Modern bath soap has come a long way not only does it fight Grime and keep things hygienic but it also smells pretty amazing it can come in a variety of shapes and textures
Let’s check the process.
Selecting Suitable Oils
The first step in bath soap production involves selecting suitable plant-based oils.
In the recent past animal fat was used that was obtained directly from slaughterhouses however this was soon replaced by plant-based oils such as olive oil.
Olive oil not only eliminates impurities but also results in Milder and skin-friendly bath soaps. The quality of the olive oil depends on the quality of the olives being harvested.
Selection of the optimal Harvest time along with careful handling is crucial to obtaining a high-quality oil that’s Sublime in aroma and taste.
Harvesting and Processing Olives
Olives can be harvested by hand or through mechanical means hand harvesting is often preferred for high-quality olive oils as it minimizes damage to the fruit. After harvesting the oils are cleaned to remove leaves and other debris.
This is usually done using equipment such as vibrating screens. The cleaned olives are then crushed to break the fruit and release the oil.
Traditionally, stone mills were used for this purpose but modern facilities often use stainless steel crushers or hammer mills.
The crushed olives are then subjected to malaxation a process that involves mixing and kneading the olive paste.
This helps the coalescence of oil droplets into larger droplets facilitating the extraction of oil.
Now that the paste has been primed for extraction centrifuge is used to separate the oil.
The olive paste is spun in a centrifuge and the centrifugal force separates the oil from the other components such as water and solids.
The extracted olive oil May undergo filtration to remove any remaining impurities or particles.
The Role of Sodium Hydroxide
Sodium hydroxide NaOH also known as caustic soda is commonly used as an alkali in soap production the precise amount is calculated based on the type and quantity of vegetable oil being used.
The Science of Saponification
The key chemical reaction in soap-making is saponification which is the process by which fatty acids and oils react with an Alkali to produce bath soap and glycerine.
This reaction typically takes place in large stainless-steel vessels.
The olive oil is heated and the alkali is gradually added while stirring this process initiates the saponification reaction.
The mixture is carefully monitored to ensure an even distribution of heat and Alkali.
Maintaining a controlled temperature during saponification is crucial for the success of their reaction.
The temperature varies depending on the specific vegetable oil being used but it is typically in the range of 100 to 150°C.
The pH of the bath soap batter is tested at various stages of the process to determine the alkalinity.
As saponification progresses the pH of the mixture changes the end point of saponification is often associated with a specific PH range.
Factory workers use pH testing strips or meters to monitor the pH and determine when it reaches the desired level.
Handling Glycerine: A Valuable By-product
During saponification, glycerine is formed as a by-product. In commercial soap production, the glycerine is often separated from the soap mixture.
Glycerine is a valuable by-product and can be used in various other industries such as cosmetics and pharmaceuticals.
After the saponification reaction is complete the liquid bath soap is sprayed over a big metal roll as it passes over the metal the bath soap solidifies and a big blade scrapes it off creating ribbons of soap.
The bath soap ribbons fall into a hopper where an augur moves it along and sends it down a chute.
The bath soap ribbons fall down the chute into a rolling mill where they’re mixed and compressed.
Small blades cut up the mil soap into ribbons once again but this time they’re much denser.
These denser bath soap ribbons fall down a hopper into an augur which throws them into an extruder called a noodle plate which shapes them into soap noodles.
The soap noodles are then collected into a bin which dumps them into a mixer.
In the mixer, very various additives are introduced to enhance the bath soap’s appeal.
Fragrance colorants and essential oils are added to give the soap a pleasant scent and appearance
Depending on the intended use of the soap additional ingredients such as moisturizer exfoliants or specialty oils may be incorporated.
These ingredients contribute to the soap’s specific properties such as moisturizing and or exfoliating capabilities.
When the batch is ready a trap door opens up in the mixer. The blades of the mixer turn and nudge the soap out of the door.
Then it’s forced through another noodle plate which mixes up the batch a little more it also helps break down any clumps or uneven textures resulting in a smoother and more uniform soap.
The soap is then extruded or plotted into the desired shape this can be in the form of long bars pellets or other shapes depending on the manufacturing specifications.
The extruded soap is precision cut into individual bars or pieces this can be done manually or using Auto automated cutting machines ensuring uniformity in the size and shape of the cut.
Drying and Stamping
Soap bars are then left to dry this can be done in open air or specialized drying rooms.
Drying is essential to remove excess moisture-solidify the soap and improve its hardness.
Once the soap bars are dried and hardened they undergo stamping.
Stamping involves pressing the soap with a Dye or Mold to imprint the brand name Logo or other identifying marks.
Packaging and Quality Control
The final step in the soap-making process is packaging.
The soap bars are packed in various ways including box wrappers or plastic.
Wrapping packaging is designed not only for protection but also for marketing and presentation.
Throughout the entire soap-making process quality control measures are implemented including testing the pH of the soap ensuring that it meets safety and Regulatory standards and conducting sensory evaluations for fragrance and texture.
Environmental Considerations
Moreover, soap production generates by-products such as excess alkali impurities.
Proper waste management practices are crucial to minimize environmental impact.
This includes recycling treatment or safe disposal of by-products.
That was all about the journey of soap
Conclusion
From olives on a tree branch to the product that occupies your bathroom shelves.
Source: Factora