LIQUID SOAP

MANUFACTURING STUDENTS
José Antonio Aldape Moncada
Jesús Alfredo Cortinas Herrera

PROCESS
Sergio Abraham Hinojosa Aguilar
Marvin Christopher Lugo de León
Gustavo Adolf Ríos García

Dynamics & Process Control UNIVERSIDAD AUTÓNOMA DE COAHUILA

FACULTAD DE CIENCIAS QUÍMICAS
Héctor Arturo Ruiz Leza
Abstract
The purpose of this document is to show the reader the liquid soap manufacturing
process, two essential topics will be addressed: the complete process of its
production from raw materials to its commercialization, and the use of controllers in
each part of the process. The soap used as an example for this document is based
on potassium hydroxide, which is different from one made with sodium hydroxide
because of its lower need for water to liquify, containing more cleaning agent. The
process for the production of liquid soap leaves as a by-product glycerol, which is
necessary in the last part of the production cycle, since it serves as a humectant,
which implies a recirculation.

Introduction
Water and oil, two completely incompatible substances that represent a problem for
cleaning, either of different fabrics or of the same human body, a disadvantage that
the soap, in bar or liquid, can solve quickly, acting as an intermediary between both
substances. The contradictory nature of the soap, having a water-loving end, oil
repellent (usually potassium or sodium) and it’s other hydrophobic end (composed
of a chain of fatty acids), make it the perfect cleaning agent.
When the soap is dissolved in water, the hydrophobic part of the soap molecule is
attracted by dirt stains from the skin or fabrics, forming a ring around it called micelle,
while the other part of the molecule is attracted to the water, pulling the soap with
the dirt stuck to the other end.

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 1. Raw Material
Coconut oil, isopropanol, distilled water and potassium hydroxide.

1.1 Sodium or potassium.

As mentioned above, potassium stands out in this decision, being much more
soluble than sodium and less prone to form crystals, making it the base of all liquid
soaps.

1.2 Coconut oil

Why is Coconut oil the main element in most liquid soaps? It is due to the amount of
lauric acid contained in the oil.
The more soluble the fatty acid, the less turbid the resulting soap will be. The
solubility also influences the speed or abundance of foam that is generated, the
dissolution in water reduces the foaming action of the soap.
Hard water minerals reduce foam, so coconut oil-based soaps work better with
non-demineralized waters.

1.3 KOH, Caustic Potash

Manufactured from the electrolysis of potassium chloride, it is sold in liquid state or
in crystalline fragments, it is much more reactive than sodium hydroxide (NaOH),
and more potassium hydroxide than sodium is necessary to saponify a quantity of
determined fats (1.4 times more).

1.4 Isopropanol
Alcohol, like glycerin and sugar, helps to reduce the cloud point of liquid soap,
achieving crystal clarity in the substance.
Ethyl alcohol can be used for the production process of liquid soap, since
isopropanol is a weaker solvent, but since these are soaps based on potassium
hydroxide, this is not a problem. The smell of isopropanol can affect the final product,
to avoid this, the mixture obtained at the end of the process has to be subjected to
high temperatures to evaporate the alcohol.

1.5 Phenolphthalein
It serves as acid-base indicator, it is sought that with this indicator the mixture is
clear (indicating the presence of excess fatty acids).

2. Tests

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2.1 Acidity Index
The acid number is defined as the milligrams of NaOH or KOH necessary to
neutralize the free fatty acids present in 1 gram of oil or fat, and is a measure of the
degree of hydrolysis of a fat.
The method is based on the neutralization of free fatty acids present in the oil or fat
with ethanolic potassium hydroxide solution in the presence of phenolphthalein as
an indicator. The acidity index is expressed in mg of hydroxide Potassium
necessary for neutralize a fatty gram. It can also be expressed as a percentage of
Oleic Acid.

2.2 Iodine Index

The iodine value is a scale used to define a degree of unsaturation of an organic
compound containing diene or trienic bonds.
This type of chemical analysis is carried out profusely in the edible oil, margarine
and lard industries where it shows the degree of unsaturation of the lipid, which is
one of the characteristic parameters of many triglycerides. For example:

Palm oil = 50 - 55
Pork fat = 40 - 55
Olive oil = 75 - 95
Soybean oil = 125 - 140
Linseed oil = 170 - 190
Fish oil = 130 - 200
Currently, in the fat sector, determinations are made more practical by means of gas
chromatography, which discriminates the acid radicals that form triglycerides.

The index of iodine, or bromine, is correlated with the refractive index, a simple and
very precise measurement that is carried out with the help of refractometry.

2.3 Saponification Index

The saponification index is the milligram amount of an alkali, specifically potassium
hydroxide, which is needed to saponify a gram of a certain oil or fat.

2.3.1 Saponification Values

Fat or oil Saponification Index: mg NaOH / g of Fat

UNIVERSIDAD AUTÓNOMA DE COAHUILA FACULTAD DE CIENCIAS QUÍMICAS 3

 Olive Oil 0.134
Coconut Oil 0.190
Almond Oil 0.136
Avocado Oil 0.133
Soy Oil 0.135
Corn Oil 0.136
Wheat Germ Oil 0.132
Bee Wax 0.069

3. Procedure

Saponification Reactor Glycerin solution

Coconut Oil Water with Borax and
Isopropanol at 80°C
sugar
Distilled Water
KOH
Liquid
Soap
Filter 1

Phase Separator
Neutralization
Pure Glycerin

Filter 2

3.1 Feeding the Reactor

The proportions in which the reactor is fed depends on the soap that is to be
manufactured. Initially the Coconut oil is poured into the reactor, then caustic potash
in isopropanol solution and finally distilled water to generate a dilution.
Thereafter, the reactor is brought to a temperature of approximately 80 ° C, where
saponification takes place. A soapy product is obtained from the reaction of an ester
with an inorganic base. As it is Coconut Oil, triglycerides of lauric acid are obtained
(this being the most abundant component of the aforementioned oil)

3.2 Two Phases Separation

After saponification, the reactor is brought to room temperature to continue with a
phase separation process, the first phase (soapy, the desired phase) and the
aqueous phase, which contains all the water of the reaction, the resulting glycerol
and all potassium hydroxide that has not reacted.

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By means of a decanting process, both phases are separated, the bleach phase
leaves the reactor by the bottom, while the soap phase remains in the reactor.

3.3 Neutralization
The glycerol formed by the saponification has value for the industry, to recover it a
neutralization is carried out, later a filtration and finally an evaporation, with these
steps a high quality glycerol is obtained and can be used for the next phase of the
production process of soap.

3.4 Mixture
The soapy product remaining in the reactor must be mixed with a regulator of acidity
(for example, borax or citric acid), pure glycerin (as in the one obtained from the
previous process) and water at high temperatures to favor mixing. More substances
can be added to the mixture, such as another humectant (propylene glycol), a
preservative (methylparaben), antioxidants (anhydrous sulphite), in addition to what
you want as a final product you choose fragrance, color, hydration level or
antibacterial (this last is not necessary).
To finish, a filtration is carried out, which aims to eliminate any solid remnants of the
final product. After this, it is stored and finally marketed.

4. Drivers
4.1 Diagrams

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UNIVERSIDAD AUTÓNOMA DE COAHUILA FACULTAD DE CIENCIAS QUÍMICAS 6
4.2 Symbology
YC Weight Controller
YE Weighing Element
LT Level Transmitter
LIC Level Indicator Controller
GT pH transmitter
GIC pH Indicator Controller
TT Temperature Transmitter
TIC Temperature Indicator Controller

4.3 Description
In the first diagram you can see three flows, which can be mixed in the pipes, but it
has been decided to separate them into three different flows with their respective
controllers to maintain the simplicity of the diagram. With controllers and weight
gauges, you can control the amount of substance needed for the reaction to take
place

Once the mixture is ready, weight controllers and gauges are again used to pass the
necessary amount of mixture to the reactor. While the reaction is taking place, a flow
of steam is used to heat the reactor, with transmitters and temperature controllers
looking to reach 80 ° C. It should be noted that this part of the process is of vital
importance, therefore, an all-nothing controller is not recommended.

After the reaction, two phases remain in the reactor, one soapy and the other
aqueous. The second mentioned is still of interest to the company, so we proceed
to neutralize it, with pH meters and controllers in the neutralizer and then a
separation process, it is looked to obtain pure glycerin, which will be used later in
the process.

Finally, with the help of weight controllers and gauges, water and a solution of
glycerin with boráx are poured into the reactor with the soapy mixture.
Once the desired level of mixing has been reached (and after having added specific
additives from the company), the product is taken to a filter in charge of separating
all the solids that may have formed.

Once this is done, the liquid soap is ready to be packaged and marketed.

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 5. Conclusions

Bibliography:

Catherine Failor. (2001). jabones líquidos / Making

Natural Liquid Soaps. Barcelona: Editorial Paidrotibo.

Benitez, J. Jiménez, I. Segura, J. (2009).

IMPLEMENTACIÓN DE UNA RED DE COMUNICACIÓN EN LOS EQUIPOS
DEL PROCESO DE SAPONIFICACIÓN DE JABÓN. México:
Instituto Politécnico Nacional.

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