What is industrial
production?
This
is a process whereby chemicals and other related substances, water inclusive,
which is a natural substance in other to create a finished product
. These also involves the production of equipments such as rubber, iron etc.
In
the cause of our discussion, we will be using chemicals and other substances to
produce finished consumable goods.
There
are a lot of Industrial consumables, but for the purpose this blog, we will be
limiting ourselves to:
1. Bleach
production
2. Soap
production
3. Cosmetics
production
PRODUCTION OF BLEACH
.Bleach
is a product, produced by the combination of certain chemicals. When such
chemicals are combined together in water, it is allowed for a period not less
than 42 hours before it can be used for washing
WHAT ARE THE USES OF BLEACH
Bleach
could be used for washing of cloths,
It
could also be used for washing of toilet bowls
Bleach
is used for cleaning of chairs and tiles.
It
equally prevent germs
When producing bleach, the quality control can be
determined using clothing material (colored), this called fiber testing.
CHEMICALS
NEEDED FOR BLEACH PRODUTION
1. Sodium
Hydroxide: this could also be called caustic soda. It serves as bleaching
agent, stain remover.
2. Chlorine:
this is a bleaching agent that helps to fades color in any production process
3. Sodium
carbonate/ soda ash: this is used to breakdown chlorine for its effect to be
felt in the course production.
DETERGENT PRODUCTION
Detergent
is a surfactant. In other words a surface active agent. It has the ability to
act on surface whereby leaving the surface clean and neat.
FORMS OF DERTERGENT
Detergent
exists in two different forms namely;
(1) Powdered
detergent
(2) Liquid
detergent
USES OF DETERGENT
Detergents
are used for various purposes. These include
(1) Washing of clothes
(2) Scrubbing of the floor
(3) Washing of hospital equipment
(4) Washing of factory equipment etc.
Detergent
could also be used as car wash. However I recommend the liquid detergent for washing
of the car because it contains little or no sodium hydroxide which is has the
ability to remove color from the surface.
PRODUCTION EQUIPMENT
Production
equipments consist of the following:
i.
Mixer: The mixer is
made up of a bowl and stirrer which can be manually or electrically powered.
This actually depends on the financial capability of the producer.
ii.
Drier: This is used to
dry the product. Drier again could also be electrically or manually powered.
Manual drying entails spreading the product under the sun so it can dry through
the heat of the sun. This however can take some time and it can delay business
especially in rainy seasons.
iii.
Hydrometer: This is used
to determine the water density in caustic soda.
iv.
Face Mask: This is used
for protection of the nose and mouth from direct inhaling of chemicals
v.
Lab Coat: This should
be made with nylon material because such material withstands the penetration of
chemicals.
vi.
Hand Gloves: This is used
For the protection of hands, this should also be made with nylon material
vii.
Plastic Bowl: For
storing of water
viii.
Weighing Balance: This
is for weighing chemicals to ascertain the quantity to be used at each point in
time.
CHEMICALS AND INGREDIENTS
1. SODIUM HYDROXIDE (CAUSTIC SODA):
Sodium Hydroxide otherwise known as caustic soda, it’s a powerful base. This
chemical must be soaked in water for a period not less than 24hrs before use in
production.
This process is simply known as
fermentation of caustic soda. Once the caustic soda is fermenting, the
temperature rises up to 1000c and later falls to between 0o
c-300c.when it is at low degree, it will then allow for accurate measurement
of water density in the chemical, using the Hydrometer.
Note: If caustic soda is hot as you pour
water into it, the temperature has risen and if you measure it at that point in
time, the degree of the water density will fluctuate, and this can negatively
affect your entire production.
2. SODIUM CHLORIDE: This substance is
popularly known as industrial salt. Sodium chloride helps to control the
harshness of the caustic soda. The absence of caustic sodium chloride in the
product can cause peeling of skin after using the product.
3. SODIUM CARBONATE: This is also known
as Soda Ash. Sodium carbonate is filler, it is there to fill the gaps and make
the detergent more compact. It helps the detergent to come out in grains and
also increase the quantity of the detergent.
4. FATTY ACID: Fatty acid can be
obtained from palm kernel oil (PKO), olive oil, vegetable oil etc. It is rich
in glycerol from where we derive glycerin, which is very nourishing on the
skin.
5. SULPHURNIC ACID: This is a foam or
lather booster. It helps the detergent to foam well thereby making the product
very active. Lather or foam in detergent suspends dirt and does not allow it to
get back to the cloth.
6. SULPHURIC ACID: It helps the
detergent to dry faster and come out in powdered form. It does not allow it to
form lumps.
7. AROMATIC AGENT: This is industrial
perfume used for giving the product the desired fragrance.
8. BLEACHING AGENT: Bleaching agent can
be obtained from chlorine or hydrochloric acid. This also helps to make the
product more active in removal of dirt.
9. WATER: This is for fermenting the
caustic soda and dissolving of the ingredients that comes in powdered form.
10. HYDROGEN PEROXIDE: This is for
oxidation and is the last thing to be added during detergent production.
DETERGENT PRODUCTION PROCESS
1. The
first thing is to determine the volume of your production.
2. Carry
out the measurement of the chemicals and ingredients that will give the
quantity of the volume.
3. Ensure
that your caustic soda is well fermented for at least a period of 24hrs.
4. Make
sure that the water density does not go beyond 12.75, 12.80 or 12.90, but note
that when the water density is too low, the product will be too harsh, though
the drying process will be faster.
5. Pour
the fermented sodium hydroxide into a bowl.
6. Pour
in soda Ash together with the industrial salt.
7. Pour
in your fatty acid.
8. Add
sulphurnic acid.
9. Add
color: Note that if the color is oil soluble, you mix it with a little fatty
acid before pouring it in.
10.
Next is aromatic agent.
11.
Finally you gradually
introduce the hydrogen peroxide.
Note: Each chemical or ingredient you
add, you are to stir well the entire product for at least three minutes before
adding another. This is to allow each chemical to blend to achieve proper
reaction.
This whole process of soap of detergent
production is known as saponification.
When you are done, you pour out and
spread the product for drying.
MEASUREMENT TABLE
Caustic
soda is to be our base determinant.
Caustic soda - 1KG
Water - 280cl
Soda Ash - 3kg
Salt - 3 table spoons
Sulphurnic Acid - 35cl
Sulphuric Acid - 5cl
Bleaching agent - 10cl
(optional)
Aromatic agent - to
taste
Colour - to taste
If chlorine is to be used - 10gm
Fatty acid - 490cl (minimum)
Hydrogen peroxide - 70 cl (must not be finished)
Note: For detergent to
be considered good, it must have good aroma and foams very well.
POST PRODUCTION
ACTIVITIES
·
After production of
detergent then move it to drier to be dried
·
Next you grind. This
can be done manually or with electric machine
After grinding, next is
to sieve it with sieve. This makes for even size of the grain,
final stage is to
measure and package for sale.