SOAP MAKING MODULE Soap is a salt formed from the reaction of fatty acids from oils/fats and base
the reaction of fatty acids from oils/fats and base substance such as
sodium hydroxide and Potassium Hydroxide. In bar soap making sodium hydroxide is used as
the base substance. A base is a substance that can neutralize an acid. An acid is a substance
that has a sour taste and neutralizes base substances.
Preface
Important reactions in soap making are
Soap products are basic requirements of every human being, hence the demand of such
products. This book is prepared for those who would want to venture into soap production in Base + acid Salt + Water. This reaction is called neutralization.
Zimbabwe. The major challenge in manufacturing soap products in Zimbabwe is mainly
associated with high costs of raw materials and operating costs. With these factors in mind the Fatty Acids + Sodium Hydroxide Sodium Soap + Glycerin + Water. This reaction is
author of this manual has come up with a cost effective way of producing bar soap. called Saponification reaction and is the most important reaction in soap making.
It is the hope of the author that this manual will be used to its best use so as to better develop The mixture of sodium hydroxide and water gives us what is called the lye solution. The
our communities and to industrialize the economy of Zimbabwe. reaction is exothermic meaning that it gives out heat. That same reaction gives out fumes which
are toxic. Sodium Hydroxide is a corrosive substance which reacts with the skin thereby
Munashe Maguranyanga damaging it.
INTRODUCTION SAFETY PRECAUTIONS
The art of making soap has been practiced for decades now. The ability of soap to increase the 1. You should wear:
i. Plastic or Rubber Gloves
washing properties of water has made it a necessity to the livelihoods of people. It plays a
ii. long sleeved clothes / work suites
major role in the health and environmental sector of all countries worldwide. iii. Safety Glasses
iv. Face mask
Soap making forms a suitable basis for a sustainable social enterprise. People can create a
sustainable social enterprise. People can create a sustainable business from this on either a 2. The working area should be well ventilated.
small or large scale. About 70% of the soap products used in Zimbabwe come from neighboring 3. Do not use aluminum or glass utensils.
countries and abroad. Soap making formulates an exciting business opportunity in Zimbabwe. 4. Do not eat when making detergents or soap.
5. Avoid naked flames in the working space.
6. Do not pour water into chemicals but the reverse.
BASIC BAR SOAP CHEMISTRY
FIRST AID
Soap is a surfactant or surface active agent meaning that it reduces the surface tension of water
causing it to easily wet surfaces. Molecules of water are held together by Van der Waal forces. Examples of accidents that may occur when making soap or detergents and what you can do when they
happen.
Soap breaks these bonds causing water to easily penetrate through surfaces. For example, if
you dip a shirt in water and remove it you will notice that some areas will not be wet but if you 1. When a chemical accidentally goes on to your skin, you should wash the affected area with
dip it in soapy water you will notice that it will be wet all over or if you drop a drop of water on running water.
a glass surface you will see that it will hold an oval shape but if you drop soapy water it will 2. In the case of a chemical accidentally getting into your eyes, you should flush the affected eye
with running water and immediately seek for medical attention.
spread on the surface.
3. If you swallow a chemical by accident, you should drink a lot of water.
SOAP MAKING RAW MATERIALS AND EQUIPMENT Steps for calculating soap ingredients
Equipment Required in Soap making 1. To determine the quantity of sodium hydroxide required one has to multiply the
quantity of oils/fats being used with the saponification value of the oil/fat.
Stainless Steel Containers or plastic buckets.
2. To determine the quantity of water to be used in the formulation, one multiplies
Measuring Scale 0.38 by the quantity of fats/oils being used.
Thermometer 3. To determine the quantity of builders and fillers to be used, one has to add all the
Stirring sticks or paddles known quantities of ingredients and calculate 10% of the total value of ingredients.
Several spoons The answer gives out the quantity of builders and fillers to be used.
Molds
Calculator
SAP value Chart SOAP MAKING PROCEDURES
The first thing you do before you start to make soap is to calculate the quantity of your
Raw materials ingredients. Before you start making soap you should wear protective clothing.
Sodium Hydroxide Step 1
Dolomite Measure carefully with your scale the quantity of sodium hydroxide and that of water that
Water you are going to use. Mix the two ingredients observing the safety precaution of mixing the
Color two substances. The solution is called lye solution. Place the lye solution in a water bath to
Perfume cool it down.
Oils / Fats
Step 2
Builders are substances that increase the washing power of soap such as sodium silicate.
Fillers are substances which add the weight of soap such as sodium carbonate. Additives are Mix your oils with the lye solution until you reach a stage called trace. Trace is the point
substances that enhance the appearance of soap. They are many other ingredients which where the oils or fats have successfully mixed with your lye solution. To be specific this is
can be used as builders, fillers and additives. These are added with experience as well on the point where your oils and lye solution turn to soap. To see if you have reached this
the type of soap that you wish to produce. stage, your soap becomes thick similar to thick milk. If you drizzle some of the soap on the
surface of the mixture, it leaves behind a trail that takes a while to sink back in the mixture.
Step 3
Recipe Formulation
After your mixture reaches the trace stage you now add your builders first while mixing.
To determine the quantity of all the ingredients that one uses in bar soap making, one When the mixture is smooth you add your fillers until the mixture is fine. Lastly add your
should be aware of the quantity of oils/fats he or she is using. additives.
Also importantly to note is the saponification value of the oil/fat to be used.
Step 4
Saponification value is that which helps one to determine the quantity of Sodium
Hydroxide required to combine with oils/fats to produce soap. Pour your soap in your molds. Cover the top of your molds with a plastic. Leave the soap for
Saponification values of oils and fats are found on the saponification value chart located 24hrs to set in the molds then remove the soap from the molds.
at the back of the module.
DISHWASHING LIQUID 3) Slowly add Sodium Chloride whilst stirring until you reach the desired
viscosity (thickness).
Makes 18 Liters 4) Add Glycerin and continue to mix.
5) Add fragrance while mixing.
6) Dissolve dye in water and add it slowly to your mixture until you reach
SLES 1 Kg the desired color.
Sulphonic Acid 1 Kg
Sodium Chloride (Salt) 250g
Water 15 Kg Toilet Cleaner
Dye q.s.
Fragrance q.s. Makes 18 Liters
q.s. – Quantity sufficient
Mix with one direction to avoid excess foam. SLES 1 Kg
Sulphonic Acid 500g
1) Charge the vessel with water and add SLES. Mix until the Sles Pine oil 100g
dissolves. Water 15 Kg
2) Add Sulphonic Acid and continue to stir Dye q.s
3) Slowly add sodium chloride whilst mixing. Mix until your product
is thick. q.s. – Quantity sufficient
4) Dissolve dye in water and add it slowly to your mixture until you Mix with one direction to avoid excess foam.
reach the desired color.
5) Add perfume and continue to stir. 1) Charge the vessel with water and add SLES. Start to mix until it
dissolves.
2) Add sulphonic acid and mix until your mixture is uniform.
FOAM BATH 3) Add sodium chloride slowly and mix until you reach the desired
viscosity (thickness) (Do not add more that the recommended quantity
Makes 15 Liters because your product might get thinner and discolor.)
4) Add pine oil and continue to stir.
q.s. – Quantity sufficient 5) Add dye dissolved in water and mix until you reach the desired color.
Mix with one direction to avoid excess foam.
DRAIN CLEANER
SLES 1 Kg
CDEA 500g Makes 50kg
Water 12 Kg
Glycerin 500g
Sodium Chloride 300g Sodium Hydroxide flakes 93%
Fragrance q.s Sodium Metasilicate 1.0%
Dye q.s Aluminium filings 6.0%
1) Dissolve SLES in water.
2) Add CDEA and continue to mix. 1) Sprinkle 46.5kg Caustic in a suitably sized container
2) Over the flakes, sprinkle 500 g Sod. Metasilicate.
3) Then sprinkle 3 kg of Aluminium filings (fine) over
4) Mix well. HIGH FOAM WASHING POWDER
Makes 2 kg
ENGINE CLEANER
Sodium Metasilicate 250 g
Makes 10 L Soda Ash Light 1 Kg
Sulphonic Acid 250 g
STPP 250 g
Parrafin 10 Kg Perfume Quantity Sufficient
NP 6 500g Sodium Sulphate 300g
Dye Quantity Sufficient
1) Mix all ingredients together until a uniform powder is obtained.
1) Mix paraffin with NP 6 until your mixture is uniform. 2) Make sure to start with the Soda Ash then Sulphonic Acid.
2) Add dye in powder foam. 3) Lastly sieve the powder to break all lumps in the mixture.
Make sure they is no water in your mixing vessel.
PINE DISINFECTANT GEL
PETROLEUM JELLY Makes 20 kgs
Makes 1 Kg Water 15 Kg
Caustic flakes 100 g
NP 9 500 g
Sulphonic Acid 2 kg
PJ 1 Kg Dye Quantity Sufficient
White Oil 100g Pine Oil 1 Kg
Dye q.s.
Perfume q.s.
1) Add caustic to water whilst stirring
q.s. – Quantity sufficient 2) Add Sulphonic and stir until completely dissolved
3) Add NP 9 and continue to stir.
1) Heat PJ until it dissolves.(not until it boils) 4) Add Pine Oil slowly with continuous stirring. Product will start
2) Add white oil whilst stirring. thickening on addition of pine oil.
3) Add dye in powder form if desired, whilst mixing. 5) Add dye diluted in Water.
4) Add perfume while you mixture is still on a heat source.
5) Remove from the heat source and pour in containers. Leave to cool
before closing the containers.
SANITISER
Makes 100lt
BAC 50 10.0%
NP 9 5.00%
Water Balance
1) Charge water into mixing vessel and start stirring
2) Mix the BAC 50 and the NP 9 in separately, mixing thoroughly after
each addition.