Detailed Project Report on soap noodle manufacture

SOAP NOODLE MANUFACTURE

[CODE NO.4325]  

Soap is an item of daily necessity as a cleaning agent. Soap production is one of the large chemical industry because it has a high demand in every part of the world. There are four basic raw materials involved in the manufacturing of soap and also there are three basic process methods that are used industrially; cold process, hot process and semi-boiled process. Soap production is mainly done in four steps, saponification, glycerin removal, soap purification and finishing.

Soap noodles are the fatty acids derived either from vegetable oil or animal fats used as the main ingredient in the production of soap bars. It is produced from the saponification of neutral fats and oil, neutralization of fatty acid and saponification of methyl esters.

There are two main types of soap noodle, i.e:

1. Made out of palm base or vegetable oil base

2. Another made from animal fats or tallow.

Due to its versatile properties, soap noodle offered by Sree Murni Global (M) Sdn Bhd able to meet the various needs of clients in the cosmetic, toiletry and laundry soap / detergent manufacturing or industries. We are able to supply according to your needs.

A typical blend of noodles would be:

• Comprising an 80% mix of palm oil and palm stearin, and 20% palm kernel oil known as 80/20, usually classified as standard 

• Other blends in the market are mix composition of 90/10, 70/30 and 60/40.

Total Fatty Matters or TFM is a measure of fat content from various oil blends, moisture and glycerin contents are important features in distinguishing grades of soap noodles.

Soap Noodle commonly varies based:

1. Colour – White, creamy, yellowish, brownish and swing.

2. Solid – usually snow white

3. and translucent

TYPES OF SOAP NOODLES

i. Translucent Laundry Soap Noodles

One of uniquely formulated and highly demanded type of noodles used in the production of laundry soap bars. Our noodle was made with the composition of palm fatty acid distillates (PFAD) and palm kernel fatty acids Distillates (PKFAD) with Total Fatty Matters within 68-70%. 

ii. Laundry Soap Noodles

As many third world countries still prefers washing their cloth by hand. Our laundry soap noodle assist many industries in this markets to formulate cost effective laundry soap bars. Our Laundry Soap has the composition of 90/10 (PFAD/PKFAD) and also made from 100% PFAD.

iii. White Soap Noodles or toilet soap noodle used my cosmetics or toilet soap manufacturers worldwide. We able to supply

1. 80/20 noodles with TFM 78-81 % min. The noodles is a blend of palm oil/palm stearin and palm kernel oil

2. 90/10 noodles suitable to manufacture multipurpose soap has Total Fatty Matters of 72% min.

COST ESTIMATION

Plant Capacity                                     50 Ton./Day

Land & Building (5000 sq.mt.)  Rs. 2.88 Cr

Plant & Machinery                             Rs. 3.40 Cr

Working Capital for 1 Month          Rs. 6.34 Cr

Total Capital Investment                 Rs. 12.86 Cr

Rate of Return                                    44%

Break Even Point                              40%

• INTRODUCTION
• THERE ARE TWO MAIN TYPES OF SOAP NOODLE, I.E:
• A TYPICAL BLEND OF NOODLES WOULD BE:
• SOAP NOODLE COMMONLY VARIES BASED:
• TYPES OF SOAP NOODLES
• I. TRANSLUCENT LAUNDRY SOAP NOODLES
• II. LAUNDRY SOAP NOODLES
• SPECIFICATION OF SOAP NOODLES
• SOAP NOODLES 90:10 [SNOW WHITE 90:10]
• SPECIFICATION
• SPECIFICATION
• USES AND APPLICATION
• CHEMICAL FORMULA: C3H8O3
• ADVANTAGE OF PALM OIL BASE SOAP NOODLE
• MARKET OVERVIEW OF SOAP NOODLES
• INDIAN SOAP MARKET
• BY TYPE, THE MARKET IS DIVIDED INTO:
• ON THE BASIS OF FORM, THE MARKET CAN BE SEGMENTED INTO:
• BASED ON PRODUCT, THE INDUSTRY CAN BE SEGREGATED INTO:
• ON THE BASIS OF DISTRIBUTION CHANNEL, THE MARKET CAN BE DISTRIBUTED INTO:
• MANUFACTURING PROCESS OF SOAP NOODLES
• PROCESS FLOW DIAGRAM FOR SOAP NOODLE
• RAW MATERIALS FOR SOAP PRODUCTION
• OILS AND FATS
• IODINE NUMBER
• SAPONIFICATION VALUE
• TABLE 1: IODINE NUMBERS, SAPONIFICATION VALUES INS FACTOR OF SOME FATS IN SOAP MAKING IN TROPICAL AREAS
• SODA LYE OR POTASH LYE
• CAUSTIC SODA | SODA LYE (NAOH)
• CAUSTIC POTASH | POTASH LYE (KOH)
• BRINE
• ADDITIVES
• SOAP MAKING PROCESS
• THE PRETREATMENT OF OILS AND FATS
• BLEACHING
• REFINING
• DEODORIZATION
• SAPONIFICATION IN SOAP MANUFACTURING
• FIGURE: REACTION CHAMBER OF SAPONIFICATION
• SAPONIFICATION: COLD PROCESS
• SAPONIFICATION: SEMI-BOILED PROCESS
• SAPONIFICATION: FULL BOILED PROCESS / HOT PROCESS
• GLYCERIN RECOVERY IN SOAP PRODUCTION
• SOAP PURIFICATION
• FINISHING
• CLASSIFICATION OF INDUSTRIAL PROCESSES
• INDUSTRIAL PROCESSES CAN ACTUALLY BE CLASSIFIED BASED ON THE PROCESS' OUTPUT
• LET?S CONSIDER THESE TWO PROCESSES.
• CONTINUOUS PROCESS
• BATCH PROCESS
• FIGURE: COLD SEMI BOILED, FULLY BOILED PROCESSES OF SOAPPRODUCTION
• PRINCIPLES OF PLANT LAYOUT
• STORAGE LAYOUT:
• EQUIPMENT LAYOUT:
• SAFETY:
• PLANT EXPANSION:
• FLOOR SPACE:
• UTILITIES SERVICING:
• BUILDING:
• MATERIAL-HANDLING EQUIPMENT:
• RAILROADS AND ROADS:
• MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
• PLANT LOCATION FACTORS
• PRIMARY FACTORS
• 1. RAW-MATERIAL SUPPLY:
• 2. MARKETS:
• 3. POWER AND FUEL SUPPLY:
• 4. WATER SUPPLY:
• 5. CLIMATE:
• SPECIFIC FACTORS
• 6. TRANSPORTATION:
• A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
• 7. WASTE DISPOSAL:
• 8. LABOR:
• 9. REGULATORY LAWS:
• 10. TAXES:
• 11. SITE CHARACTERISTICS:
• 12. COMMUNITY FACTORS:
• 13. VULNERABILITY TO WARTIME ATTACK:
• 14. FLOOD AND FIRE CONTROL:
• EXPLANATION OF TERMS USED IN THE PROJECT REPORT
• 1. DEPRECIATION:
• 2. FIXED ASSETS:
• 3. WORKING CAPITAL:
• 4. BREAK-EVEN POINT:
• 5. OTHER FIXED EXPENSES:
• 6. MARGIN MONEY:
• 7. TOTAL LOAD:
• 8. LAND AREA/MAN POWER RATIO:
• PROJECT IMPLEMENTATION SCHEDULES
• INTRODUCTION
• PROJECT HANDLING
• PROJECT SCHEDULING
• PROJECT CONSTRUCTION SCHEDULE
• TIME SCHEDULE
• ADDRESSES OF RAW MATERIAL SUPPLIERS
• ADDRESSES OF PLANT AND MACHINERY SUPPLIERS
• TURNKEY SUPPLIERS FOR SOAP NOODLE PLANT

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)