Discontinuous Soap Manufacturing Process with Controlled Electrolyte Washing
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Solution Overview
Problem
Traditional Marseille soap manufacturing processes are inefficient in terms of water and energy consumption, leading to high environmental impact and product costs, while also resulting in soap that is not processable due to high salt and soda content, which eliminates the beneficial glycerin and affects the soap's quality.
Innovation Solution
A discontinuous soap manufacturing process that optimizes the washing stages using a specific aqueous solution of electrolytes with controlled soda and salt content, reducing the number of washing steps and preserving glycerin, allowing for a processable soap with controlled water, salt, and soda levels, and improved dermatological qualities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional multiple washing stages with large volumes of salt water are used to remove impurities and glycerin, then the soap is free of impurities and soda, but large quantities of waste are generated and significant energy consumption occurs
Solution Approach 1:
The patent changes the parameters of the washing solution by using a controlled concentration of sodium chloride (1-10% instead of saturated solution) and controlling soda content (0.1-5% NaOH), heating temperature (70-90°C), and pH (8-10). These parameter modifications allow effective washing with fewer stages, reducing energy consumption while maintaining soap purity.
Solution Approach 2:
The washing process is segmented into a limited number of controlled stages (1-3 washes) with specific parameter ranges for each stage, rather than using traditional multiple unwashed stages. This segmentation allows optimization of each stage to achieve the desired purity with minimal energy input.
2Manufacturing precision
If traditional washing stages with saturated salt water are used to extract glycerin and impurities, then impurities are removed, but the soap has inhomogeneous grainy appearance and high salt content making it unprocessable
Solution Approach 1:
The patent controls the salt concentration in the washing solution at 1-10% NaCl instead of using saturated solutions, and maintains soda content at 0.1-5% NaOH. This parameter control prevents excessive salt deposition in the soap, maintaining homogeneous structure and processability while still achieving effective washing.
Solution Approach 2:
The patent implements monitoring and control of washing parameters including pH (8-10), temperature (70-90°C), and composition of the washing solution. This feedback control ensures that the washing process achieves the desired purity without excessive salt and soda content, maintaining soap processability.
3Manufacturing precision
If multiple washing stages are performed to remove all glycerin, then the soap is free of glycerin, but the beneficial dermatological properties and creamier lather are lost
Solution Approach 1:
The patent modifies the washing parameters by using controlled sodium chloride concentration (1-10%) and sodium hydroxide (0.1-5%), along with controlled pH (8-10) and temperature (70-90°C). These parameter changes allow the washing process to remove impurities and excess soda while preserving a controlled amount of glycerin (1-10%) that maintains dermatological benefits and lather quality.
Solution Approach 2:
Instead of completely removing glycerin through multiple washing stages, the patent applies partial action by using controlled washing parameters that retain a beneficial amount of glycerin (1-10%). This partial retention of glycerin maintains the soap's dermatological properties and creamier lather while still achieving effective purification.
4Manufacturing precision
If traditional process with 4-6 washing stages is used, then complete removal of impurities is achieved, but water consumption and waste generation significantly increase
Solution Approach 1:
The patent changes the washing solution parameters to controlled sodium chloride (1-10%) and sodium hydroxide (0.1-5%) concentrations, with pH control (8-10) and temperature (70-90°C). These parameter modifications enable effective washing in fewer stages (1-3 washes), significantly reducing water consumption and waste generation while maintaining complete impurity removal.
Solution Approach 2:
The washing process is divided into a limited number of optimized stages (1-3 washes) with specific parameter ranges for each stage, replacing the traditional 4-6 washing stages. This segmentation achieves complete impurity removal with minimal water usage and waste generation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This process significantly reduces water and energy consumption, minimizes waste, and maintains the quality of the soap by preserving glycerin, making it environmentally friendly and economically viable while ensuring the soap's processability and dermatological benefits.
Implementation Method 1
washing the soap paste obtained in step a. with an aqueous electrolyte solution... the soap paste is mixed with an aqueous solution comprising 1 to 42% by weight of a mixture of sodium hydroxide and salt
Implementation Method 2
the mixture is heated, and left to settle until two phases are formed: the grained soap comprising salt, sodium hydroxide and glycerin, and an aqueous solution comprising salt, sodium hydroxide and glycerin, the grained soap and the aqueous solution are separated
Implementation Method 3
at least one fatty acid and/or fatty acid ester is mixed with an aqueous sodium hydroxide solution, the mixture is heated to obtain a soap paste
Implementation Method 4
The basic principle of soap preparation is based on a saponification reaction in which fatty acids and/or fatty acid esters contained in fatty substances are hydrolyzed in a basic medium to form alkali salts (carboxylates), constituting the soap, and glycerin
Data Source
Figure 1
AI summary
The present invention relates to a discontinuous method for manufacturing soap, which includes at least the following steps: a) a step of mashing and cooking, wherein: at least a fatty acid and/or a fatty acid ester are mixed with an aqueous soda solution; and the mixture is heated to obtain a soap paste; b) at least one step of washing the soap paste obtained in step a), wherein: the soap paste is mixed with an aqueous solution including 1 wt % to 42 wt % of a mixture of soda and salt; the mixture is heated and allowed to settle until two phases are formed: the curd soap including salt, soda and glycerine, and an aqueous solution including salt, soda and glycerine; and the curd soap and the aqueous solution are separated; and c) a step of smoothing the curd soap obtained in step b) by neutralisation, wherein: the curd soap is mixed with at least one neutralisation agent which can be an acid, a fatty acid or a fatty acid ester; the mixture is heated, and the smoothed soap is obtained. The invention also relates to a method according to the preceding claim, in which the fatty acid and/or the fatty acid ester used in step a) is a fat, preferably of plant origin, and more preferably a plant-origin or vegetable oil or paste. The invention likewise relates to the smooth soap likely to be manufactured by means of said method.