or were further explanation is needed.
3. Use plastic containers for storage, measurement and mixing to avoid corrosion and rusting.
4. Ordinary mild steel will corrode and rust easily but can however be used where reduction of cost for a start is absolutely necessary.
5. Prepare each solution on a separate container.
6. Store all materials properly.
POWDERED DETERGENT (synthetic) FORMULATIONS
Alkyl Benzene sulphonate (ABS) or D.D.B.S. - 20 parts (kg)
Soda Ash (Light) - 40 parts
STPP - 26 parts
Sodium Metasilicate - 8 parts
CMC - 2.0 parts
Colourant (optional) - Q.S. (50g for 20kg DDBS)
Tinapol - Q.S.[100g “ “ “ ]
Papain (enzyme) to remove stains - Q.S.[100g “ “ “ ]
Water - 15 parts (or kg)
Total about 100kg
Q.S. means sufficient quantity (usually 0.05 – 0.2%)
PROCESSING:
Add all the materials into a low speed mixer except ABS. Mix very well. Add the ABS or DDBS kg by kg as you mix. Let the mixture set then strain through a fine mesh (About 200 ms) DDBS and Idet 10 are brand names of ABS.
Dry in a low temperature spray dryer set under 600c or less.
Other Formulation
Idet 10 - 45 parts(kg)
STPP - 35 parts
Soda Ash Light - 16 parts
CMC - 2 parts
Colourant - 0.1 part
Tinapol - 0.2 part
Papain (optional) - 0.2 part
Water - 15parts
PROCESSING:
Treat as in No. 1 above. Detergent of No. 1 is harder than detergent No. 2 yet cheaper in production cost.
Note: This is the modern synthetic detergent made without vegetable oil. It foams more and easily removes stains from fabrics. It is replacing the oil base detergent.
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