Shampoos are used to wash and clean hair. During old days, very rough soaps and other materials were used to wash hair. The rough type of soaps contained major proportion of caustic soda among their constituents. No doubt these soaps had good cleaning power due to caustic content in the shape of saponified materials yet they spoil the human skin by their drastic action. This actually produced irritation and in some it ended in the production of some skin diseases like irritation, skin itching and also in some cases gave rise to demodectic scabies.
Shampoos are used to wash and clean hair. During old days, very rough soaps and other materials were used to wash hair. The rough type of soaps contained major proportion of caustic soda among their constituents. No doubt these soaps had good cleaning power due to caustic content in the shape of saponified materials yet they spoil the human skin by their drastic action. This actually produced irritation and in some it ended in the production of some skin diseases like irritation, skin itching and also in some cases gave rise to demodectic scabies.
With the introduction of shampoos all the above diseases and problems was removed as they replaced the soaps at a very high speed. These shampoos are available as solid, paste or liquid varieties.
The demand for shampoos especially the liquid type has never been greater than it is today. For several reasons these have superseded the ordinary shampoo powders owing to the abundance of soft lather produced and it is possible that the use of liquid shampoos does not entail so much trouble. Liquid shampoos are virtually solutions of soft soap in water with just sufficient spirit to aid through saponification. At one time more spirit was used to prevent a slight gelatnation. The popular demand in bulk shampoos being for those with a high viscosity, this can be obtained by leaving the shampoo exposed to air for a week, or a fortnight liquid variety but the demand for coconut preparation is probably not so great as it was. The reasons are the difficulty in covering the odour of the oil and the fact that some coconut shampoos have the hair in a slightly greasy condition.
The number of types of shampoos are available like coconut, which are described below:-
The formulation, process conditions etc. are different for different type of shampoos but all types of shampoos can be manufactured in the similar plant without change of set of machineries.
VARIOUS FORMULATION
1.
Liquid Shampoos :
Formula No.1
Coconut oil
14%
Olive oil
3%
Castor oil
3%
Caustic Potash(8%Be)
4.7%
Glycerol
2%
Ethyl Alcohol
4%
Sodium hexametaphosphate
1%
Perfume
0.3%
Water
68%
Formulation No.2
Triethanolamine laural sulphate
35%
Sodium alginate
2.5%
Water
2.5%
Perfume
0.5%
2.
Vegetable oil Shampoo
Formula oil Shampoo
1.
Coconut
8%
2.
Palm oil
4%
3.
Potassium hydroxide(90%)
5%
4.
Ethyl alcohol
8%
5.
Glycerol
6%
6.
Water
to make 100%
7.
Perfume
0.5%
8.
Olive oil
8%
9.
Oleic acid
2.8%
Formula No.2
1.
Refined coconut oil
800 gms.
2.
Refined till oil
200 ,,
3.
Caustic Potash lye 44obe
500 ,,
4.
Glycerine
100 ,,
5.
Distilled water
2500 m.l.
6.
Iso propyl glycol
300 gms
7.
Perfume
50 cc.
8.
Saponax
4 gms
9.
Organize colour for cosmetic
2 ,,
1.
White of egg.
4 eggs.
2.
Water
10 oz.
3.
Ammonia water
6 oz.
4.
Cologne water
1/2 oz.
5.
Alcohol
8 oz.
Almond shampoo
23.8% Coconut oil
450 parts.
26.45 oleic acid
500 parts.
26.45% Trethanlance
500 parts.
23.28 Propyleneglycoal
440 parts.
.529 oil of almond
1 parts.
.026 perfumes
5 parts.
MANUFACTURING PROCESS FOR COCONUT OIL SHAMPOO
The shampoo based on coconut oil is prepared by two conventional methods viz.
In this process, caustic potash and soda is dissolved in 1/10 of total water requirement and the natural heat generated during the combination is sufficient.
Now, the coconut oil as per formula is melted. The exact calculated amount of lye and oil should be mixed together.
The melted coconut oil is poured in a thin stream in the lye with cntinuous stirring. In the last, when saponification is completed, the solution of spirit and perfume etc. is mixed. This solution is prepared separately. The stirring is continued until the liquid become a light amber colour.
The whole mass is now allowed to stand overnight and the remaining water is added. The shampoo is ready but before filteration and packing it is kept aside for a fortnight.
In this process, heating is required and the coconut oil is melted in a steam jacketed pan at a temperature of about 120oF. The alkali is dissolved in 1/5th of total water requirement separately and added in the hot coconut oil. The addition of lye should be done slowly and the temperature be maintained between 120 to 130oF. The stirring is done for a short time for emulsification of whole mass and then the spirit is added and the temperature is gradually raised to 180oF. This temperature is maintained till the saponification is Ompleted. The soap is allowed to cool and stand overnight.
Now the remaining water is heated to boiling and the soap as prepared, above is added and the stirring is continued till fully dissolved. A little quantity from 3 to 4 Oz. of potassium carbonate may be added in this shampoo if a much clear solution is desired. The prepared shampoo is now kept aside for 8-10 days and then filtered and packed in bottles.
In both the above processes, the cold process, although being much better and yield good quality. The investment on machineries is comparatively less than hot process.
In order to increase the lathering properties is the coconut oil shampoo,
the mixture of following ingredients.
Glycerine
3
1bs.
Borax
1
1/2 1bs.
Potassium Carbonate
1/2 1bs
Oleic acid
1
1/2 1bs
Rectified spirit
1/2 gall.
The oleic acid is mixed with alcohol, then borax and potassium carbonate is dissolved separately in glycerine and added this solution in previous one.
After storing the final product in a tank, the shampoo is fed into the bottling machine where the shampoo is filled in bottles and packed.
PLANT ECONOMICS OF SHAMPOO
Rated Plant Capacity
=
15,00,000 Bottles/Annum
Land & Building (Total area 250 sq.mt.) =
Rented
PLANT & MACHINERY
FIXED CAPITAL
1.
Plant & Machinery
3,10,000.00
2.
Other Fixed Assets
80,000.00
TOTAL
3,90,000.00
RAW MATERIALS
TOTAL WORKING CAPITAL/MONTH
1.
Raw Material
15,14,520.00
2.
Salary & Wages
50,875.00
3.
Utilities & Overheads
90,000.00
TOTAL
16,55,395.00
TOTAL CAPITAL INVESTMENT
Total Fixed Capital
3,90,000.00
Total Working Capital for 1 Month
16,55,395.00
TOTAL
20,45,395.00
TURN OVER/ANNUM
1.
Pay sale of 15,00,000 Bottles
2.
Pay sale of 1,12,00,000 Pouches
TOTAL
2,81,00,000.00
PROFIT SALES RATIO = Profit / Sales x 100 = 28.16 % RATE OF RETURN = Operating profit / T.C.I x 100 = 386.84 % BREAK EVEN POINT (B.E.P) = 1.21 %
Machinery and Spare Parts:
Machinery and spare parts are easily available at almost all the regions of
The country. You can also get them online with free delivery all over
India. Log on to www.easysparepart.com
