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STARTING A SOAP MAKING BUSINESS WITH GUARANTEE TO SUCCESS.
Household or laundry soap is the best known domestic hygiene product. Production of good quality soap helps reduce family expenses. Hand-crafted production of household and laundry soap is based on two main processes: the semi-boiled process and the cold process.
And also soap is important in preventing the spread of disease by helping people keep themselves, their clothes and their surroundings clean. In some places, soap is unavailable or expensive. This Technical Brief gives some practical guidelines on a cheap, easy way to make soap on a small scale, using ingredients which are available locally.
Making soap is a fun hobby that can be turn in to full time business or at least a way to make a little extra money. Soaps especially those that use beautiful designs, are a hit with many customers since soap is a necessity.
WHAT IT TAKES TO START A SOAP MAKING BUSINESS.
Building a part time or full time business takes time. It also takes some little money. So don’t quit your day job yet. Roll up your sleeves and be prepared to work on the new venture when you are not at your full-time job _ evenings, weekends, whatever it takes. This is a great first indicator whether you have the passion and drive to be an entrepreneur.
Making a Long lasting Strong, Mild and Durable Bar of Soap.
Some qualities of a good bar soap, which are much sought-after by customers are: White bars, Long lasting/durable bars, Foamy bars and non-drying bar soaps. Many upcoming soap manufacturers find themselves in challenging situations when it comes to maintaining color uniformity for their soaps. Others find it hard to make low-cost soaps, often citing perceived “high” cost of raw materials. Still, others can’t find the right soap making raw materials. Lack of expertise training is to blame for over 90% cases of poor soap production. Soap making is just not about boiling a strong alkaline solution and fatty acids, but an in-depth understanding of the major FIVE (5) components/ingredients that are mandatory in achieving high quality durable bars.
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PROPERTIES OF BEST BAR SOAP:
Bubbly - this gives the soap ability to lather.
Cleansing - the ability of the soap to trap dirt on the skin and wash it away.
Hardness - the firmness of the soap bar, it should be strong, mild and durable.
Conditioning - the amount of moisture that is left on the skin, this helps to sooth the skin and keeps it soft.
Creamy - this measures the stability and creaminess of the soap lather.
THE PRODUCTION PRINCIPLE:
Making soap involves a chemical decomposition of fats and oils into their constituent parts, namely: fatty acids and glycerol. The fatty acids combine with an alkali, usually caustic soda, and the glycerol remains free. In the ‘cold’ process, which will be described in this Technical Brief, oil is treated with a definite amount of alkali. The aim is to complete the reaction, which generates its own heat, without any free alkali being left in the soap.
EFFECTS OF THE ALKALI.
Caustic soda is the most commonly-used alkali, but if it is too expensive or not available, caustic potash can be used. Caustic soda produces a hard soap, whereas caustic potash makes a softer soap which is more soluble in water.
The type of alkali metal used determines the kind of soap product. Sodium soaps, prepared from sodium hydroxide, are firm, whereas potassium soaps, delivered from potassium hydroxide are softer or often liquid. Historically potassium hydroxide was extracted from the ashes of bracken or other plants.
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EFFECTS OF FATS.
Soaps are derivatives of fatty acids. Traditionally they have been made from triglycerides (oils and fats.) Triglyceride is the name for the triesters of fatty acids and glycerin.
In Our long outstanding career-experience in teaching and mentoring young soap manufacturers both in Uganda and all African countries, we have gained tremendous exposure on a myriad of case studies where people have been confronted by challenges of making good, long-lasting white bars of soap.
WATER.
Water needs to be ‘soft’ to make good soap, so rainwater is a good source. ‘Hard’ water contains dissolved mineral salts which prevent soap lathering and hinder cleansing. To make water soft, add 15ml (1 teaspoonful) of lye to each 3.8 litres (1 gallon). Stir and leave to stand for several days, to allow the sediment which has been precipitated to sink to the bottom. Then pour off the softened water.
EQUIPMENT:
To make soap, you will need:
• Two large bowls or buckets. Soap-making equipment should never be made from aluminium, as the alkali will corrode it.
• Measuring cups
• Wooden or enamel spoons or smooth sticks for stirring
• Moulds: water-tight containers which can be made from wood, plastic, cardboard or waxed paper
• Cloth or waxed paper to line the moulds, so that the soap can be removed easily.
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SOAP MAKING PROCESS [SAPONIFICATION]:
There are two types of soap: soft soap and hard soap. Soft soap can be made using either a cold process or a hot process, but hard soap can only be made using a hot process. To make Soap making Practical Action 3 any soap it is necessary to dilute the lye, mix it with the fat or oil, and stir the mixture until saponification takes place. In the processes described below, the word 'fat' is used to mean either fat or oil. The cold process may require several days or even months, depending upon the strength and purity of the ingredients, whereas the hot process takes place within a few minutes to a few hours. Soap is made from fats and oils or their fatty acids. Soaps are sodium or potassium salts of long chain fatty acids… since this reaction leads to formation of soap, it is called the saponification process. Therefore, saponification is the grouping of a strong alkaline solution with fatty acids to form a salt. And soap is a salt of fatty acids
There are two methods for making bar soap from scratch:
Hot process. In hot process soap-making, external heat accelerates saponification. Most soaps can be used the next day, though it’s ideal to wait 1 week if you want a harder bar.
Cold process. Cold process uses the internal heat that’s naturally produced during saponification. The bars will completely harden in 4 to 6 weeks.
The cold process does not use a heat source, rather a system that maintains the temperature in a cold environment. This process consists of gradually adding a caustic soda solution to fat and constantly stirring until the solution has been completed used up. This is done in a system composed of a tub of ice or salt water allowing the temperature to be maintained at between 0 and 40 °C for mixtures less than 15 kg. For those greater than 15 kg, the fat and caustic soda solution mixture must be maintained at the ambient temperature (between 24 and 30 °C). Once the soap paste has been obtained, chemical or natural substances are added to increase the antibacterial, softening, lightening, antioxidant or purifying properties of the toilet soap.
Below, you’ll find instructions for hot process soap. This method is beginner-friendly and has a fast turnaround. It makes 30 ounces, or 7 to 10 bars, of custom bar soap.
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{here is a complete Guide}
PRODUCTION PROCEDURE:
Directions
1. Measure your ingredients and put on your safety gear.
2. Set the slow cooker to low.
3. Add the coconut oil to the slow cooker. As it melts, prepare the lye solution. Slowly add the lye to the water. (Do not add water to lye this is unsafe.)
4. With a spatula, carefully stir the solution as you add the lye. It’ll become hot and release fumes, which is OK.
5. Set aside the lye solution. Let cool for 15 to 20 minutes.
6. Check the oils. If the coconut oil has completely melted, add the olive oil. Stir well.
7. Check the temperature of the oils using the candy thermometer. Once the oils have reached 120 to 130°F (49 to 54°C), place the immersion blender on the side of the slow cooker.
8. Gently pour in the lye to avoid splashing. Stir slowly.
9. Set the blender to low. Stir the mixture, moving in circles. Keep the blender immersed to avoid air bubbles.
10. Continue blending and stirring for 10 to 15 minutes, or until the soap has reached trace. This is when the oils and lye solution have thickened and look like pudding.
11. Cover the slow cooker. Cook on low for 50 minutes. If the mixture bubbles, stir it gently.
12. Turn off the slow cooker. Let cool until the mixture drops below 180°F (82°C). Add essential oils and colorants, if using. Mix well.
13. Pour the mixture into the soap mold. Smooth the top with a spatula. Tap the mold onto your work surface to eliminate air bubbles
Follow the bellow procedure for easier production.
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{here is a complete Guide}
• Add alkali to water, never the other way round. The alkali solution should be at body temperature (37°C). Never put your finger in the solution to test the temperature, or it will burn you, but feel the outside of the container.
•Add perfume and color (if desired) to the contents. (Must be alkaline resistant)
•Add soap enhancements. (Described below)
• Melt any solid fat in the oil/fat mixture
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FIG 1
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• Pour the alkali slowly into the oil/fat mixture, stirring it continuously in one direction only. The mixture needs to be stirred for at least half an hour after all the alkali has been added. The mixture should become thicker, and lines of white particles should follow the spoon as you stir,
• Blend until you reach TRACE.
• Pour the mixture into lined moulds and leave it to set undisturbed for two days in a dirty place. If it has obviously not set after two days or grease is visible on the top, leave it a little longer.
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FIG 3:
FIG 3:
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• When the soap has set, remove it from the moulds and cut into bars.
• Stack the bars on trays and leave them for four to six weeks to allow the chemical reaction to finish completely.
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fig 3:
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• When the soap is finished, it will shave from the bar in curls. Cover the bars of soap to prevent further loss of moisture.
NOTE:
Soap “enhancements” include any ingredient that has been added to a basic soap recipe to provide color, fragrance and/or beneficial properties. Examples of “enhancement” ingredients include natural/synthetic colorants, essential oils, fragrant oils, “texturizers” (i.e. oatmeal, cornmeal, etc.) and ingredients such as rose hips, herbs, wheat germ oil, vitamin E, etc. that add beneficial properties to soap (i.e. soften skin, nourish skin, etc.) Note: “Essential” oils are oils obtained from plants and are usually fairly expensive, however, just a little goes a long way! “Fragrant” oils are synthetic versions of essential oils, and are significantly less expensive. Other fragrance options include “fun scents” such as peach, raspberry, chocolate, etc. Very Important! Make sure that any and all colorants, essential oils, fragrant oils and/or other “enhancements” you add to your soap are cosmetically safe! Many soap making books include a list of safe ingredients that can be added to soap.
ANY CHALLENGE?
If the soap you made was not successful, it may have been because:
• You used the wrong materials
• The fat or oil was rancid or salty
• The alkali was too hot or cold
• The mixture was stirred too fast or not for long enough
•Using dirty or rancid fat Dirty or rancid fat must be cleaned before it can be used for making soap. This can be done by melting it and straining it through a finely woven cloth or by boiling it up with water, leaving it to cool and separating it when set.
pg. 9 We welcome you to train with us and excel in soap making career. We pledge support, mentorship and facilitation where necessary to achieve your goal. Talk to us on Phone.{here is a complete Guide}
Overcoming Poor Soap production Practices:
This can be achieved in two ways:
1. Comprehensive background theory in soap formulation
2. Intensive practical training on soap production
TOILET SOAP.
it contains more acid which is called fatty material. With high fatty material, these soaps clean and remove almost all germs. It includes few agents which are helpful for skin.
BATHING BAR SOAP.
They are generally quote as "beauty soaps". Bathing bars are mix of fatty material and other agents like moisturizing cream, Glycerin. These soaps are not meant for pure cleaning so the cleaning capacity is less. Toilet soap must mention the percentage of fatty material it contains but it is not compulsory for bathing bars because TFM percentage of these soaps will be less.
HOTEL/GUEST HOUSE SOAP/ TOILET SOAP PRODUCTION.
Toiletry means - an object or cosmetic used in making up, dressing, etc. Due to the word toiletry, Most of you misunderstood the concept of toilet soap. We define the toilet soap as “a sweet smelling soap that is intended for washing the body”. It is amazing how much return on investment (R.O.I) you can get on toilet soap making from as little as ugx600000 startup capital. If you'd like to start such projects but don't know how to, Enroll now for our soap production courses for our proven practical perfect know how.
pg. 10 We welcome you to train with us and excel in soap making career. We pledge support, mentorship and facilitation where necessary to achieve your goal. Talk to us on Phone.{here is a complete Guide}
WARNING:
1. ALWAYS wear eye protection (goggles) and rubber gloves. Clothing should consist of long sleeve shirt, long pants and socks and shoes.
2. AVOID breathing the dust released and fumes created when adding either sodium hydroxide or potassium hydroxide to water. ALWAYS work in a well-ventilated area!
3. DO NOT use aluminum pans, utensils, or foil with soap recipes that require the use of sodium hydroxide or potassium hydroxide, since these chemicals will react with aluminum. Stainless steel is the container/holding vessel of choice when using either of these caustic chemicals in a soap making process.
4. ALWAYS add the sodium hydroxide or potassium hydroxide slowly to water. NEVER add water to either of these chemicals!
5. “CURE” SOAPS made using sodium hydroxide or potassium hydroxide 3 - 6 weeks before using. If in doubt whether the soap is properly “cured” test the “pH” of the soap. A “pH” test measures the relative acidity or alkalinity of a substance. The pH scale ranges from 0 to 14, with 7.0 being “neutral” (neither acidic nor alkaline), and numbers less than 7.0 representing “acidic” substances, and numbers greater than 7.0 representing “basic” substances. Soaps that are properly cured and safe to use should have a pH in the range of 5.5 - 8.0.
6. Caustic soda will burn skin and eyes, so try and wear protective gloves while making soap. If you get burnt, wash the skin immediately with cold water and then put citrus juice or vinegar on it to neutralize the alkali.
7. Lye is extremely caustic. It causes burns if splashed on the skin and can cause blindness if splashed into the eye. If drunk, they can be fatal. Care is needed when handling lye and 'green' (uncured) soap. Details of the precautions that should be taken are given below.
8. Do not breathe lye fumes. Use rubber gloves and plastic safety goggles. You should also wear an apron or overalls to protect your clothes. If lye splashes onto the skin or into your eyes, wash it off immediately with plenty of cold water. When lye is added to water the chemical reaction quickly heats the water.
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{here is a complete Guide}
9. Never add lye to hot water because it can boil over and scald your skin. Never add water to lye because it could react violently and splash over you. Always add the lye to the water in small quantities.
10. Dispose of soap-making wastes carefully outside the house. Do not put them in the drain
11. Because of these dangers, keep small children away from the processing room while soap is being made.
TIPS ON CHOOSING SOAP INGREDIENTS.
The basic ingredients of soap are:
animal fat or vegetable oil
100 percent pure lye
distilled water
essential or skin-safe fragrance oils (optional)
colorants (optional)
GLOSSARY:
Lye, Lye water, potash lye - interchangeable terms for alkali made from wood ashes soaked in water Potash (caustic potash) - lye water evaporated to a powder.
Lime (or stone lime) - ground or agricultural limestone.
Quicklime - lime that has been baked.
Soda lye - quicklime slaked in water and heated with soda.
Soda - hydrated sodium carbonate.
pg. 12 We welcome you to train with us and excel in soap making career. We pledge support, mentorship and facilitation where necessary to achieve your goal. Talk to us on Phone.Caustic soda - soda lye evaporated to a powder.
{here is a complete Guide}
Commercial lye - usually caustic soda and is the equivalent of 'lye' in most recipes.
Saponification – Chemical process for the manufacture of Soap.
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ANNEX #1: Sample of Soap Making Machines.
FIG 6: FIG 7:
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PROFILES OF AUTHOR.
1. MR. WALAKIRA BRUNO - industrial chemist
BSc. Industrial Chemistry; Makerere University Kampala
Certificate in project planning and management
Certificate in lean management
Experience in project management, quality analysis and manufacturing start – up.
WATSAP: +256770833485
CALL: +256758314586
ADDRESS: Namanve industrial area, Mukono.
Email : walakirabruno70@gmail.com
o RESEARCH GATE: http://www.researchgate.net/profile/Walakira-Bruno
o LINKED IN ACCOUNT: http://www.linkedin.com/in/bruno-walakira-383718127
o ORCID http://orcid.org/0000-0001-8429-2618
MANDELA ENTERPRISES LTD
Quality l Value
NOTE:
FOR THE RECIPE (FORMULATION), COSTINGS (CALCULATING PROFITS) AND PRACTICAL LESSONS. IN BOX ME.
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Fig 09: Mr. Walakira Bruno