Guide to Soap Production Process

on

 
SOAP PRODUCTION PROCESS (2023 UPDATED)
 

Soap production is a fascinating process that combines science and creativity to yield beautiful, handcrafted soap. 


In this guide, we will explore the essential ingredients, safety precautions, and detailed steps to create your own soap from scratch. 


Whether you're an aspiring soap artisan or a seasoned pro, there's something here for everyone.


Understanding the Basics


Before we dive into the soap-making process, let's lay the foundation:


Saponification


This is the chemical reaction that transforms fats or oils into soap and glycerin when combined with an alkali-like caustic soda (lye).


Types of Soap


We'll focus on the cold process, which offers creative flexibility.


Safety First


Your safety is paramount.


Safety Gear


Always wear protective gear, such as rubber or plastic gloves, when handling caustic soda and other chemicals.


Proper Ventilation

Work in a well-ventilated area to disperse any fumes.


Preparing Solutions


Let's start with the basics


Caustic Soda Solution:

  • Measure caustic soda as needed.
  • Mix with water at a ratio of 1:3½.
  • Use a hydrometer to gauge the solution at 1275 - 1250 S.G.


Soda Ash Solution:

  • Combine soda ash (dense) and water at a ratio of 1:3½.
  • Use a hydrometer to gauge the solution at 1275 S.G.


Sodium Sulphate: (optional)

  • Mix 1 cup of sodium sulfate with 3 cups of water.


Soap-Making Formula (For Approximately 1 Carton of 100g Soap Bars)


Here's a basic formula to get you started:

  • P.K.O (Palm Kernel Oil) - 2 parts or 4 litres
  • Colourant - 1 teaspoonful
  • Caustic soda solution - 1 part or 2 litres
  • Soda Ash Solution (and/or sulfate) - ½ part or 1 litre
  • Sodium Silicate - 4-5 tablespoonfuls
  • Perfume (2-3 tablespoonfuls)


The Soap-Making Process (Semi-Hot Method)

Let's create soap:


Prepare the Oils:

  • Measure out the required oil into a mixer.
  • Addolorant and warm the oil (not too hot).
  • Mix after heating.

Mixing the Solutions:

  • Add the caustic soda solution and mix. Allow it to react for about 3 minutes if necessary.
  • Add the Soda Ash solution (and/or sodium sulfate) and mix.

Adding Ingredients:

  • Incorporate all other ingredients and mix until the soap paste is smooth (approximately 2 minutes).

Molding and Curing:

  • Transfer the mixture into moulds lined with nylon and allow it to rest for about 8 hours.
  • Remove the soap from the mould and cut it into bars.

Finishing:

  • Optionally, grind the soap before tabulating if you prefer.
  • Pack the soap for sale.


Additional Formulation (For 1 Carton of 100g Soap Bars)

Here's another formulation that yields more soap bars:

  • P.K.O. - 2 parts or 4 litres
  • Colourant - 1 teaspoonful
  • Caustic soda solution - 1 part or 2 litres
  • Soda Ash Solution - ¼ part or 1 liter
  • Kaolin or calcium carbonate - ¼ part or 1 kg
  • Sodium Silicate (optional) - 4-5 tablespoonfuls
  • Perfume - 2-3 tablespoonfuls


Conclusion


Making soap from scratch can be a fulfilling endeavour. Whether you're making it as a hobby or starting a small-scale soap production business, the semi-hot method provides an efficient way to create beautiful soap bars. 


Comments

Post a Comment

You comment here