DETERGENT POWDER & CAKE MANUFACTURING (FENA TYPE) (MIXING PROCESS)

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 basic 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 eg. Fena, Hipoline, T.Series, Areal, Surf, Sunlight, Nirma, Wheel detergent powders and cakes are most popular.

Soaps are the earliest form of detergents. Though at present the term detergent is used for synthetic detergents derived from petroleum products. The origin of soap making is unknown. The phoenicians were acquainted with it by at least 600 B.C. and it was known the gauls not later than about 300 B.C.

From the 1940’s on-ward, synthetic detergent have expanded rapidly all over the world. Their rapid development has been stimulated by the enormous and fast growth of the international petro-chemical industry. The transition from conventional hard soaps to synthetic detergent cake has been rapid and irreversible response by consumers. So that to-day, synthetic detergent accounts in most developed and under developing countries in the world. To improve detergency of the detergent cakes powders, certain  other  components were added to it  known as builders, synergers, fillers and brighteners etc.

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.

INTRODUCTION
PROPERTIES OF WASHING SOAP AND WASHING POWDER
USES AND APPLICATION
FEATURES OF DETERGENT POWDER FOR HARD WATER
B.I.S. SPECIFICATION
RAW MATERIAL REQUIREMENT
OVERVIEW OF DETERGENT INDUSTRY IN INDIA
TIDE
PRODUCT MARKET ANAYSIS
SWOT ANALYSIS
BCG MATRIX
MARKETING STRATEGY
MARKETING MIX
PROMOTION:
MARKET ANALYSIS
MARKET SURVEY
MARKET OVERVIEW
FIGURE 2: SUB-CATEGORY BY DETERGENT TYPE
DOMINANCE BY MNCS
FIGURE 3: MARKET SHARE BY MANUFACTURERS
FIGURE 4: MARKET SHARE BY BRAND
DEFINING THE RESEARCH PROBLEM
DEVELOPMENT OF PRODUCT CONCEPTS:
DATA ANALYSIS AND INFERENCE BUILDING
A) ASSESSMENT OF THE OPPORTUNITY FOR A NEW VARIANT
1) REASON FOR USING CURRENT BRAND / VARIANT:
TABLE 1 REASON FOR USING CURRENT BRAND
2) USE OF MULTIPLE MEDIUM FOR WASHING CLOTHES
TABLE 2 MEDIUM OF WASHING CLOTHS
TABLE 3 NO. OF MEDIUM USED FOR WASHING
3) USE OF MULTIPLE WASHING DETERGENT BRANDS
TABLE 4 DETERGENT BRANDS USED
TABLE 5 NO. OF DETERGENT BRANDS USED
B) CHECKING IMPORTANT ATTRIBUTES/BENEFITS
ON THE BASIS OF RANKS
TABLE 6 MEDIAN RANKS FOR FEATURES IN DETERGENT BRAND
ON THE BASIS OF RATINGS
TABLE 7 STATISTICS FOR EACH FEATURE OF DETERGENT BRAND
EXPORT DATA OF DETERGENT POWDER
EXPORT DATA OF DETERGENT CAKE
PRESENT MANUFACTURERS/SUPPLIERS/EXPORTERS OF
DETERGENT POWDERS
COMPARATIVE ANALYSIS AND TEST OF DETERGENTS
NO STOPPING AS OF NOW
BRANDS TESTED
KEY FINDINGS
TEST RESULTS FOR PHYSICOCHEMICAL PARAMETERS
FRAGRANCE
WHICH VARIANT TO USE AND WHERE?
PACKING AND MARKING
PLASTIC ALERT
MANUFACTURE OF DETERGENT POWDER
PROCESS – I
PROCESS – 2
1. FORMULATION : FOR 500 KG BATCH.
2. FORMULA : FOR 100 KG. BATCH.
THE FORMULATION USED FOR MANUFACTURING THE DETERGENT
POWDER IS GIVEN BELOW:
PROCESS OF MANUFACTURE
OF WASHING DETERGENT POWDER
SURF EXCEL TYPE DETERGENT POWDER
FORMULATION – 1
HIGHER GRADE/QUALITY ARIEL TYPE DETERGENT POWDER
(ENZYME BASED DETERGENTS)
FORMULATION – 1
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:-
PRECAUTION
THE GRINDING MACHINE
RAW MATERIALS
METHODS FOR PERFORMANCE TESTS FOR SURFACE ACTIVE AGENTS
PART-I RELATIVE DESPERSING POWDER
SURFACE ACTIVE AGENTS
OUTLINE OF METHOD
APPARTUS
PREPARATION OF SOLUTIONS
PROCEDURE
CALCULATION AND REPORTING
CALCULATION
WHERE
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
FORMULATION OF DETERGENT POWDER
FORMULATION OF DETERGENT CAKE (FENA TYPE)
FORMULATION OF DETERGENT POWDER (FENA TYPE)
TYPICAL FORMULATION OF DETERGENT POWDER AND BAR
MANUFACTURING PROCESS OF DETERGENT CAKE
PROCESSING DETAILS OF DETERGENT BAR & CAKES
CORRESPONDINGLY RAISED.
SURF EXCEL TYPE DETERGENT POWDER
FORMULATION – 1
PROCESS    113
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PLANT AND MACHINERIES
MACHINERY USED
SIGMA MIXER
BELT CONVEYOR
SIMPLEX PLODDER
ROTARY CUTTER

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