HAWASSA TEGEBARED POLY

TECHNIC COLLEGE

Design and Manufacture Solid Soap/Ajax

Making Machine Proposal
Group members
1. Mintesnot Demissie
2. Abebe Botala
3. Abera Jinka
4. Gacheno Gezhagn
5. Girma Kelemework
Hawassa Sidama
2016 E.C
 Table of Contents
Chapter one......................................................................................................................................3

1. Introduction..............................................................................................................................3

1.1. Background.......................................................................................................................3

1.2. Statement of the problem..................................................................................................4

1.3. Objectives..........................................................................................................................5

1.3.1. General objective.......................................................................................................5

1.3.2. Specific objectives.....................................................................................................5

Chapter two......................................................................................................................................6

2. Literature review......................................................................................................................6

Chapter three....................................................................................................................................8

3. Methodology............................................................................................................................8

3.1. Raw material for the project..............................................................................................8

Chapter four.....................................................................................................................................9

4. Work plan and cost estimation.................................................................................................9

4.1. Work plan..........................................................................................................................9

 Chapter one

1. Introduction
1.1. Background
Soap is a cleaning agent made of a combination of fats, a base and water. It comes in different
varieties such as bars, liquid, and powders (e.g., detergents). Other ingredients can be added to
soap to give it different qualities. In some places, soap is unavailable or expensive. This
Technical Brief gives some practical guidelines on a cheap, easy way to make soap on a small
scale, using ingredients which are available locally. Making soap involves a chemical
decomposition of fats and oils into their constituent parts, namely: fatty acids and glycerol. The
fatty acids combine with an alkali, usually caustic soda, and the glycerol remains free. In the
‘cold’ process, which will be described in this Technical Brief, oil is treated with a definite
amount of alkali. Soaps are produced in different shapes, sizes, colors and qualities/grades
depending on their specific uses and manufacturer.

However, soaps produced by different manufacturers may have identical shapes and sizes
especially when the shape is not part of the manufacturers trade mark. Hence, it is always
difficult to differentiate soaps of the same features produced by different manufacturers. Soaps
are cleaning agents that are usually made by reacting alkali (e.g., sodium hydroxide) with
naturally occurring fat or fatty acids. A soap is a salt of a compound known as a fatty acid. A
soap molecule consists of a long hydrocarbon chain (composed of carbons and hydrogen’s) with
a carboxylic acid group on one end which is ionic bonded to a metalion, usually a sodium or
potassium. The hydrocarbon end is nonpolar and is soluble in nonpolar substances (such as fats
and oils), and the ionic end (the salt of a carboxylic acid) is soluble in water. Good soap must
achieve a balance between oil and caustic. If it is too oily it will be soft and melt fast. The soap
will take a long time to dry and will not make a good foam. If it is too caustic it will be harsh and
dry or burn your skin. It will wear out your clothes fast can cause a rash. The secret of good soap
making is to achieve the balance you want in your soap.
 Fig 1.1. Ajax making machine

1.2. Statement of the problem

Ethiopia is most populated country in the world as well as in Africa content. Soap is important in
preventing the spread of disease by helping people keep themselves, their clothes and their
surroundings clean. The major factor that has augmented this market is the increase in per capita
income. As the income of residents throughout India and the rest of the world rises, so does the
demand for soap. As expendable incomes rise, people are more able to afford soap products,
particularly specialty soaps that are intended to provide different results. Another problem that is
boosting the size of the soap market in Ethiopia is the growing awareness of the importance of
personal hygiene. Soaps are used to cleanse the skin, thereby removing the buildup of dead skin
cells, bacteria and other elements that could have negative effects on personal hygiene, as well as
personal health. As more people are becoming aware of the value of good personal hygiene,
there is a higher demand for soap products.
 1.3. Objectives
1.3.1. General objective
The general objective is to design and manufacture solid sop/Ajax machine for mass production
of soap around Hawassa.

1.3.2. Specific objectives

The specific objective of this project/Ajax making machine used to produce ajax soap for
cleaning material and self hygine.

 Increase productivity of SME.

 Speed up the production process of Ajax.
 The machine also helps in the reduction of labor and time required to produce soap
products.
 Chapter two

2. Literature review
Soap has been available for a long time. A soap recipe carved into a tablet from Ancient Babylon
shows that soap has been available since 2200 BC. There is also evidence that the Egyptians
used a soap-like substance made of animal and vegetable fats mixed with alkaline salts. Ancient
Rome used pomade for their hair that was similar to soap, and Ancient China also has evidence
of the use of a soap-like product. Islamic documents from the 12thcentury describe the process of
making soap and by the 13th century, soap making had become industrialized in the Islamic
world, with production centers in Nablus, Fes, Damascus and Aleppo (Soap History, 2014).
Today soap is widely used. We now understand its role in proper hygiene. Hand washing with
soap significantly reduces the number of pathogens on hands compared to washing with water
alone. Soap helps to break down the grease and dirt that carry the largest concentration of
pathogens. In the late 18thcentury, industrially manufactured soap was paired with campaigns in
Europe and the United States that taught the relationship between soap and health. With this
knowledge and promotion, soap has become a household item in many countries.

Qualities of Soap

When creating soap recipes, ingredients can be adjusted in order to control the qualities of the
soap produced. There are seven qualities of soap.

Hardness: The hardness value describes how hard the soap is. Different fats create soaps with
different hardness values. The higher the hardness value, the harder the soap will be.

Cleansing: The cleansing value describes well the soap grabs onto oils and, therefore, how well it
cleans. However, a soap that has too high of a cleansing value may grab both the dirty surface
level oils and deeper, protective oils in your skin. This will have a drying effect on your skin.

Condition: The condition value describes the soap’s emollient content. Emollients—or
moisturizers—stay on the skin to help the skin retain moisture. Emollients make skin feel soft
and soothe the skin.

Bubbly: The bubbly value describes how much lather or bubbles the soap will create. Higher
values produce foamy, fluffy lather while lower numbers will produce a creamy lather with
fewer bubbles.
Creamy: The creamy value is almost the reverse of the bubbly value. As the creamy value
increases, the creamier the lather of the soap will be. The lower the value, the more foamy lather
the soap will create. Soap made with olive oil creates creamy soaps that have no bubbles.

Iodine: The iodine value is another indicator of the hardness of a bar of soap. The lower the
iodine value, the harder the soap will be.
 Chapter three

3. Methodology
3.1. Raw material for the project
Raw materials are material used in the primary production or manufacturing of goods. Raw
materials are the input goods or inventory that a company needs to manufacture its product.

No Raw material Specification Qty.

1. Round tube/Black Internal Dia. 16.5cm*length 50 1 pieces
cm.
2. Galvanized pipe External dia. 4.5 cm * length 70 1 piece
cm.
3. Flat iron 40*3mm 1 piece
4. Square pipe 50*50*4mm 1 piece
5. Square pipe 25*25*1.5mm 2 pieces
6. Round bar Dia. 30mm 1 piece
7. Angle iron 40*40*4mm 2 pieces
8. Reinforcement bar Dia 25 mm ½ piece
9. Motor Diesel engine 3 HP 1 piece
10. Pulley Dia. 320mm 2 pieces
11 Bearing FCP 204 3 pieces
12. Bolt and nut Dia. 10 10 pieces
13. Sheet metal 1m*2m*1.5mm 1 piece
14. Belt A 40 2 pieces
15. Gear box 1/12 2 pieces
16. Electric motor 3 HP 2 pieces
 Chapter four

4. Work plan and cost estimation

4.1. Work plan
A work plan is a document that helps everyone communicate more clearly about the project. It
makes clear what the desired outcome is and the major streams of activities and also a blue print
of the goals, objectives and tasks needed to accomplish a specific project/technology.

Months 2016

No. Activities/Tasks January February March

1. Select value chain sector

2. Prepare value chain based on

selected sector
3. Analyze value chain and
identify technologies
4. Select one technology title

5. Prepare raw material list for

selected technologies
6. Layout according to design

7. Cut and join parts

8. Assembly work

9. Grinding

10. Check the machine

11. Finishing and painting