The Process of Industrial Soap Manufacturing
Soap-making is a relatively easy process that requires minimal investment when done right. Soap production consists of saponification, oil removal, purification, and refining. There are also three distinct methods used in industrial soap production (hot, cold, and semi-boiled processing).
Many of the best private label soap manufacturers use high-quality ingredients for crafting soap. Custom soap manufacturers add ingredients that can soothe different skin types. Skilled artisans may also blend natural oils or butter to add nourishing vitamins to the soap’s makeup.
Here’s everything you need to know about the materials and processes involved in soap-making.
Industrial Soap Production Process
Soap manufacturing includes an alkaline solution for hydrolyzing a triglyceride. These compounds contain esters of glycerol and long-chain carboxylic acids.
The initial phase in soap manufacturing starts with selecting raw materials. Many factors determine the quality of the soap, such as production costs, safety standards, and performance characteristics.
The actual production process may vary from company to company. Private label soap manufacturers use some basic materials in the production phase. These include oils and fats, lye, brine, and other additives. There are three standard process methods used at an industrial level:
- Cold processing — This method does not use heat to make soap. Cold process soaps undergo saponification at room temperature. It is a lengthy process that results in a homogenous mixture.
- Semi-boiled processing — This method saponifies to a certain point (never reaching the boiling point). All the raw materials remain in the final product.
- Hot processing — This method involves using lye, various types of oils, and an external heat source to turn soap into a gel base. Hot processing helps speed up the saponification process.
Soap production includes a few primary steps:
Saponification
Saponification is a chemical process that produces soap from fatty acid derivatives. It hydrolyzes esters under standard conditions to form an alcohol and a carboxylate. It is an exothermic reaction. This means it releases heat when the fatty acids react with lye. To produce certain types of soaps, manufacturers may also add salt during the reaction to precipitate the solid product.
Soap manufacturers use saponification values to check the amount of lye needed in a single batch. Each type of oil features a distinct value. Other variables that impact saponification are the types of ingredients used.
Bleaching
Fat bleaching in soap production is necessary with ingredients like palm oil when making soaps like toilet sap. It involves the oxidation of the oil particles using thermal energy. There are various bleaching agents for oils and fats, including oxidizing agents, halogen compounds, and acids.
A reliable industrial method is earth bleaching. Most custom soap manufacturers source raw clay to purify and bleach edible oils, mineral oils, fatty acids, and wax. Bleaching earth results in a light-coloured oil perfect for making toilet soap bars.
Refining and Deodorization
Both treatments help remove impurities and foul odours, and free fatty acids. Oil refining consists of two methods: a chemical process and a physical process. The chemical process method mixes the oil with caustic soda, which is then heated and stirred. It separates the fatty acids from the mixture in the form of soap suds. The purification also removes minerals, lipids, and other impurities.
Meanwhile, the physical process helps refine palm oil through distillation. It takes place under high-temperature conditions and uses a vacuum. The fatty acids form the distillate, which is then removed from the refined oil.
Find the Right Soap Manufacturer in Ontario
Our experts will guide you whether you’re looking for liquid soap manufacturers or detergent suppliers. Wilson Chemical Innovations Inc offers high-quality cleaning products. With years of experience in the commercial cleaning industry, we can help you find products that are best suited for your business.
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