DAYANANDA SAGAR COLLEGE OF ENGINEERINGDEPARTMENT OF CHEMICAL ENGINEERING

l l l Internship at :-l Karnataka Soap and Detergent Limitedl Rajajinagar , Bangalore-55

Presented by :- Piyush Kumar 1DS12CH026

8th

March 2016

Contents 1. Introduction (company profile) 2. Product profile 3. Production process 4. Quality aspects 5. Effluent Treatment plant 6.Conclusion & Outcomes 7. References.

Introduction 1.Established in year 1918.

2.Key people :- -- Maharaja of Mysore, His Highness Nalwadi Krishna Raja Wadeyar. -- Sri S G. Shashtry

3.Year 1944 another sandalwood oil

factory was setup in Shimoga.

4.Year 1980 government merged these factories as Karnataka Soaps & Detergents Limited.

5.Today, the company produces a variety of products.

Product Profile

Products manufactured at KSDL are :-

• Mysore sandal soap• Detergents• Agarbathis • Sandalwood oil• Talc• Body wash• Hand wash• Face wash. • Room freshener

Intro to Soap1. Soaps are sodium or potassium salts of long chain fatty acids.2. The elementary chemical structure of soap can be represented by the general formula RCOOM

Cleaning Action of Soap -- lowering the surface tension -- emulsifying grease -- absorbing dirt into the foam -- Each soap molecule has a long non- polar hydrocarbon chain “tail”(hydrophobic) -- And a hydrophilic head.

Production of Soap :-Raw materials required • Fatty acids• Alkali • Common Salt• Perfumes• Additives

Saturated – Lauric,Palmitic,Stearic , etc.

Unsaturated- Oleic,Linoleic ,etc.

NaOH, KOH

Process Description:-The entire soap manufacturing process consists of following sequence of operations:1. Blending of fatty acids2. Neutralization of fatty acids in kettle boiler section.3. Drying of neat soap in soap drying plant4. Finishing of soap in finishing lines.

Flowchart of manufacturing practice followed at KSDL :-

• The kettle process is the oldest process known for the manufacturing of soap this process is still used today by soap manufacturing companies for production .

• This process is carried out in a steel tank or kettle from which it gets the name. The various steps involved in this process are:-1. Boiling2. Saponification reaction.3. Salting4. Strong Change5. Pitching

Kettle Boiling method:-

Tests to find the composition of soaps:-• 1. Determination of volatile matter and moisture content.• 2. Determination of total fatty matter content (TFM).• 3. Titre• 4. Determination of free caustic alkali content.• 5. Determination of Chloride content .• 6 .Determination of free fatty acid content.Parameter for chemical analysis of fatty acids:-• 1. Saponification value.• 2. Iodine value.• 3. Acid value

Quality assurance:-

Effluent treatment plant

Characteristics of untreated water stream:-1.pH value: 6-102.suspended solids:200-350 mg/l3.BOD: 250-400 ppm4.COD:600-800 ppm5.Flow: 300-400 meter cube /day

Method used :-• Pre-Treatment

• Secondary Treatment• Sludge Treatment & Disposal

Characteristics of treated Effluent:-1.pH value: 6-8.5

2.Suspended solids: 80-100 mg/l

3.BOD: 20-30 ppm

4.COD:150-250 ppm

5.Colour and Odour ; Clear,no odour

ScreeningEqualizerNeutralization

Aeration TanksClarifier

Drying Beds

• 1. I am able to learn the process of soap manufacturing at KSDL.• 2. Varieties of quality assurance tests used for soap were clearly • understood.• 3. I am able to learn the process of wastewater treatment at KSDL.• 4. Working in a team.

• 5. Various maintenance operations.

Internship Outcomes:-

References:-

1. Viorica, P., Alina, S. and Simona, D. (2011) Quality Control and Evaluation of Certain Properties for Soap Made in Romania. Journal of Scientific Study and Research, Chemistry and Chemical Engineering, Biotechnology, Food Industry,12

2. Ogunsuyi, O. and Akinnawo, C. (2012) Quality Assessment of Soaps Produced from Palm Bunch Ash-Derived Alkali And Coconut Oil. Journal of Applied Science and Environmental Management, 16, 363-366.

3 Right To Information. (2007) Bureau Of Indian Standards, IS : 286 – 1978. 4. Consumer Voice Report . (2014), 14-20

5. Hui, H.Y. (1996) Bailey’s Industrial Oil and Fat Products, John Wiley and Sons Inc,