Detailed Project Report on washing powder, liquid detergents, lotion and shampoo
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WASHING POWDER, LIQUID DETERGENTS,LOTION AND SHAMPOO [CODE NO.3510]
Synthetic detergents occupy a vital place in the present age particularly when the modern society is constantly looking for quick, effective and economic cleaning agents. Synthetic detergents emerged as a regular industry after Second World War only. The development of this industry is closely linked with Petro-chemical industry which forms the basis for its raw materials.
Detergents when dissolved in water, acquire better cleaning properties and hence facilitates easy removal of dirt & dust and grease etc.
Apart from their use in clothes washing, detergents also have applications in the following industries.
1. In industry, in laundry and dry cleaning.
2. In textile processing, grain milling, metal plating and foods canning.
3. In dairy foods and beverages processing and in restaurants.
4. In plant maintenance and industrial house-keeping.
The principal types of synthetic detergents are an ionic, non-ionic and employtics. Sodium dodecyle benzene sulphonate is an example of the ionic type while nylon phenol, nylone oxide obtained from ethylene oxide is the non-ionic type. The amploytic detergents like the alkyl amino propionates behave as cations in acidic solutions and like anions in alkaline solution.
Among the numerous detergent powders are available today in the market e.g. Hipoline, T.Series, Areal, Rin, Ghari, Surf, Sunlight, Nirma, Wheel detergent powder is most popular.
The synthetic detergent industry is one of the largest chemical process industries. The most recent estimates indicate an annual U.S production of synthetic detergents of about 3 million tones with an approximate annual value of 2 billion. The industry differs from many other chemical process industries, however, in that the bulk of its production is sold directly to individuals for house hold consumption primarily as branded products, rather than to industrial or institutional users.
The detergent are highly popular replacing the soap because of their favourable characteristics. Almost all the detergent, despite their difference in origin and methods of manufacture, have two points in common. One part the long hydrocarbon chain that is oil soluble (linophilic) and the other portion, a water soluble (hydrophilic) group. The latter property may render the whole molecule so soluble in water as to impart some or all of the characteristics mentioned.
The oil soluble portion may be derived from a natural fat or from petroleuum, or aromatic hydrocarbon, such as benzene etc. with an alkyl side chain. The water soluble portion may be derived from material acids, alklylene oxides, polyhydric alcohols and polyamides.
The detergents are further divided into several classes e.g.
a. Anionic
b. Cationic
c. Non-ionic
d. Amphoteric.
Each type acts differently in aqueous solutions.
When detergent is mentioned, the cake, bar or powder usually comes to mind. For small manufacturers, the best advice on making liquid detergents is to purchase from primary producers an intermediate dodecyl benzene sulphonic acid (DDBSA) better known as acid slurry. They themselves,can neutrilize the doecyl compound in a variety of ways. They may use ammonia amines, soda or potash to yield liquid detergents.
COST ESTIMATION
Plant Capacity WASHING POWDER,LIQUID DETERGENT
Land & Building (6000 sq.mt) Rented
Plant & Machinery Rs. 2.30 Cr
Working Capital for 2 Months Rs. 6.84 Cr
Total Capital Investment Rs. 9.34 Cr
Rate of Return 42%
Break Even Point 41%
INTRODUCTION
GENERALLY, THERE ARE TWO TYPES OF LIQUID DETERGENTS.
PROPERTIES OF WASHING SOAP AND WASHING POWDER
USES AND APPLICATION
PROPERTIES OF SHAMPOO
USE AND APPLICATION OF SHAMPOO
B.I.S. SPECIFICATIONS
SKIN LOTION INGREDIENTS
MOISTURIZING INGREDIENTS
OTHER INGREDIENTS
MARKET SURVEY
CAPITALISING ON REGIONAL DEMAND
THE SOAPS AND DETERGENTS AND COSMETICS INDUSTRIES IN ZAMBIA
AND SOUTH AFRICA
THE COSMETICS MARKET IN SOUTH AFRICA AND ZAMBIA
MAPPING THE COSMETICS AND SOAPS AND DETERGENTS VALUE
CHAIN INDUSTRIES
SOURCING UPSTREAM INPUTS
FACTORS AFFECTING FIRM COMPETITIVENESS
SCALE
PACKAGING
STANDARDS AND REGULATIONS
GROWTH CONSTRAINTS
BARRIERS TO ACCESSING SUPERMARKETS AND EXPORT MARKETS
ZAMBIA
COMPETITION FROM IMPORTS
OTHER CONSTRAINTS
GROWTH OPPORTUNITIES
NATURAL AND ETHNIC PRODUCTS
CONTRACT MANUFACTURING
GETTING THE GOODS TO MARKETS
RIDING ON THE SPREAD OF SUPERMARKETS
TAPPING INTO ALTERNATIVE ROUTES TO MARKETS
SALONS AND SPAS
DIRECT MARKETING
HOTELS
CLEANING SERVICES
MANUFACTURERS/SUPPLIERS
MANUFACTURING PROCESS OF DETERGENT POWDER (SPRAY DRYING METHOD)
DETERGENT POWDER MANUFACTURE
STEP 1 - SLURRY MAKING
STEP 2 - SPRAY DRYING
STEP 3 - POST DOSING
TABLE 2 - THE INGREDIENTS OF DETERGENT BASE POWDER
ENVIRONMENTAL IMPLICATIONS
SYNTHETIC DETERGENT BIODEGRADABILITY
DETERGENT POWDER
ROLE OF THE LABORATORY
STANDARD DETERGENT POWDER MANUFACTURING PLANT CONSISTS
OF MIXING, DRYING AFTER DRYING PACKAGING AND ANTIPOLLUTION
UNITS.
MANUFACTURING OF DETERGENT POWDER
PROCESS - I
PROCESS - 2
PROCESS OF MANUFACTURE OF WASHING DETERGENT POWDER
SURF EXCEL TYPE DETERGENT POWDER
PROCESS OF MANUFACTURE OF WASHING DETERGENT POWDER
HIGHER GRADE/QUALITY DETERGENT POWDER
FORMULATION OF DETERGENT POWDER
FORMULATION OF DETERGENT POWDER, SURF EXCEL TYPE
FORMULATION OF DETERGENT POWDER, WHEEL TYPE
OTHERS FORMULATION AND PROCESS OF GOOD QUALITY DETERGENT POWDER
THE FOLLOWING FORMULATIONS ARE FOR MANUFACTURE OF DETERGENT POWDER:-
THE GRINDING MACHINE
RAW MATERIALS
METHODS FOR PERFORMANCE TESTS FOR SURFACE ACTIVE AGENTS
PART-I RELATIVE DESPERSING POWDER
SURFACE ACTIVE AGENTS
OUTLINE OF METHOD
APPARATUS
WHITE OIL-
PREPARATION OF SOLUTIONS
PROCEDURE
CALCULATION AND REPORTING
PART - II RELATIVE EMULSIFYING POWER
OUTLINE OF METHOD
REAGENTS
LIQUID PARAFFIN
APPARATUS
PREPARATION OF STOCK SOLUTION
PROCEDURE
CALCULATION AND REPORTING
PART - V WETTING POWER
OUTLINE OF THE METHOD
APPARATUS
PROCEDURE
FORMULATION OF DETERGENT POWDER
SURF EXCEL TYPE DETERGENT POWDER
FORMULATION OF LIQUID LAUNDRY DETERGENT
MANUFACTURING PROCESS OF LIQUID DETERGENT
MANUFACTURING PROCESS OF LIQUID DETERGENT IN DETAILS
FORMULATIONS FOR LIQUID DETERGENT FOR WOOL,
COLD WATER WOOL DETERGENTS
OTHER FORMULATIONS FOR LIQUID DETERGENTS
FORMULA 1:
FORMULA NO.2
FORMULA NO.3
MANUFACTURING PROCESS
FOR LIQUID DETERGENT FOR WOOL
PROCESS FLOW DIAGRAM
GENERAL PROCESS OF MANUFACTURE OF LIQUID DETERGENT
THUS THE BATCH REQUIRES:
DETAILS OF RAW MATERIALS FOR SHAMPOOS
1. OPACIFYING AGENTS
OPACITY OR PEARLESCENCE EFFECT IS PROVIDED BY:-
2. CARIFYING AGENTS
TRANSPARENCY EFFECT:-
3. FINISHING AGENTS
4. SEQUESTERING AGENTS
5. CONDITIONING AGENT
6. THICKENING AGENTS
7. FOAM BUILDERS
8. PRESERVATIVES
9. ANTIDANDRUFF COMPOUNDS
COLOURS:-
PRESERVATIVES:-
PERFUMES:-
WATER:-
VARIOUS FORMULATIONS
1. LIQUID SHAMPOOS:
FORMULA NO.1
FORMULATION NO.2
2. VEGETABLE OIL SHAMPOO
FORMULA OIL SHAMPOO
FORMULA NO. 2
3. EGG SHAMPOO:
ALMOND SHAMPOO
TONIC SHAMPOO
TRANSPARENT CLEAR LIQUID SHAMPOO:-
FORMULATION - 1
FORMULATION - 2
FORMULATION - 3
FORMULATIONS
1. SHAMPOOS:-
2. COCONUT OIL SHAMPOO:
3. TRIETHANOLAMINE SHAMPOO
MANUFACTURING PROCESS (SHAMPOO)
THE FORMULATION BEING DEALT WITH IS AS DESCRIBED BELOW:
PROCESS FLOW SHEET DIAGRAM (SHAMPOO)
MANUFACTURING PROCESS FOR COCONUT OIL SHAMPOO
1. COLD PROCESS
2. HOT PROCESS
ANALYSIS OF SHAMPOOS
GENERAL ANALYSIS:-
NET CONTENTS:-
DESCRIPTION OF SHAMPOO:-
PH OF SHAMPOO:-
ASH AT 600OC:-
EXAMINATION OF ASH:-
NON-VOLATILE MATTER AT 105OC:-
TEST FOR AMMONIA:-
TEST FOR BASIC NITROGEN COMPOUNDS INCLUDING AMMONIA:-
DETERMINATION OF WATER BY TOLUENE DISTILATION:-
ETHYLENEDIAMINETETRAACETIC ACID:-
LANOLIN AND/OR STEROLS:-
WATER-SOLUBLE GUMS:-
FORMULATIONS OF BODY LOTION
FORMULATION OF BODY LOATION
FORMULATION OF BODY LOATION
GENERAL STAPS FOR MANUFACTURE LOTION
MANUFACTURING LOTIONS AND CREAMS CAN BE COMPLETED IN TWO CYCLES:
A TYPICAL OIL-IN-WATER MANUFACTURING PROCESS MIGHT GO LIKE THIS:
THE PROCESS OF LOTION MAKING
THE PROBLEMS OF TRADITIONAL LOTION MIXER
THE SOLUTION OF LOTION MANUFACTURING
SUPPLIERS OF RAW MATERIALS IN AFRICA
SUPPLIER OF LINEAR ALKYL BENZENE SULFONATE IN AFRICA
SUPPLIER OF CARBOXY METHYL CELLULOSE IN AFRICA
SUPPLIERS OF RAW MATERIALS
LINEAR ALKYL BENZENE (LAB)
CARBOXY METHYL CELLULOSE (CMC)
SODIUM SILICATE
SODIUM SULPHATE
DETERGEN FRAGRANCES/PERFUMES
DETERGENT ENZYMES
SUPPLIERS OF DETERGENTS MACHINES IN AFRICA
SUPPLIERS OF PLANT AND MACHINERY
STORAGE VESSEL
PACKAGING MACHINE
INSTRUMENTATION AND PROCESS CONTROL EQUIPMENTS
MATERIAL HANDLING EQUIPMENTS
LABORATORY EQUIPMENTS
D.G. SETS
APPENDIX – A:
1. COST OF PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET
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