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Tuesday, May 3, 2011

How to Make Bleach (Sodium Hypochlorite)

Sodium Hypochlorite is prepared by reacting dilute caustic soda solution with liquid or gaseous chlorine, accompanied by cooling.

Sodium Hypochlorite is commonly produced either through a batch process or through a continuous process.

See Also:

AUTOMATIC TRANSMISSION FLUID: HOW TO MAKE LIQUID BLEACH PRODUCTION

AUTOMATIC TRANSMISSION FLUID: HOW TO MAKE LIQUID BLEACH PRODUCTION: "HOW TO MAKE LIQUID BLEACH PRODUCTION"

LIQUID AIR FRESHENER (LIQUID DEODORANT)

LIQUID AIR FRESHENER
(LIQUID DEODORANT)

Introduction: This is a liquid mixture used to refresher the air. It is a deodorizer. The material replaced a bad odour with a good scent.

Raw materials:

1. Active Ingredients: These are strong and good smelling perfumes. The perfumes must be heavy or oily to last long when used. Examples are

a. Citronella, H & R and super.
b. Lavender, Rose, Vanilla etc
c. Xalang, Pears, One man show etc.
These perfumes can be used separately or blended in twos, threes or more.
2. Emulsifiers: They help blend oil perfumes into water which is the major solvent.
Genapol, Calcel, Empicol, Sodium lauryl sulphate and liquid detergents are used.
3. Diluents: Diluents help keep the ingredients stable in the system. Ethanol, Butanol, Isopropanol (IPA) or secondary butanol can be used.
4. Antiseptics: They kill germs. Some of these germs cause smell to occur. Cetrimide, irgasan, paraben are very good types. These materials are however optional.
5. Water: Water is the major solvent. Water is used to dissolve the other materials needed. The water must be clear and clean.

Equipment & Tools:

1. Mixer:- This can be manual or motorized. The mixing tank can be plastic or stainless steel. This is to prevent rusting.
2. Storage Tanks:- Plastic or stainless steel types should be used.
3. Filling and sealing Unit:- This can be automatic or manual. It fills and seals the containers and the cartons. This is however optional as the process here can be handled manually as the case may be.
4. Measuring Device:- Weighing Scale and measuring cylinder are needed.
5. Others: These includes laboratory tools, personal protection equipment and other miscellaneous tools.

Packaging Materials:

They include plastic and glass bottles of 20mls, 50mls, 100mls, 500mls, 1000mls, and 4 litres. They will need to be labeled and put in good cartons or laminates.

Production Process:

1. Formulations
20 Litres Batch
a. Perfume (e.g Xalang) - 400g (about ½ Litre)
Genepol (Emulsifier) - 200g (about 1/5 Litre)
I.P.A. (Diluent) Optional - 100g (about 1/10 Litre)
Water - 19.30 Littres
Total - 20 Litres.

20 Litres Batch – Volume Measurement

b. Perfume citronella or H & R - ½ Litre
Liquid Detergent - ¼ Litre
Water - 19 ¼ Litres
TOTAL - 20 Litres



Toilet Clean Batch - 5 Litres

c. Rose perfume - ¼ Litre
Hydrochloric Acid (cetrimide) - ¼ Litre
Empicol - ½ Litre
Water - 5 Litres
Total - 6 Litres

Notes:

1. Any good perfume can be used.
2. Two perfume can be equally mixed.

Processing Method

1. Mix the perfume with the emulsifier.
2. Mix this till well blended. It may turn white.
3. Add dilute (i.e IPA) and any other additive needed as required.
4. Add the required water and mix slowing but steadily till product is fully blended and pack as needed.

Note:

1. A good liquid detergent can be used to replace Genepol or empicol weight for weight.
2. Hydrochloric acid is a germ killer.


TOILET CLEARNERS FORMULATIONS

(A) Toilet Cleaner Batch 20 litres

Rose perfume or others) 1/10 litre

Hydrochloric Acid (or Cetrimide) ¼ litre

Empicol (or Liquid Detergent) 1 litre

Soda Ash (or STPP) ½ kg

Natrosol 5TSP

Colourant (e.g Blue) 2 TSP

Water 13-15 litrers

Total 20 litres


Note:

1. Any good perfume can be used
2. Two perfume can be equally mixed
3. STPP is sodium Tripolyphosphate
4. TSP is Tablespoonful, tsp is teaspoonful.



(b) 20 litres batch Toilet Cleaner

Jasmin perfume 1/10 litre (100ml)

Sulphonic Acid ½ litre

Hydrochloric Acid ¼ litre

Soda Ash 1kg

Natrosol 5TSP

Colourant (green) 2tsp

Water 18 litres

Total 20 litres
Note:

1. A good liquid detergent can be used to replace Sulphonic Acid.
2. Hydrochlooric Acid is a germ Killer and stain remover
3. Natrosol is a thickner
4. Use only water soluble colourants
5. Empicol is a foaming agent and emulsifier to help the ingredients to mix well.

PROCESSING METHOD

1. Measure out the ingredients in separate containers
2. Place the water in the mixer (bowl or tank) and add the soda ash (or STPP) and mix till fully dissolved. (about 20 minutes)
3. Add the empicol, detergent or sulphonic acid and mix slowly to avoid excessive foaming.
4. Add the perfume and mix till well blended (if not well blended, add ¼ litre empicol or others to blend well). (About 10 minutes).
5. Into a ½ litre cup of water, put the 5TSP natrosol and mix well (about 10 seconds) and immediately add this mixture into the main product and continue mixing till the product becomes thick (about 10 minutes).
6. Add the Hydrochloric acid or cetrimide and mix well (about 5 minutes)
7. If colourant is needed, add as the last item and mix to blend (about 3 minutes)
8. Pack product as needed in the market.

HOW TO MAKE LIQUID BLEACH PRODUCTION

LIQUID BLEACH PRODUCTION
INTRODUCTION:
Bleach is a mixture or a single compound used to remove minor stains from white fabrics, ceramics, metals and related surfaces.
RAW MATERIAL REQUIREMENTS:
• Caustic Soda – It is a wetting agent here.
• Soda Ash – It helps to soften water and also cleans materials
• Sodium Hypochlorite – It is the bleaching agent that removes stains in materials
• Water – It helps to put all the materials in solution for easy use.

EQUIPMENT / TOOLS REQUIREMENTS:
• A mixer –m Manual or motorized. It should be low speed (200-500rpm).
• Filter Unit: (Manual or automatic)
• Filling / Packaging Unit – Used to fill the bottles. (It can be done manually or otherwise).
• Storage tanks, measuring devices, etc.
• Factory Wears/protectors.

PACKAGING MATERIALS:
Bleach can be packed in ½litre, 1litre, 5litres plastic or metal jerry cans. The cans should carry well made labels with he relevant information such as brand name, maker, instruction for use, etc. smaller packs like ½litre and 1litre can in turn be packed in cartons as needed by the users.
SPACE:
A standard room size space is enough for a small beginner to take off.



PRODUCTION METHOD:
(a) FORMULATION: 10 Litres Batch 100 Litres Batch
Sodium Hypo chlorite -0.5kg 5kg
Soda Ash -0.5kg 5kg
Caustic Soda -0.2kg 2kg
Water -8.7kg 87.5litres
Perfume -50mls 500mls
TOTAL -10LITRES 100 LITRES

Note: Bleach has a life span of about 2 years only.

METHOD: Mix all the ingredients except perfume in a suitable container. Keep for about 8-12 hours. Mix again very well. Keep for another 2-3 hours or when the materials clearly separates, decant the liquid portion, add perfume and pack as bleach. Filter press can be use to filter the product after the second mixing immediately.

PRODUCTION OF WHITE DISINFECTANT:

As earlier discussed, this disinfectant is based on PHENOLS or CRESOLS. It is a very powerful disinfectant used in heavily soiled areas such as Farms, Toilets, Hospitals etc.

FORMULATION I:
The formulation given below, is widely used all over the world as it meets all pharmaceutical requirements and regulatory bodies like NAFDAC. Usual precaution are however necessary.

20 Litres Batch

Sodium Stearate - 5kg
Cresol liquid (or Phenol) - 10litres
Distilled water (or others) - 5 litres
TOTAL - 20LITRES

It may be necessary to add more water and sieve after boiling. Kg can be used as parts.

PROCESSING:

Mix the sodium stearate, the cresol and water. Boil till the mixture dissolves. You may leave the mixture to stand for about one hour before boiling to see if dissolution can occur. If it does just warm the solution almost to boiling and pack. If not boil till all dissolves or for say 30 minutes. Pack when cold. You may need to filter.

FORMULATION II:

This is the commonest formulation among small scale manufactures. It is easy to make but profit is lower due to the use of phenol (disinfectant) concentrate.

20 Litres Batch Disinfectant Germicide

White Germicide Concentrate - 5 litres
Pine Oil - 2 litres
Genapol (or empicol) - 40mls (8TSP)
White Colourant Powder (optional) - 40g (8TSP)
Water - 12 litres
Total - 20 Litres

PRODUCTION METHOD:

1. Mix the concentrate with the genepol (or empicol) and add the pine oil. Then mix to fully blend. If not fully blended i.e. not homogeneous add a little extra genepol (about 1-2TSP).
2. When fully blended, add the need water and mix.
3. Add the white colourant if the colour is not whitish enough and mix till homogeneous.

Note: (I) Manual operation may take up to 50 minutes but mixing in a low speed mixer will be about 20 minutes for a small batch of less than 200 lites.
(II) The exact quantity of concentrate will depend on the quality of the one
in use. It may be more or less. Ask the supplier.

QUANTITY PARAMETERS:

Test in an approved laboratory for quality.

Note: This product, like other disinfectants require registration with NAFDAC

HOW T MAKE INSECTICIDE PRODUCTION

INSECTICIDE PRODUCTION
INDRODUCTION:
Any compound or miture that is capable of getting rid of insect pests is known as an insecticide. Most insecticides are in liquid form. However there are solid (powder) types.
SCOPE OF USAGE:
Insects such a Tse-tse fly, Housefly, Mosquito, Bedbug etc are disease vectors and hence must be checked. Insecticides are mostly used to kill or knock them down in homes, offices, churches, mosques, factories, farms and other places of human endeavour.
RAW MATERIALS REQUIREMENTS:
Permethrin, Pyrethrin, Camphor, Vapona-DDVP are active ingredients that are safe for use.
Carriers or medium include water, kerosene, butane, etc as solvents, others are powders such as Talc, Clay, Kaolin, Petroleum Jelly, Calcium Carbonate etc. Additives (optional) are colourants, perfumes, buffers etc.
EQUIPMENT/TOOLS REQUIREMENTS:
• Mixer – manual or motorized (This can be powder or liquid mixer)
• Weighing scales & factory tools.
• Storage tanks, Boilers, Fillers etc.
• Protective wears including gas chambers.
PACKAGING MATERIAL REQUIREMENTS:
The liquids are packed in pressurized metal cans or in plastic or metal bottles for dispensing by use of spray gun.
The powders are packed in plastic jars or bottles as needed.
In pressurized cans, butane should be included as a carrier gas. The cans or bottles carry instructive labels and are in turn packed in cartons or film palettes.
SPACE:
If open space with cover if available, should be preferred. If not the factory must be very well ventilated to reduce health risk. A big room or two can do for cottage beginner.
PRODUCTION METHOD:
FORMULATION: LIQUID TYPEE: 20 LITRES BATCH
Camphor 0.2 kg (i.e. 200g)
Vapona (DDVP) 0.1 kg (i.e. 100g)
White Spirit (or kerosene) 19.6 litres
Perfume (optional) 0.1 litres (i.e. 100mls)
TOTAL 20 LITRES
Note: Perfume is used to deodourise the kerosene where in use.
Vapour Type; 100 Litres Batch
Vapona or DDVP - ½ - ¾ (litre) (500mls)
Pyrethrin - ¼ - ½ kg (500 mls)
Butane - 15 – 20 litres
White Spirit - 78 – 80 litres
TOTAL - 100 LITRES
This is mixed in a pressurized mixer and transferred to a special pressure filling and corking machine where the product is packed by the machine. This mixing takes about 20 minutes.
Powder Type: 50 kg Batch
Permethrin - 1 part (kg)
Camphor powder - 1 part (kg)
Calcium carbonate - 48 (kg)
Total - 50 litres
The powders are mixed in a ribbon (powder) mixer and filled as required into bottles or sachets. This mixing should be done for at least 30 minutes.
Candle Type: 10 kg Batch about 500 sticks
Permethrin - 0.1kg (100g)
Camphor powder - 0.1kg (100g)
Dibutylpthalate (DBP) - 0.05kg (50g)
Candle wax - 9.7kg
Total - 10KG

PROCESSING METHOD:
1. Set the candle mould to receive the product.
2. Melt the wax in a separate pot or tank heater
3. Remove the heat and add the other ingredients
4. if colour is needed, add at this stage. Colour must be oil soluble, in this batch ITSP is ok.
5. Mix all the ingredients quickly and well, then pour in the cavities of the candle mould.
6. Allow solidifying – about 60 minutes and bring out the sticks for packaging. This operation must be made with the operator wearing a RESPIRATOR and in an open space or a fumed cupboard.

MODERN SOAPS,DETERGENT & DISINFECTANTS TECHNOLOGY-HOW TO PRODUCE STANDARD LAUDARY (BAR) SOAP

DISINFECTANTS

FORMULATION 1

BROWN DISINFECTANT/ANTISEPTIC STANDARD FORMULATION

Chloroxylenol Crystals - 1 part (kg)

Isopropanol (IPA) - 4 parts (litres)
Pine Oil - 3 parts (litres)
Genapol (or empicol) - 1 part (litre)
Water (with caramel) - 15-16 parts (litres)
Total - 25 litres
Adjust with IPA to clearity, if not clear brown colour.
PRODUCTION METHOD:
1. Mix chloroxylenol with IPA to dissolve the chloroxylenol.
2. Add pine oil and mix
3. Add Genapol and mix
4. Measure out the water needed in a separate container and add brown colourant to taste. This can be caramel or other safe brown colourant soluble in water.
5. Add the coloured water and mix. Adjust to clearity if necessary by adding IPA or ethanol in drops till mixture is clear. That is clear brown colour like Detol.

PRODUCTION METHOD:

FORMULATION II: This formulation is now common with small scale operators because it is easy to use and the materials are commonly available. Use is made of chloroxylenol concentrate which has the appearance of the disinfectant but it is very “heavy”
30 litres Batch formulation
Chloroxylenol liquid (concentrate) - 12 litres
Pine Oil - 3 litres
Isopropanol – IPA - 4 litres
Empicol (or Genepol) - 40 mls(8TSP)
Caramel (optional) - 40 mls (8TSP)
Water - 10 mls (8TSP)
TOTAL - 30 LITRES
PROCESSING METHOD:
1. Mix the chloroxylenol, pine oil and empicol in a mixer till they are fully blended. If not increase empicol by 1-2 TSP.
2. Mix water with the caramel colour if needed and add the mixture to no. 1 above. Mix well. The mixture may turn white.
3. Add IPA little at a time as you mix. Continue this process till the product turns
from white to golden brown stop and pack. If the 4 litres of IPA above is not enough to clear the white colour, you can add more IPA.
Note: The exact quantity of concentrate depends on the quantity of the one in use. You may need to use more than 12 litres in the case above if the quality is low. Ask the supplier.
Quality parameters: see the white disinfectant

COLD WATER STARCH PRODUCTION

COLD WATER STARCH PRODUCTION

Introduction: Cold water starch is a modified starch used to stiffen textile and other related fabric. It is simply used in cold (room temperature) water or directly on the material to be treated.
Types: There are two types, namely the powder and the liquid. However, the liquid is also found in aerosol pack.

Uses:

1. Landry and dry cleaning
2. Textile finishing (cloth, bandages, rug towels) etc
3. Fishing and other nets finishing
4. Paper smoothening (in paper production)
5. Printing finishing (Anti-set-off powder)
6. Gluing and gumming (labeling, binding & gumming)

RAW MATERIALS REQUIRMENTS:

1. Cassava starch or other modified starch, dextrin, polyvinyl aalcohol, polyvinyl acetate, soda ash, borax, formalin, Isopropanol (IPA), water and soluble colourants and perfumes. The exact materials for use depends on the type to be made.


EQUIPMENT REQUIREMENTS:

1. Dryer such as flash dryer of other drying equipment. Flash dryer is the best option as it is most efficient.
2. Roller mills with heater (this is noptional)
3. Planetary or Ribbon blender
4. Filling and sealing machine. This can be powder, liquid or aerosol type.
5. Pulverisers or grinders
6. Weighing scale and other measuring devices
7. Laboratory tools. Thermometers, viscometers etc.
8. Personal protective gadgets. Coverall, mask gloves, boots, earplugs etc.

PACKAGING MATERIALS:

Cold water starch can be packaged in sachet, bottles and spray cans depending on the type. Cartons are also needed for bulk packaging. Sizes of packs should depend on market demand. However, 20g, 25g, 30g, 50g sachets are in the markets 0.5 litres, 1 litre and 4 litres packs for the liquid type can be found. The aerosol type include 250mls, 450mls, 500mls etc. The packs are well labeled with the appropriate information like maker, quantity, registration etc.



Space: The standard requirement is a minimum of four rooms excluding a cloakroom. However, a cottage scale can start with a room or two. Bigger scale will require bigger space.

Labour: A skilled hand can produce up to 1 ton of the product per day if the system is automated. Far less will be make if operation is manual. Except about 250kg of finished and package product for manual operation by one hand.

Production Process: There are three or four stages of making cold water starch depending on where you start from some of these stages can be omitted by a small scale to save cost.

1. Cold water starch powder
(a) Modification of raw starch methods

i Dry method: Here the roller mills are heated to above 1000C. The raw starch mixed with ash is fed into the rollers. The starch gells as it rolls over the hot cylinders of the rollers. The gelled starch now in cakes or flakes are collected and grinded in the pulveriser. Perfume and colorant may be added at this stage.

Roller formulation: 50kg batch
Cassava (or other) starch - 49.5kg
Soda ash (optional) - 0.5kg
Total - 50 kg

This mixture is rolled in the hot cylinder of the rolers


Pulveriser formulation: 50 kg batch

Gelled starch mixture - 50 kg
Colourant (optional) - 1 TSP
Total - 50kg

The mixture is grinded

The grinded starch is now packed in the required sachets and cartons for sale. This method is expensive because of the cost of the rollers.
ii. Wet method: Here the mixture as in roller formulation above is boiled with some water to gell. The gelled starch mixture is dried in the flash dryer then pulverized as in the pulveriser formulation above.

Boiler formulation: 50 kg batch

Cassava (or other) starch - 49.5kg
Soda Ash (optional) - 0.5 KG
Water (to form sturry) - 20 kg
Total - 70 kg
Note: while boiling, the product must be in constant mixing. The gelled starch is collected and dried in the chosen dryer. This is to remove the water used during boiling. The dried starch, now in cake form is placed in the pulveriser and grinded with or without colourants and perfumes. The product is then packaged as required in the market. This is also expensive because of the dryer.

iii. Dextrin method: This method is most suitable for micro and small scale entrepreneurs. It eliminates the use of roller mills, flash dryer and pulverisers.

(b) Cold water starch powder: 50 kg Batch
Dextrin - 49.5 kg
Soda ash light - 0.5 kg
Perfume (optional) - TSP
Colourant (powder) - 1 tsp (optional or blue)
Total - 50 kg

Note: TSP means tablespoonful. Tsp means teaspoonful.

PROCESSING: The materials as above simply measured out and mixed manuallym if batch is below 100kg or in ribbon mixer for bigger batches. When homogeneous, it is packed as required.


(c) Cold water starch powder: 50 kg Batch
Dextrin or gelled starch - 20kg
Polyvinyl Acetate (PVA) - 10kg
Water - 20kg
Formalin - 200 g
Perfume (optional) - 1 TSP
Total - 50 kg Apr.


PROCESSING:

(1) Gel local cassava starch with hot water: This can ba done by mixing the raw starch with equal amount of cold (ordinary) water. The mixture is the mixed with about 4 to 5 times quantity of boiling water (1000C) and properly mixed till homogeneous.

(2) The gelled starch or dextrin is mixed with the water in the formulation above. When smooth, the other ingredients (PVA, formalin etc) are then added and mixed well for feeling into the appropriate bottles for sale.


Note: The use of cassava starch here instead of dextrin ensures very good profit without changing the desired quality.


(3) Cold water starch Aeroslo. 50 kg Batch

Dextrin or gelled starch -10 kg

Polyvinyl Acetate - 10 kg

Isopropanol (IPA) - 2 kg

Water -28 kg

Formalin - 200 g

Total - 50 kg. Apr.

Note: Colourant and or perfume may be added as in other processing. Mix all other ingredients together except IPA. When homogenenous, add IPA and mix very well. Pack or fill into the aerosol cans with theaerosol filling machine. The IPA guarantees the spray ability of the product and its fast drying. For better spraying IPA can be increased if desired.

QUALITY PARAMETERS:

1. Product should stiffen cotton fabric well compare with accepted brands in its market.
2. Odour must be well controlled. Use good fragrance.
3. Spoilage. This is especially for the liquid type. However if the powder type is not well dried, it can also decay. Use good preservative (formalin) to avoid bad odour in the liquid types.
Consult a good chemical consultant or a public analyst for detailed quality control tests and analysis.

TOILET CLEARNERS FORMULATONS:

(A) Toilet Cleaner Batch 20 litres

Rose perfume (or others) - 1/10 litres

Empicol (or Liquid Detergent) - 1 litre

Soda Ash (or STPP) - ½ KG

Natrosol - 5 TSP

Colourant (e.g. Blue) - 2 tsp

Water - 13-15 litres

Total - 20 litres

Note:

1. Any good perfume can be used
2. Two perfume can be equally mixed
3. STPP is sodium Tripolyphosphate
4. TSP is Tablespoonful. Tsp is teaspoonful.

(b) 20 litres Batch Toilet Cleaner
Jasmine perfume - 1/10 litres (100ml)
Sulphonic Acid - ½ litre
Hydrochloric Acid - ¼ litres
Soda Ash - 1 kg
Natrosol - 5 TSP
Colourant (green) - 2 tsp
Water - 18 litres
Total - 20 litres

Note:
1. A good liquid detergent can be used to replaced Sulphonic Acid.
2. Hydrochloric Acid is a germ killer and stain remover
3. Natrosol is a thicker
4. Use only soluble colourants
5. Empicol is a foaming agent and emulsifier to help the ingredients to mix well.
PROCESSING METHOD:
1. Measure out the ingredients in separate containers.
2. Place the water in the mixer (bowl or tank) and add the soda ash (or STPP) and mix till fully dissolved. (about 20 minutes)
3. Add the empicol, detergent or sulphonic acid and mix slowly to avoid excessive foaming.
4. Add the perfume and mix till well blended (if not well blended , add ¼ litre empicol or others to blend well). (About 10 minutes)
5. Into a ½ litre cup of water, put the 5 TSP natrosol and mix well (about 10 second) and immediately add this mixture into the main product and continue mixing till the product becomes thick (about 5 minutes)
6. Add the Hydrochloric acid or cetrmidie and mix well (about 5 minutes)
7. If colourant is needed, add as the last item and mix to blend (about 3 minutes)
8. Pack product as needed in the market.

Hand wash liquid detergent-Car wash liquid-LIQUID SOAP/DETERGENT PRODUCTION

LIQUID SOAP/DETERGENT PRODUCTION

Stage 1

Production Method.

1. Formulations
(a) C.M.C. Solution 100 litres 10 litres
C.M.C. Powder 1-1 ½ kg 100 g(20 TSP)
Glycerine 2-3 kg 250g (50 TSP)
Water 9-5 litres 9.5 litres
Total 100 litres 10 litres

C.M.C. is carboxylmethylcelluose sold as Antisol, Baravis, Wallocell etc.
Mixing: Mix C.M.C. powder and glycerine in a small separate container. Place the water needed in another,(bigger) container. Add the C.M.C./Glycerin mixture into the water as it is stirred. Add gradually, while stirring. Continue stirring after addition of the cmc mixture till the solution thickens. Leave or keep for about two hours to fully dissolve. Finally mix again and store for use. If the cmc solution is to store for more than 5 days add ¼ kg of formalin to the quantity above (i.e 100 litres)

Stage 2

(b) Soda Solution
Caustic soda powder 1kg
Soda Ash Powder 1kg
Water 50kg (litres)
Total 52kg (or litres)


Mixing: Place the whole water in a plastic or stainless stell tank. Add the caustic soda and the soda ash into the water and mix till the whole salts are fully dissolved. This will be noticed by the solution turning clear from milky colour. The salts can also be mixed separately in 25 litres of water a piece. The two solutions are then mixed together.

Note: Allow to cool to room temperature before use

Stage 3

(a) Industrial Detergent
Soda solution 50 litres
Sulphonic Acid (good grade) 10 litres
TOTAL 60 LITRES

Mixing: Place the soda solution in a plastic or stainless tank, add the sulphonic little at a time and turn, till all the sulphonic is added. Mixing should be slowly here as the product may foam heavily. This can be diluted and packed for use. Though it is very strong but light in viscosity.

Caution:

(1) Caustic soda is very corrosive. Wear rubber or plastic hand gloves.
(2) Make this detergent in a tall tank, for instance do not charge more than 100 litres of this detergent into 240 litres capacity tank. The bigger the container, the more space available.
(3) Turning i.e stirring should be very slowly here. Vigorous turning will cause excessive foaming.
(4) If foaming is excessive, stop turning and allow to stand and turn when the foam has gone down, turn again and pack as desired.

(d) General purpose detergent

Industrial Detergent 60 litres
CMC Solution 40 litres
Colorants (e,g yellow) 1 tsp or QS
Perfume (e.g lemon) 3 TSP or QS
Total 100 litres
Note: tsp means teaspoonful, TSP means tablespoonful, Q.S means as required.
To get thicker detergent, use more CMC solution and less industrial detergent.
(e) Domestic liquid detergent
Industrial detergent 20 litres
C.M.C. Solution 40 litres
Colour (e.g green) 1
Perfume 4 TSP
TOTAL 60 LITRES

(f) Hand wash liquid detergent

Industrial detergent 20 litres
Good sodium silicate (optional) 20 litres
Water 10 litres
Colour (e.g green) 1 stp
Perfume 4 TSP
TOTAL 50 litres

Mixing: for (d) and (e) the ingredients are measured into a mixing tank and mix well to blend. The product is tested for foaming and viscosity before it is packed. If foaming is low, increase industrial detergent by about 5 per cent (i.e 3-4 litres). To increase the viscosity adds more CMC Solution.
For (f), mix sodium silicate and water first, then add the industrial detergent and other materials and mix. In the absence of good sodium silicate use CMC Solution.
Note: if sodium silicate is not suitable, the final product will turn milky or very cloudy. Use liquid detergent grade of sodium silicate. Many other detergent can be formulated from industrial detergent. Obtain the users specification to guide you on what he wants.

Car wash liquid

Industrial Detergent - 20 litres
CMC Solution - 30 litres
Good Sodium Silicate - 10 litres
Colourant - 1 tsp
Perfume (Optional) - 3 TSP
TOTAL - 60 LITRES

Shampoo

Material Hair Other
Industrial Detergent 20 Litres 20 Litres
CMC Solution 28 litres 30 litres
Glycerine (Conditioner) 2 Litres -
Thymol, Menthol or Camphor 5 tsp -
Colourant 1 tsp 1 tsp
Perfume 4 TSP 4 TSP
TOTAL 50 Litres 50 LITRES

Processing: Mix just as in domestic detergent. If menthol or camphor is to be used, melt in a separate container before adding into the shampoo. Mix well to blend.

Quality parameter.

a. Should foam very well. 1 TSP in a 4 litre bucket should produce foam that should not collapse in 5 minutes.
b. It should clean very well in minute.
c. It must not be harsh on hand, articles or fabrics
d. It should soften or blend with oil on equal proportion.
e. The product should meet NAFDAC and SON Specifications.
f. A good liquid detergent soap will show a faint yellow (or light green when blue or red litmus paper is dipped into it (orange is fair)
If colour is deep Red or deep Blue, the detergent soap will be too harsh to the body.

HOW TO PRODUCE POWDERED DETERGENT

HOW TO PRODUCE POWDERED DETERGENT

A. INTRODUCTION:

Detergent like soap is used in wide range of cleaning activities. It is employed at home, office, factories, hospitals, farms etc. The major deferent between detergent and soap is that detergents have the advantage of retaining its efficiency in hard water.
Nowadays soap can also be powder or liquid as found in detergents. These liquid or powder soap are differentiate by the use of word SYNTHETIC for detergents.

B. RAW MATERIALS (ALL TYPES) FUNCTION

1. Vegetable Oil (e.g PKO)- To form soap
2. Fat - To form soap
3. Sulphonic Acid - To form soapless soap
4. Hydrogen peroxide - To help in breaking dowetergent
5. Sodium Silicate - Hardener and Bristleness
6. STPP or TSP - Water softener (optional)
7. Sodium Sulphate - Hydration (Removing water) (ptional)
8. Sodium perborate - Cleaning Material (bleach)(optional)
9. Tinapol - Brighter (Like blue dye)
10. Caustic Soda - To form soap and detergent
11. Soda Ash - Basing agent (Neutralizer) (optional)
12. Urea - To Neutralize (optional)
13. Colourant - To impact colour
14. Perfume - To impact scent
15. Sodium - Foam Booster (optional)
16. Water - To solubilize Solids

C. EQUIPMENT / TOOLS FUNCTION

1. Reactor(s) (Mixer/Heater)
(Stainless steel or Plastic) For Boiling
2. Storage Tanks (Stainless Steel
or plastic) For various purposes
3. Drying Chamber For drying (Oven, Rotary or Flash)
4. Pulveriser (Grinder) or sieve For Grindings/sieving
5. Filling machine (optional) For Filling
6. Packaging Machine (optional) For Sealing / Packaging
7. Weighing scales For Various Weighing
8. Hydrometer For Guaging of Solutions

D. PACKAGINGS:

The product is packed in a paper packets, polythene bags, plastic cans etc which in turn will be put in bigger cartons. Packaging should carry brand name, quantity, manufacturer and any other relevant instructions.

E. FORMULATIONS:

Many formulations are available for use. The producer however must consider the factors in choosing one of them adopt.

VIZ:

1. Cost of production materials
2. Availability of these materials
3. Ease of production process
4. End user requirements (Quality)
It is important to mention that a combination of soap type and synthetics detergent type formulations have been adopted when the process is cheaper. Use in made of oils, sulphonic acid and caustic soda as the basic materials.

PRATICAL PRODUCTION PROCESS:

1. Making of solution: Measure out in the container of your choice as below

(a) Caustic Soda Solutions: (N.B. Caustic Soda is corrosive)

Caustic Soda - 1 part
Water - 4 parts

Note: This means that to every one part of caustic soda pearls add 4 parts of water (e.g 1 milk cup of caustic soda plus 4 cups of water). Mix well till the colour (milk) is clear. Do not touch with bare hand or body.

(b) Soda Ash Solution: Treat as in caustic soda solution

Soda Ash light - 1 part
Water - 4 parts
Mix these two materials till Soda Ash is fully dissolved.

(c) These two solutions (a) and (b) are kept for use.



CAUTION:

Use rubber or plastic hand glove anytime you are producing to avoid direct body contact with caustic soda. Caustic soda is corrosive. Avoid body contact.

IMPORTANT NOTES:

1. The formulation given above if carefully followed and good materials are used given s a good and affordable detergent that will guarantee the investor good return on investment.
2. Do not hesitate to make further inquiries where in doubt or were further explanation is needed.
3. Use plastic containers for storage, measurement and mixing to avoid corrosion and rusting.
4. Ordinary mild steel will corrode and rust easily but can however be used where reduction of cost for a start is absolutely necessary.
5. Prepare each solution on a separate container.
6. Store all materials properly.

POWDERED DETERGENT (synthetic) FORMULATIONS

Alkyl Benzene sulphonate (ABS) or D.D.B.S. - 20 parts (kg)
Soda Ash (Light) - 40 parts
STPP - 26 parts
Sodium Metasilicate - 8 parts
CMC - 2.0 parts
Colourant (optional) - Q.S. (50g for 20kg DDBS)
Tinapol - Q.S.[100g “ “ “ ]
Papain (enzyme) to remove stains - Q.S.[100g “ “ “ ]
Water - 15 parts (or kg)
Total about 100kg

Q.S. means sufficient quantity (usually 0.05 – 0.2%)

PROCESSING:

Add all the materials into a low speed mixer except ABS. Mix very well. Add the ABS or DDBS kg by kg as you mix. Let the mixture set then strain through a fine mesh (About 200 ms) DDBS and Idet 10 are brand names of ABS.
Dry in a low temperature spray dryer set under 600c or less.

Other Formulation

Idet 10 - 45 parts(kg)
STPP - 35 parts
Soda Ash Light - 16 parts
CMC - 2 parts
Colourant - 0.1 part
Tinapol - 0.2 part
Papain (optional) - 0.2 part
Water - 15parts

PROCESSING:

Treat as in No. 1 above. Detergent of No. 1 is harder than detergent No. 2 yet cheaper in production cost.

Note: This is the modern synthetic detergent made without vegetable oil. It foams more and easily removes stains from fabrics. It is replacing the oil base detergent.

MODERN SOAPS,DETERGENT & DISINFECTANTS TECHNOLOGY-HOW TO PRODUCE STANDARD LAUDARY (BAR) SOAP

INTRODUCTION:
Soap are metallic salts of higher fatty acids (found in oils/fats) resulting from a reaction called saponification. Basically it is a simple reaction represented by a base (Alkalis) and an acid (oil).
RAW MATERIALS:
SODAS: Caustic Soda, Caustic Potash, Soda Ash, representing some of the sodas that are used in soap making. (Alkalis).
OILS:
The oils range from palm kernel oil (P.K.O) to groundnut oil, cotton seed oil, coconut oils, palm oil and many other vegetable oils. Some other oil resources such as lard, tallow, etc can also be used to produce soaps. Note: mineral oil cannot be used.
Apart from sodas and oils other ingredients, which help to increase the quality and quantity of soaps are also used. These include Rosin, Sodium Silicate, STPP, Salt, Sodium Sulphate, Kaolin, Calcium Carbonate, etc.
OTHERS:
Other additives include perfumes, colorants, antiseptics, bleach, etc depending on types of soap to be made.
SOLVENT:
Water is the major solvent used to dissolve the solid components.
TYPES OF SOAPS:
There are many types of soaps:
Hard Soaps: These types of soap are obtained from caustic soda (sodium hydroxide). Examples are key soap, duck soap, happy day soap and much other laundry soap in the market. It properly made, they are hard and tend to last longer than other types of soap that are soft.
Soft Soaps: these are soaps obtained from caustic potash (potassium hydroxide). They are very soluble in water. Examples are Imperial leather soap, Joy soap, Lux soap and many more. They are mainly toilet soaps.
Medicated Soap: These are toilet soaps that contain medicinal substances that can kill germs. They are used for skin and body protection from germs by many people. The medicinal chemicals that are used to make medicated soaps include: mercuric iodide, phenol, iodide, cetrimide etc. There are many medicated soap in the market they include:- Carat, Antisol, Roberts, skin guard soaps etc.
Transparent soap: Toilet soaps that do not have any types of colour are known as transparent soap. One can see through the soap bar of a transparent soap. They are made by washing toilet soaps in alcohol to remove the colours available.


Some of them contain glycerol. Examples are Voxe soap, etc. One needs sophisticated equipment to produce them.

Soda Soap: This is hard and harsh soap locally produced using palm oil or PKO and caustics soda. Occasionally filler such as calcium carbonate, starch or kaolin is added to increase yield. It is very popular soap type among the ordinary people at the grass root of the economy. The soap is usually not branded but occupies a good positioning the local soap market.

SPACE REQUIREMENT:
The minimum of one or two standard rooms of not less than 3mx4m each will be needed. This should be properly secured for raw materials, equipment and other items of value. (Reserved for more discussion). However any other open shaded space can be used where better space is not available (at least for a start).

LIST OF IMPOTENT RAW MATERIALS:
The raw materials for laundry soap making includes:
A. Vegetable oils: High quality grade
i. PKO (mostly used, cheapest)
ii. Palm oil (usually boiled to remove the red colour)
iii. Coconut oil
iv. Animal fat (most expensive). Best for toilet soap
v. Factory fat sludge (fatty acid) can be used in place of P.K.O.

B. Caustic soda and or caustic potash
C. Soda ash, Industrial Grade or Dense.
D. Sodium silicate,(Hard and Glassy)
E. Perfumes, strong and oily like Citronella, Rose, Jasmine etc.
F. Colourants, Clean type (Yellow R, Red G, Green G, Blue, White etc)
G. Sodium Sulphate, Industrial Grade
H. Kaolin, Washed Kaolin (Calcium Carbonate is ok too)
I. Water, Clean and clear.
The selection is usually based on targeted quality. The safest thing to do in purchasing raw materials is buy from reputable suppliers (see list of raw materials dealers or contact the resource person)

EQUIPMENT/TOOLS:
The equipment required includes:
A. A heater: Stove for type under consideration, firewood can also be used as source of heating. Boilers are also needed for big operation.
B. A mixer: Manually operated. This can be ladle and plastic bucket or drum. It can also be automated which will need electricity.
C. Moulds made of wood, plastic or metal. Moulds are also called soap boxes.
D. Cutting Machine: This can be manual or motorized. There is the extruder type, which moulds and stamps the soap. Tableting machine cuts and stamps too.
E. Stamper: Manual or motorized type.








All equipments needed can be locally fabricated at very good cost. There are wooden
F. Hydrometer: To measure SG of solutions
G version cutters and tampers in the market.. Storage tanks: Plastics preferred because it is cheaper than stainless steel. Hand Groves: Nose mask, overalls, Boot, Eye goggles. Caps and other PPEs.
H. Storage racks: This is a storage shelf or table.
I. Working Table: For operations
J. Miscellancous tools as may be needed.

PACKAGING MATERIALS:

Currently laundry soaps are packed cartons both in bars, or tables and in various sizes. There are 30 or 50 pieces in bars and there are 50 to 100 pieces in tables of either 100g or 200g or more. These cartons should be strong, printed in colours if affordable. The cartons should carry:-
(a) Brand name
(b) Manufacturer
(c) Quantity packed
(d) Other sales information
Note that innovativeness is the sole of business. Other packaging materials can also be used to promote sales. For instance, there is a laundry soap that is packed inplastic film now in the market. It looks very beautifull.

PRODUCTION ESTIMATES:

Laundry (Bar) soap
For a production capacity of 20 cartons of 100g each, about the following raw materials will be needed.
(a) 100 litres of PKO @ N12,500.00
(b) 12kg of Caustic soda @ N01,200.00
(c) 8kg of soda ash or sulphate @ N00,400.00
(d) 5kg of sodium silicate @ N00,250.00
(e) 3 sachets of colour @ N00,150.00
(f) 100mls of good perfume @ N00,200.00
(g) Water needed for 12kg of Caustic soda will be about 45 litres(please guage at 1275sg).
Remember to add the cost of water if you buy it for use here.

Note that buying more quantity brings the prices of these items down.
At the present wholesale prices of N1,000.00, N950.00 is recommended. This gives revenue of N19,000.00 minus N14,750.00 (cost of materials) i.e =N3,250.00. This gives approximately 30% gross profit margin. Note that cost of package etc has been deducted. This capacity can be scaled up or down depending on available fund. If you make and sell more soap you will make more money.

Note that 20 cartons can be mixed in 1 hour at a rate of 5 cartons every 15 minutes. Taking 6 effectives working hour a day and 24 working days in a month, N680,000.00 is realizable monthly in this business.

PRODUCTION PROCESS
Caution: Caustic soda is very corrosive to the skin. Handle it and other chemicals with rubber or plastic hand gloves only.

HOW TO MAKE:
1. Caustic soda solution: Measure out as below using a cup or bucket as needed.
Caustic soda 1part
Water 3½ part
Mix and guage with hydrometer at 1275 – 1250. s. g.
This means that to every measure of caustic soda, add 3 and half measure of wateer e.g. 1 cup of caustic soda or 1 bucket of caustic soda to 3½ cups of water or buckets of water.
2. Soda Ash Solution
Soda Ash (Dense) 1 part
Water 3½
Mix and guage with hydrometer at 1275 S.G. following the same procedure and method as in caustic soda above.
3. Sodium Sulphate: (option) sodium sulphate 1 cup, water 3 cups.(no need to guage)

FORMULAR FOR PRODUCTION: (about 1 carton of soap of 100g each)

P.K.O - 2parts or 4litres
Colourant - 1teasoopnful
Caustic soda solution - 1part or 2litres
Soda Ash Solution(and or sulphate) - ½ part or 1litre
Sodium Silicate - 4-5 tablespoonfuls
Perfume (eseetronells) - 2-3 table spoonfuls

SOAP MAKING: SEMI-HOT METHOD.

1. Measure out the oil needed into the mixer, add the colourant and heat or warm. Mix after heating. Note that the oil should not be too hot.
2. Add the caustic soda solution and mix (cover and leave for about 3 minutes if necessary) i.e if reaction does not occur immediately.
3. Add the Soda Ash solution and or sodium sulphate solution and mix.
4. Add all other ingredients at this stage and mix till soap paste is smooth.(about 2 minutes).
5. Transfer into the mould, previously line with nylon and allow to stand for about 8 hours.
6. Remove from the mould into cutting table and cut, then stamp or tablet as required.
7. If full boil method is used soap could be grinded before tabulating (cutting will not be necessary). Full boil is suitable for large scale only.
8. Pack soap as required for sale.
Note keep all solution not used and use them with the new batch of solution. i.e. mix any left over of caustic soda solution with a newly prepared one, guage (at 1275) and use. Same applies to Soda Ash etc. We recommend a batch of not more than 5 cartons at a time at the manual level and leave either oil or the caustic soda cold. And the other just warm to touch (especially for beginners as they gain experienced more can be handle).

Another formulation for 1 carton of soap (100grm each).

P.K.O. - 2parts or 4 litres
Colourant - 1teaspoonful
Caustic soda solution - 1part or 2litres
Soda Ash Solution - ¼ part or 1litre
Kaolin or calcium carbonate - ¼ part or 1kg
Sodium Silicate(optional) - 4-5 tablespoonfull
Perfume - 2-3 tablespoonfull
This batch will yield about 108-110 tables of 100g each. The yield here is more.
Kaolin or calcium carbonate can be increase up to 1 and half kg as desired.
As a small-scale soap production business the semi-hot methods is
recommended.


MAKING SOAP:-
The hot oil is placed in the mixer and the require quantity of colourant is added
and mixed. The kaolin or calcium carbonate is added and mix well. Caustic soda
solution is then added and mixed. The solution thickens. Soda Ash solution
required is also mixed. All other materials are then added and soap paste is
thoroughly mixed to give a smooth paste. The paste is at once poured into the
mould previously lined with polythene sheets.
The moulds are covered and left undisturbed for another 4-6 hours or still the
soap block hardens.
Note: Foaming of soap can be greatly increase by adding one table spoonful of
Sulphonic Acid to every 2 litres of P.K.O. for soap making.

FINISHING THE SOAP:

The soap block in turn is cut in the cutting tables. The tablet or bars are
stamped with stamper and left in the shelf at least 24 hours before they are
packed into cartons for sale. If the cutter and mould are well made there should
be little or no off cut.


HOW TO PRODUCE 20-24 MILK CUP-SIZE OF SODA SOAP (Local soda)
Soda soap:

Oil (Palm or PKO) - 10 litres (10 jugs)
Kaolin or calcium carbonate - 4-5 kg
Caustic soda solution - 5 litres (5 jugs)
Colour (optional) - 1 teaspoonful
Measure out 10litres of PKO or Palm Oil and add kaolin (or others) mixes with 5 litres of caustic soda solution made as above. Note: that colour may also be added if desired. Add colour to the oil before adding soda solution. The mixture is poured into oil coated or polythene line milk cups and allow solidifying for at least 6 hours. The products are carefully removed for sale.

QUALITY TIPS ON RAW MATERIALS:

The following raw materials if not good are usually responsible for poor quality products.
(a) PKO or other oils: Should smell clean odour of the plant seed. Offensive odour indicates rancid (spoilt oil). Taste should not be sour or sweet. Colour should be golden.
(b) Sodium silicate: should be glassy on drying. It should not easily mix with cold water.
(c) Perfume: this should be very oily and heavy. Odour should be very strong and typical. It should last long on touch (or after touch)
(d) Sulphonic acid: use for detergent and some times soap should be hot to touch. It should be foam excessively in water. It has an acidic odour.
(e) Hydrogen peroxide: (for detergents). It should foam in dropping on a sooth or rough surface. It foams in dirty water and turn the skin whitish on contact.

Caution: handle all chemicals with plastic gloves only.


Toilet & Medicated Soaps Formulations


S/N Raw Material Toilet soap Medicated soap
1.
2.
3.
4.
5.
6.
7.
8.
9.
10. Vegetable Oils (eg. P.K.O)
Caustic soda solution (1275/1250)
Soda Ash solution (1275)
Sodium silicate
Glycerin (and or cetyl Alcohol)
Petroleum Jelly
Colorant
Perfumes
Chloroxylenol/or pink oil
Cetrimide/or 1 rgasan 20 parts
10 parts
2 parts
1 part
1 part
1 part
2-3 TSP
2-3 TSP
-
- 20 parts
10 parts
2 parts
1 part
½ part
½ part
2-3 TSP
2-3 TSP
1/8-1/5 part
1/8-1/5 part


Note:

1. Only one antiseptic material such as chloroxylenol, pine oil, 1rgasan, cetrimide, phenol, carbolic Acid, etc can be used up to 0.5% required (in medicated soap).
2. TSP means Tablespoonful.

OTHER SOAP FORMULATION

Medicated Soap

P.K. Oil 20 parts
Caustic Soda Solution 10 parts
Sodium Silicate 2 parts
Carbolic Acid 0.8 part
Colour 2-3 TSP
Perfume 2-3 TSP

Toilet Soap (Alao Vera)

P.K. Oil 20 parts
Caustic Soda Solution 10 parts
Soda Ash 2 parts
Sodium Silicate 1 part
Glycerin/or cetyl/Alcohol 1 part
Alao Vera gel 2 parts
Colour 2-3 TSP
Perfume 2-3 TSP

Processing of Toilet or Medicated Soaps

1. Treat P.K.O. or other oils needed as in the case of laundry nsoap above.
2. Prepare Caustic Soda & Ash solution as in the case of laundry soap above.
3. Mix the Oil with the colour needed.
4. Add caustic soda solution and mix till soap is formed (about 3 minutes)
(If not formed, cover for about 3 minutes)
5. Now add all other remaining ingredients as contained in the particular formular in used and mix to blend well.
6. Pour soap paste into previously prepared mould and leave to harden (about 12 hours)
7. Cut and mould soap from the mould into the desired shape and sizes.

Note: Automatic machines can be used here for modern packaging.
8. Pack soap are required in sachets, packets and cartons for sale.

HOW TO PRODUCE 20-24 MILK CUP – SIZE OF SODA SOAP

1. Caustic Soda Solution
Caustic Soda - 2kg (or 2 plastic Jugs)
Water - 7kg (or 7 plastic jugs)


Mix well and guage at 1275 or a littler less
Note: Jug here refers to 1 litre capacity plastic jug

2. Palm Oil – This should be boiled (If the red colour is not desired) till colour is greatly reduced.

SODA SOAP

Oil (palm or p.k.o.) - 10 litres (10 Jugs)
Caustic Soda Solution - 5 litres (5 Jugs)
Colour (optional) - 1 teaspoonful
Measure out 10 litres of PKO or Palm Oil and mix with 6 litres of caustic soda solution made as above. Add 4-5kg of kaolin or calcium carbonate if it is desired and mix very well to smoothness.
Note that colour may also be added if desired. Add colour to the oil before adding soda solution.
The mixture is poured into oil coated or polythene line milk cups and allow to solidify for at least 12 hours. The products are carefully removed for sale.

SCOURING POWDER
Calcium carbonate - 1 PART
Soda Ash - ¼ part
Powder Soap - ¼ part

Mearsure out these materials and mix thoroughly and pack as desired.

Note: Powder soap can be sodium lauryl sulphate, detergent or others.

PRODUCTION OF CHAIN LUBRICANT AND MOULD RELEASE AGENT

PRODUCTION OF CHAIN LUBRICANT AND MOULD RELEASE AGENT.

INTRODUCTION: These products are used mainly in the manufacturing industry. Chain lubricants are used in bottling companies like breweries, soft drink and pharmaceutical firms where chain conveyors carry bottles. It prevents breakage of glass bottles. Mould release agents are used in plastic metal and other related moulding companies. The agent is used to ensure that the product being moulded does not stick to the mould itself.

RAW MATERIALS:

Chain Lubricant Mould Release Agent

1. Industrial liquid Detergent Pine oil

2. Glycerine Palm kernel oil

3. Sodium silicate (good grade) Mineral oil (Thick)

4. Water Diesel (optional)

5. Colourant (optional) Oil colourant (optional)

6. Propylene Glycol (PPG)

EQUIPMENT / TOOLS:

1. Low speed mixer (or manual mixer).
2. Weighing scale or measuring device (cylinder)
3. Storage Tanks - plastic preferable
4. Filling and sealing machine
5. Miscellaneous tools.

PACKAGING MATERIALS: These are industrial product packaging is in plastic or metal drums of 50 litres, 100 litres or 200 litres, are desirable with appropriate information such as brand name, maker and direction for use.

CHAIN LUBRICANT PRODUCTION:

50 Litres Batch

(a) Industrial liquid Detergent - 10 litres

(b) Sodium silicate (original type - 5 litres

© Glycerine or PPG - 5 litres

(d) Water - 30 litres

TOTAL 50 Litres

PROCESSING METHOD:

The processing is simple. Measure out all the ingredients in the formulation and mix in a manual or motorized mixer. Mixing takes about 30 minutes.

MOULD RELEASE AGENT:

50 LITRES BATCH

(a) Pine Oil - 25 litres

(b) Palm Kernel Oil (PKO) - 10 litres

(c) Thick Mineral Oil - 15 litres

TOTAL 50 Litres




PROCESSING METHOD:

Measure out all the materials in the formulation above and mix in a manual or motorized mixer till mixture is smooth. This will take about 20-30 minutes.

Note: In both case colourant can be added (2 teaspoonfull each) oil type for mould release and water type for chain lubricant.

HOW TO MAKE CUTTING OIL

CUTTING OIL

INTRODUCTION:

Cutting oil is used to lubricate and cool during cutting, filling and sawing. Lathe machines, woodwork machines and other equipment use it in cutting and filling.

RAW MATERIALS:

1. Oleic Acid
2. Spindle oil
3. Potash
4. Butanol
5. TEA
6. Mineral oil etc.



FORMULATION:

Spindle oil 10 parts e.g. 20 litres
Oleic Acid 1.2 parts e.g 2.4 litres
Butanol 0.7 parts e.g 1.4 litres
TEA 0.05 parts e.g. 0.1 litres
Potash 4.5 parts e.g 9.0 KG
TOTAL 16.3 PARTS 32.5 LITRES

EQUIPMENT:

As in penetrating oil or other lubricants

PRODUCTION: Requires good skill.

The oleic acid is first mixed with the potash to form soap. The spindle oil is then added to soften the soap formed. Butanol and TEA are added to blend with the product. This operation takes about 50 minutes for a batch of about 100 litres and less for the batch above (i.e. 32.5 litres).

Quality Parameter:

Test as in penetration oil.

PRODUCTION OF AUTOMATIC TRANSMISSION FLUID

Introduction: ATF is a lubricant in the automation gear system. It is an oily liquid lubricant that comes in reddish or orange colours mainly. There are some in neutral colour. It is packed in plastic and metal cans as required by the major consumers.


USAGE:

Modern cars and other vehicles are fast turning to automatic gear system. The use of ATF will therefore continue to be oon the increase. In Nigeria, presently two out of every four road worthy vehicles are of the automatic gear system. This means that the market here in Nigeria is very big and will continue to grow. Other auto based machines use ATF.

RAW MATERIALS:

1. Neutral oils: These are synthetic base oils used as lubricant and for other purpose. Good ones are polyalphaolefin oil (PAO) and sulfolene.
2. Paraffin oils: They include mineral oil, technical white oil, and transformer oil among others.
3. Fuel oils: they include diesel, kerosene, and white spirit.
4. Glycols: Propylene glycol, glycerin, polyethylene glycol, etc are used as antirust and heat suppressants.
5. Colorant: Oil red, green, orange, yellow, blue can be used.

Equipment & Tools:

1. Low speed mixer (about 300 r.p.m) or manual mixer can also be used
2. Storage tanks of plastic or stainless steel
3. measuring cylinder or other device
4. filling & sealing unit (optional)
5. personal protective equipment (PPE)
6. Other tools like laboratory testing tools etc as affordable.

Packaging Materials:

1. Bottles and jars of ½ litre, 2 litres, 4 litres, 20 litres, etc
2. Labels or prints on bottles
3. Cartons or film laminates.

a. Production Methods

Formulation: 20 litres Batch

A. Synthetic Base oil (e.g sulfolene) 8 litres

Polyalphaolefin oil (PAO) 6 litres

Mineral oil (Technical) 4 litres

Glycerin 2 litres

Red oil colorant ½ tsp or QS
TOTAL 20 litres

Note:

(a) This formulation is a high quality one but it is also expensive. Colour can be other types or optional.
(b) Neutral base oil (e.g. PAO) 10 litres
Mineral oil 8 litres
1 ransformer oil or diesel 2 litres
Colorant (oil type) QS
TOTAL 20 LITRES

(c) Base oil (Neutral) 14 Litres
Diesel 4 litres
D.O.K. 1 ½ Litre
Propylene Glycol ½ litre
Colourant (oil type) Q.S.
TOTAL 20 LITRES

Note: D.O.K. means deodorized kerosene. In cheaper formulation, propylene glycol can be omitted to reduce the cost. However, the quality is also reduce. Formulation (A) is better than (B) and B is also better than (C). tsp means teaspoonful, while TSP means tablespoonful. If PAO is replaced with petrochemical base oil, a good and cheap local version of ATF is obtained as in C.

(B) Processing

The processing method is very easy. The materials needed are measured out and mixed in a stainless or plastic tank. The speed should not be higher than 300 r.p.m. the mixing may take about 10-20 minutes if the quantity is between 20 litres and 500 litres. Higher quantity may just take a little more time. The well mixed product is packed as desired by the market.

© Quality Parameters

Product should meet API and SAE specifications. These includes 20 – 39 sec. in Zham. No. 4. Flash point not below 660C. Boiling point, not below 2120C.

The product should be able to reduce operating temperature extend bearing and bushing life span and inhibit corrosion.

HOW TO MAKE PENETRATING OIL

PENETRATING OIL

INTRODUCTION:

This is a lubricant formulated for lubricating joints, contact point, movable contacts etc. it is used in the industries as well as workshops and other working places where machines and equipment are in factories.

RAW MATERIALS:

1. Acetic Acid
2. Gasoline oil
3. Minerals oil
4. Carbon Tetrachloride
5. Kerosene
6. Amyl Acetate
7. Vegetable oil etc.
EQUIPMENT:

1. Weighing scale or measuring device
2. Mixer-manual or motorized
3. Filling Device
4. Others as required

FORMULATIONS:

1. Carbon Tetrachloride - 2 parts e.g. 10 litres
Acetic Acid - 1 part e.g. 5 litres
Gasoline oil - 2 parts e.g. 10 litres
Mineral oil - 4 parts e.g. 20 litres
TOTAL 45 litres

2. Mineral oil - 1 parte.g. 10 litres
Kerosine - 1 part e.g. 10 litres
Amyl Acetate - 1.5 parts e.g 15 litres
TOTAL 3.5 parts 35 litres

PRODUCTION:- Measure out all the ingredients and mix according to the formulation in a speed or manual mixer for about 30 minutes.

Quality parameters:

Compare with a standard in the market or test in an approved quality assurance laboratory.

PRODUCTION OF RADIATOR COOLANT

PRODUCTION OF RADIATOR COOLANT

FORMULATIONS:

1. Sodium Tripolyphosphate (STPP) 12-13 parts (kg)
Sodium Chromate (or Dichromate) 0.3-0.5 parts (kg)
Water (Distilled or others) 87-88 kg or litres
TOTAL 100 LITRES

2. Soda Ash (light) 3.5 parts (kg)
Sodium Dichromate 6.5 parts(kg)
Water (Distilled) or others 90parts(kg) or litres
TOTAL 100 LITRES

3. Propylene Glycol 35-40 parts (litres)
Water Distilled 55-60 parts (litres)
Colour (Green) 1-2 TSP or Required
TOTAL 100 LITRES

Note: T.S.P. Means Table Spoonful.

Equipment & tools:- see Brake fluid section.
Simple equipment and tools are needed for the production of brake fluids. These are:

(a) Low Speed Manual or Motorized Mixers (100 – 200 Rpm)
(b) Weighing and Measuring Devices
(c) Storage Tanks (stainless types)
(d) Filtration Unit (optional)
(e) Filling and Packaging Units
(f) Laboratory Tools for Measuring and testing quality parameters such as viscosity, flash point, and other good lubricant properties.
(g) Personal protective gadgets such as boots, overall, gloves, mask, respirators caps, goggles etc.

These items can be sourced locally or abroad.


PRODUCTION METHOD

Do a careful selection of the recipe to use, based on availability of raw materials, ease of processing, cost of production (profit margin) and end users requirement. Now measure (weigh) out all the selected raw materials in separate containers. Share the water needed into two unequal parts. Put the sodium salt (e,g. STPP or others) with the largest proportion into the lager part of water and dissolve the smaller sodium salt(e,g Sodium Chromate or other Chromates) in the smaller part of water and mix well.

Now mix the two solutions and add color if desired to the level required.

Note: For Formulation no. 3 measure the two components and mix them and add the colourant and Mix well and pack. Mixing for 100 litres should take about 20-30 minutes in all.

Formulation No. 3 is the modern type.

Quality parameters:

1. The product should mix easily with water
2. It should not separate out on heating
3. It should resist temperature up to a difference of 10-200C
4. It should be clear on standing
5. It should not cause rusting
6. The product must not disrupt radiator performance.

Note: Where there are no resources for quality control contact this aspect to a Public Analyst.

BRAKE/CLUTCH FLUID PRODUCTION-AUTOMATIC TRANSMISSION FLUID

BRAKE/CLUTCH FLUID PRODUCTION

Introduction: Brake/Clutch fluid is a liquid lubricant used as a transmission fluid (liquid) in the vehicle brake and clutch systems. The product is designed to reduce friction, prevent rust, and freezing in the areas of its application. The standard ones include DOT 3 and DOT 4 which are varying viscosities as determined by Society for Automobile Engineers (SAE) and the American Petroleum Institute (API). DOT 3 is more fluid than DOT 4. These brake fluids must not spoil the rubber components of the brake system.

RAW MATERIALS REQUIREMENTS

1. Vegetable Oils: These includes Castor Oil, Olive Oil, Coconut Oil, Groundnut Oil, and other Vegetable Oils as long as they are refined. Oils provides lubricant and anti-rust properties of the brake fluid.
2. Glycols: Dioxitol, Methly proxitol, Butyl Oxitol, Polyethylene Glycol (PEG) etc.
3. Diacetoalcohol: They are sometimes used in place of Glycol. The ability of brake fluid to clean off common paints depends on the type of glycol used.

EQUIPMENT/TOOLS REQUIREMENTS

Simple equipment and tools are needed for the production of brake fluids. These are:

(a) Low Speed Manual or Motorized Mixers (100 – 200 Rpm)
(b) Weighing and Measuring Devices
(c) Storage Tanks (stainless types)
(d) Filtration Unit (optional)
(e) Filling and Packaging Units
(f) Laboratory Tools for Measuring and testing quality parameters such as viscosity, flash point, and other good lubricant properties.
(g) Personal protective gadgets such as boots, overall, gloves, mask, respirators caps, goggles etc.

These items can be sourced locally or abroad.

PACKAGING REQUIREMENTS:

Brake fluid can be packed in metal or good (chemical resistant) plastic bottles and jars. The containers can be 250mls, 500mls, 1000mls or 5 litres depending on the market requirements. They can also be supplied to big users in 200litres drums. Small packs are put in cartons. All containers should carry good labels and appropriate instructions.


PRODUCTION METHODS

(a) Formulations: A good brake/clutch fluid can be obtained following a good formulation and a careful selection of good raw materials. however, each formulation must consider.
(b) Availability of raw materials needed.
(c) Cost of production
(d) Ease of processing
(e) End users requirement (Quality)

STANDARD FORMULATIOINS (100 LITRES BATCH 100 LITRES BELOW

1. Dioxitol or Methyl Proxitol 7-8 parts (litres) 75 litres
Polyethylene Glycol 2-3 parts (litres) 25 litres
TOTAL 10 LITRES 100 LITRES

2. Methyl Proxitol 6-7 parts (litres) 65 litres
Pure Vegetable Oil (eg Castor oil) 3-4 parts (litres) 35 litres
TOTAL 10 LITRES 100 LITRES

3. Butyl Oxitol of DAA 3-4 parts (litres) 35 litres
Polyethylene Glycol 3-4 parts (litres) 35 litres
Refined vegetable oil (eg Groundnut Oil 3-4 parts (litres) 30 litres
TOTAL 10 LITRES 100 LITRES

Note: Choose the formulation that meets yourn clients expectation as long as the raw materials are readily available.

(b) Processing: The production of brake fluid is simple. Following the chosen formulation, measure out the raw materials into a stainless mixing tank and mix for about five – ten minutes if the batch is up to 200 litres. More quantity can be mixed for a little longer. When homogenous the fluid is subjected to various quality tests before they are packed in the appropriate containers as desired for sale. It may be necessary to filter if there are particles using a fine mesh.

Note: some local manufacturers simply pack any of these glycols directly as brake fluid. E.g Polyproplyene glycol.

© QUALITY PARAMETER
Viscosity: Compare with an existing standard or comply to your clients specifications.
Strength: Very oily and should not dry up a metal surface within five minutes, Quality control can be contracted to a Public Analyst where the resources for quality
control is not available.

ENGINE OIL PRODUCTION--MODERN LUBRICANTS TECHNOLOGY

ENGINE OIL PRODUCTION

INTRODUCTION: Engine oil or motor engine oil is a liquid lubricant used to oil (lubricate) heat engines. Auto engines of two stroke or multiple stroke use different grades of engine oil depending on the requirements of the cylinders and other components of the particular engine chamber.

Engine oil comes in viscose liquids of transparent to golden, yellowish or greenish to reddish colour. They are mainly base on synthetic or petroleum derived oils. Hence motor engine oil is oil with specific additives for specialized functions. Engine oil is used in all types of petrol and diesel engines.

The synthetic engine oil is fast replacing the petroleum Base oil especially for multi grade engine oils.

RAM MATERIALS

The major raw material for engine oil:

(1) BASE OIL or SYNTETIC OILS: such as polyalphaoliphene(PAO) and sulpholene. The other additives include:-
(2) Oxidation & corrosion inhibitors: Zinc Dialkyl-dithiophosphate and zinc-Di-iso-octyldithio-phosphate combine the antirust, oxidation and corrosion properties of zinc and phosphorus in this regard. There are ready made packs in the market that requires just about 5-6% dosage in the engine oil production.
(3) Viscosity index improvers: These materials keep the viscosity in a stable form even at extreme high or low temperatures. Ethylene-propylene copolymer(EMP) is one of the most efficient. They are also regarded as Thickeners here.
(4) Extreme pressure Additives: Chlorinated-paraffin-Di-n- butyl phosphoric Acid and Trycresyl-phosphate are good ones. They keep the oil intact at extreme pressures.
(5) Antifoams: Methyl silicon oil.
(6) Detergents: calcium sulphonate helps to cleans foreign dirt that find their way into the engine chambers.
(7) Dispersants: They ensure that all ingredients mix properly and stay homogeneous. Polyisobutylene-succimide and Alkyl sucimide are in use.
(8) Pour point Depressant: Alky naphthalene, polyAlpha olefin and polymethacrylate are used separately. They reduce free flow of the oil in plane language.
(9) Oiliness Additives: pulverized olefin, cotton seed oil and benzotriazole are used.
(10) Others are metal passivator, emulsion inhibitor etc. NN-disalicy lidene-propyl-diamine (metal passivator) and Amine epoxide condensate (emulsion inhibitor) are available.
(11) Colorants are optional but where needed, oil green red, yellow, etc are used.


Note: There is an all purpose oil additive pack that is in the market which requires that 5.4-11% of it is used and you would have added “all” the needed additives in that batch of production. It is called lubricant Addition single base, available from: www proschem. Com

Equipment/Tools

1. Mixer:- This can be manual or automated with stainless steel tanks (150-300rpm)
2. Storage Tanks:- Various types and stainless.
3. Weighing scale and measuring Cylinders.
4. Boiler kettle:- Stainless Tank heated directly or indirectly using conventional fuels and others. The boiler can be fitted with a lw speed mixer of about 150-500rpm
5. filling & Packaging Units: this can be manual or automated.
6. Personal productive equipment such as Respirators, Eye goggles, Caps, Hand gloves, Boots etc
7. Clay Treatment Tank fitted with heating coil(optional).
8. Laboratory Tools like Viscosity Cup, Flash Point Apparatus, Friction
Tester Pour Point Apparatus
9. Filtration unit-filter press
10. Cooling/Condenser unit (As required)


PACKAGING MATERIALS

2 Liters, 4 Liters, 20 Liters and higher plastic or metal container in use. These containers will carry labels containing.

• Band Name
• Manufacturer
• Date and Batch Numbers
• Other useful instructions.

Smaller 2 litres and 4 litres can be packed in cartons.

Space:- A capacity of 200 litres per day (i.e 1 ton per week) will require about two to three standard rooms depending on the size of the rooms, smaller scale will need smaller space. The bigger the scale the bigger the space that will be required.

Labour:- One person can produce 200 to 1000litres per day. If only blending is involved there may be used for other staff as sales and secretary ship. Where production starts from refining base oil, 2-3 people will be needed to produce 1000-2000 litres but cost of production will lower as cheaper material will be used.

QUALITIES OF A GOOD LUBRICANT (ENGINE OIL)


1. It must reduce friction between two moving surfaces to the least minimum.
2. It must reduce wear of asperities (peaks) of surface that are in motion.
3. It must provide continuous fluid film between two surfaces
4. It must act as a cooling medium
5. It must act as a sealing agent
6. It must prevent corrosion
7. It must have a low pour pressure (i.e. must resist high pressure)
8. It must resist high temperature
9. It must maintain adequate viscosity for the particular service condition
10. It must have low freezing point
11. It must resist high oxidation
12. It must have a high boiling point.

QUALITY MEASUREMENTS INSTRUMENT FOR LUBRICANTS.

1. Viscosity:- Zhan Cup, Viscosity
2. Flash Point:- Pensky marten’s apparatus
3. Pour Point:- Pour Point apparatus
4. Emulsification:- Chemical Tests
5. Volatility:- Vapourmeter
6. Specific Gravity:- API Instrument
7. Viscosity Index (i.e. low variation of viscosity with temperature): viscometer.



IMPORTANT STANDARD SPECIFICATIONS

Most engine oil standard specification are tailored to meet the following standardization agencies namely:-

Society for Automobile Engineers - SAE
American Petroleum Institue - API
Other agencies are available but most of the manufactures follow SAE and API because they have been there for long.

General Specifications

(1) Regular Oil - Straight Minerals Oils
(2) Premium Oil - Contains oxidation Inhibitor
(3) Heavy Duty Oil - Contains Oxidation Inhibitor and Detergents
(4) Multigrade Oil - A Hybird of Oils that can:-

(a) Resist Heat - May contain Silicone etc
(b) Resist Pressure - May contain Silicone etc
© Anti-Rust - May contain Glycol etc
(d) Anti-Foaming - May contain no Vegetable Oil
(e) Resist Oxidation - May contain no Vegetable Oil
(f) Resist Sludge formation - May contain detergent
(g) Anti-Freeze - May contain Glycols etc

They include the following:-

SAE10W-20

SAE10W-30

SAE10W-40

PRODUCTION PROCESSES:

1. Base Oil Based Engine Oil: If petroleum type base oil is to be used it will
be necessary to test the water, wax, other impurities before it is used for blending engine oil as it is called.

The process of removing unwanted water, wax and other impurities is called base refining.

Step 1: The oil is (say 100 litres) is placed in the clay treatment tank and 4-5kg of clay is mixed with it and heated to about 2500C by the heating coil. At 1000C the water content evaporates and at 2500C to 3000C, the oil vaporizes and it is condensed with a condenser and collected in a clean tank. The collected oil is filtered in a fitter press after cooling.

Oil can also be filtered after boiling without condensation.

Note: This type of purified Base Oil is also available from the major oil marketing companies and can be used directly as below:

Step 2: Refined base oil from above is blended as contained in the formulations below:

Standard Engine Oil Formulations

1. Regular Grade: 100 liters Batch
Base Oil - - - - 81 liters
Lubricant Additive Compound - - 4.5 liters
Polyalphaolefin (optional) - - 4.5 Liters
TOTAL 100 Litres

2. Premium Grade: 100 litres Batch
Base Oil - - 80-81 litres
Cotton seed oil (Refined) - - 4 – 5 litres
Oxidation & Corrosion inhibitor - 4 – 5 litres
Viscosity index improver - - 1.5 – 2 litres
Calcium Sulphonate - - 0.5-1 litre
Trycresylphosphate - - 0.5-1 litre
Dispersant - - 0.5-1 litres
Polyalphaoletin (optional) - - 4.0 litres
Colorant (optional) - - 1 -2 TSP
TOTAL 100 Litres


Add 3-4% (i.e 3-4 litres o9f Extreme pressure additive for Heavy Duty (HD) grade.

SYNTHETIC ENGINE OIL

3. Multigrade: 100 litres Batch
Note: Multigrade engine oil should be PAO or sulpholene synthetics oil.
A 50:50 blend of PAO and Base oil is also in use.
P.A.O. (or Sulpholene) - 90 litres
Zinc-D-Dithiophosphate - 5 litres
Lubricant Oil Additive - 5 litres
Colorant (optional) - 1-2 TSP
TOTAL 100 litres

Note: Colorant can be oil soluble Green, Red, Yellow Etc.

(d) Processing

Measure out all the ingredients as contained in the formulation and mix in
Stainless tank mixer of medium or low speed. The Thickener may be added last. When homogenous check for Clearity, Viscosity and pack. If notr clear allow to stand for about 1 hour and filter if necessary through a filter press.

Note:

1. To obtain SAE 10W – 40, the viscosity of SAE 10W-20 can simply be raised by using PAO or more synthetic oils. The later will be preferable.
2. Thickeners like polystyrene or other compounds like ethyl acetate .
3. TSP means table spoon full (5 mls) while tsp means teaspoon full (2 ½ mls). ½ litre is 500 mls, ¼ litre is 250 mls, 1/8 litre is 125 mls and 1 litre is 1000mls.
4. Q.S. means sufficient quantity (as required)
5. Materials may be varied according to specific requirements.
6. To make 10 litres of oil divide all inputs by 10.

QUALITY PARAMETERS

1. Viscosity - should meet standard as expected
2. Clearity - clear not turbid
3. Lubrication - should prevent friction as expected
4. Oiliness - should not dry fast or skin
5. Anti Rust - should resist rusting

Note: Synthetic Engine Oil (Multigrade) meets all these parameter. More quality control can be contracted to an expert like a public analyst.




Quick test methods

How to test for water in oil.

Take about 10mls of Base or other oils that is clear in a conical flask observe the colour and note it. Add ½ to 1tsp of white copper sulphate salt into the oil and shake well for about 1 minute.

Result: If a blue colour is observed, water is in the oil.

HOW TO TEST FOR WAX IN BASE OIL

Place 10mls of base oil in a container like conical flask and cover well. Put the container into the freezer and freeze to about 200C. if wax is present it will start forming solids.

Note: Avoid using base oils with a lot of wax content. Above 5% is not ok.

AUTOMATIC TRANSMISSION FLUID-GEAR OIL

GEAR OIL PRODUCTION

RAW MATERIALS:

(a) Base oil: e.g. PAO, Sulpholene, petroleum base oil, etc.
(b) Lubricant Additive compound
(c) Cotton seed oil (Refined)
(d) Calcium Sulphonate – Dispersant/Detergent
(e) Pricresyl phosphate
(f) Zinc dialkyl-Dithio phosphate
(g) Ethylene-propylene copolymer (EPM)
(h) Amine Epoxide condensate
(i) Others as may be required.

B. EQUIPMENT/TOOLS (As in other lubricants like Engine oil)

1.Mixer:- This can be manual or automated with stainless steel tanks (150-300rpm)

2. Storage Tanks:- Various types and stainless.
3. Weighing scale and measuring Cylinders.
4. Boiler kettle:- Stainless Tank heated directly or indirectly using conventional fuels and others. The boiler can be fitted with a lw speed mixer of about 150-500rpm
5. filling & Packaging Units: this can be manual or automated.
6. Personal productive equipment such as Respirators, Eye goggles, Caps, Hand gloves, Boots etc
7. Clay Treatment Tank fitted with heating coil(optional).
8. Laboratory Tools like Viscosity Cup, Flash Point Apparatus, Friction
Tester Pour Point Apparatus
9. Filtration unit-filter press
10. Cooling/Condenser unit (As required)



C. PACKAGING MATERIALS (As in Engine oil)
2 Liters, 4 Liters, 20 Liters and higher plastic or metal container in use. These containers will carry labels containing.

• Band Name
• Manufacturer
• Date and Batch Numbers
• Other useful instructions.

Smaller 2 litres and 4 litres can be packed in cartons.

Space:- A capacity of 200 litres per day (i.e 1 ton per week) will require about two to three standard rooms depending on the size of the rooms, smaller scale will need smaller space. The bigger the scale the bigger the space that will be required.

Labour:- One person can produce 200 to 1000litres per day. If only blending is involved there may be used for other staff as sales and secretary ship. Where production starts from refining base oil, 2-3 people will be needed to produce 1000-2000 litres but cost of production will lower as cheaper material will be used.


PRODUCTION METHOD:

50 LITRES BATCH

(a) Synthetic Base Oil (PAO) - 40 litres

Zinc-D-Dithio phosphate - 4 litres

Ethylene-propylene copolymer - 1 litre

Tricresyl phosphate - 4 litres

Calcium sulphonate - 1 litre

Colourant (optional) - 1 TSP

TOTAL - 50 LITRES

(b) Petroleum Base Oil - 30 litres

PAO (Synthetic Oil) - 10 litres

Lubricant Additive compound - 5 litres
Thick mineral oil - 5 litres

TOTAL 50 LITRES

Note: Formulation (a) is superior to formulation (b) but also more expensive.

PROCESSING: Following any of the formulations, the materials are measured out into the low speed mixer and mixed for about 20-30 minutes. The product is checked for quality snd packed for use. Manual mixer can also be use to make up to 500 litres.

HOW TO MAKE OR HOW TO PRODUCE ANYTHING

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