Submitted To: Submitted By:

Mr Gyaneshwar Singh Cdt. Nitin

PGT- Chemistry Sch. No. : 5825
Class/Sec : XII-B

SESSION 2024-25

INVESTIGATORY FILE
 PURPOSE OF THE DOCUMENT

This particular pre-feasibility is regarding Detergent Powder making

Unit.

The objective of the pre-feasibility report is primarily to

facilitate potential entrepreneurs in project identification for
investment and in order to serve his objective; the document
covers various aspects of the project concept development,
start-up, marketing, finance and management.

[We can modify the project capacity and project cost as per
your requirement. We can also prepare project report on any
subject as per your requirement.]
 Introduction

Synthetic detergents occupy a vital place in the present age

particularly when the modern society is constantly looking for
quick, effective and economic cleaning agents. Synthetic
detergents emerged as a regular industry after Second World
War only. The development of this industry is closely linked
with Petro-chemical industry which forms the basic for its raw
materials. Detergents when dissolved in water acquire better
cleaning properties and hence facilitate easy removal of dirt &
dust and grease etc.

Apart from their use in clothes washing, detergents also have

applications in the following industries.

1. In industry, in laundry and dry cleaning.

2. In textile processing, grain milling, metal plating and foods
canning.
3. In dairy foods and beverages processing and in restaurants.
4. In plant maintenance and industrial house-keeping.

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 Major Application of Detergents
Synthetic detergents are preferred to soaps on account of economy and efficiency. Unlike soaps
synthetic detergents remain un effected by the presence of natural lime and magnesium salts in
water and maintain cleaning properties in hard water with practically no wastage. Therefore these
are more economical.

Synthetic detergents available in the market are used for washing cloth cotton linen and other
fabrics. Liquid detergents are also sold for the purpose of dish washing and cleaning floors
industrial use in textiles, and commercial buildings, hospitals, and hotels, similarly railway
coaches, road vehicles, aircrafts, milk bottling plants and food preservation equipment are washed
with the help of detergents.

Textile industry is one of the largest consumers of synthetic detergents. In the processing stage the
cotton, rayon and synthetic fibers are scoured wetted with chemical detergents. They are used as
dyeing and finishing operations and also in the printing trade in woolen textile industry.
Detergents are used in the scouring operations of raw material, yarn and woven fabrics.

In paper industry detergents are used as wetting agents to facilitate the pulp making operations.
Detergents are used in degreasing of rags, in pretreatment in the electroplating and galvanizing
process, for wetting of ores, and mineral extraction.

In scouring of leather, detergents are employed to impart softening and penetrating properties
to the leathers. In rubber industry, detergents are used as wetting and dispersing agents and as
lubricants.

Synthetic detergents are regularly used for cleaning equipment, packing containers employed in
the food processing industry, in brewing and wine making industry. In brewing and
wine making industry, the process cleaning and sterilization of vats, still and bottles is
facilitated by detergents.

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 Market Potential.
According to India Detergent Market Outlook, 2024, the overall market for detergent is growing with a
CAGR of 13.06% from the last five years.

Detergents are available in three forms, namely powder detergent, bar detergent and liquid detergent.
Powder detergents are widely accepted by Indian consumers and dominate the industry. Even though
detergent bars are still used in rural areas, they are fast disappearing from the market because of
ineffectiveness.

The detergent industry in India is mostly captured by organized players, but unorganized regional players
have a significant hold on the rural areas. HUL, Rohit Surfactants, P&G, Nirma and Jyothy Laboratories
are the major players in the organized market. They have popular brands like Ghari, Surf Excel, Active
Wheel, Rin, Tide, Nirma, Ariel, Mr. White and Henko in their product portfolio.

On the basis of pricing, the organized detergent market can be further divided into three categories, such as
popular (economy), mid-range and premium. The popular category consists of brands like Ghari, Nirma
and Wheel; the mid-range category consists of Tide, Rin and Mr. White; and the premium category
includes Surf Excel, Henko and Ariel. Hindustan Unilever dominates the high- priced premium and mid-
range category, whereas Ghari dominates the low-priced popular category.

Detergent Powder Making Formula

Different companies have their own customized formula. In addition, you have to craft the formula
according to your target market demographic. However, a basic formula with the ingredients in
percentage for ready reference is.

Ingredients Premium grade (Wt, %) Popular grade (Wt, %)

85% active LAB acid slurry 18 15

Sodium carbonate (soda ash) 35 32

Sodium metasilicate 2 No

Alkaline sodium silicate No 7

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Sodium bicarbonate 10 10

Sodium Sulphate (anhydrous) 20 25

Sodium tripolyphosphate 10 7

Sodium carboxy methyl cellulose 1.5 1

Phthalocyanine blue color or
oil- soluble yellow colour 0.1 0.1

Optical whitener 0.3 0.2

Perfume 0.1 0.1

Detergent powder manufacturing Process.

Although there are three ways of manufacturing dry detergent, only two are commonly used
today. In the blender process favored by smaller companies, the ingredients are mixed in
large vats before being packaged. The second commonly used method of production is called
the agglomeration process. Unlike the blender process, it is continuous, which makes it the
choice of very large detergent manufacturers. In the third method, dry ingredients are blended in
water before being dried with hot air. Although the resulting product is of high quality, the fuel
costs and engineering problems associated with venting, reheating, and reusing the air have led
to this method being largely replaced by agglomeration.

The blender process

First, ingredients are loaded into one of two machines: a tumbling blender or a ribbon blender.
The tumbling blender, shaped like a rectangular box, is turned and shaken from outside by a
machine, while the ribbon blender is a cylinder fitted with blades to scrape and mix the
ingredients. After the ingredients inside the blender have been mixed, a doorway at the bottom
of the bowl is opened. With the blender still agitating the ingredients, the mix is allowed to run
out onto a conveyor belt or other channeling device. The belt then moves the detergent to another
area of the factory where it can be dropped into boxes or cartons for delivery to wholesalers or

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distributors.

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The agglomeration process
In this method, dry ingredients for a detergent are first fed into a large machine known as a
Shuggi agglomerator (Shuggi is the manufacturer). Inside the agglomerator, sharp, whirling
blades mix the material to a fine consistency; the process resembles food being textured inside a
food processor.

After the dry ingredients have been blended, liquid ingredients are sprayed on the dry mix through
nozzles fitted into the agglomerator's walls. The blending continues, causing an exothermic (heat-
producing) reaction to occur. The resulting mixture is a hot, viscous liquid similar to gelatin that
hasn't hardened.

Next, the liquid is allowed to flow out of the agglomerator. As it leaves the machine, it collects on
a drying belt where its own heat, exposure to air, and hot air blowers render it friable—easy to
crush or crumble. The newly made detergent is then pulverized and pushed through sizing screens
that ensure that no large lumps of unmixed product go out to the market. The result of this process
is a dry detergent made up of granules of the mixed detergent.

The slurry method

In this process, ingredients are dissolved in water to create a slurry. With a pump, the slurry is
blown through nozzles inside the top of a cone shaped container as hot, dry air is simultaneously
forced into the bottom of the cone. As the slurry dries, "beads" of dry detergent fall to the bottom
of the cone, where they can be collected for packaging.

Liquid detergent

If the detergent is to be liquid rather than powder, it is simply mixed back in—after all ingredients
are blended—with a solution consisting of water and various chemicals known as solubilizers.
The solubilizers help the water and detergent blend together more fully and evenly.

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Detail of raw material used in manufacturing of
detergents.
Major raw materials used in the making of detergent powder are :- Soda ash, Carboxy methyl
chloride, sodium perborate, lather forming chemical, colours and perfume. Following is the utility of
the given ingredients.

Soda ash (Sodium carborate)

Soda ash depresses acid bleary and makes the washing process alkaline. moreover, soda ash
is a low priced salt to break the dirt.

Carboxy methyl chloride (cellulose)

This prevents the dirt from resettling on the surface of the cloth and is particularly useful
for cotton clothes.

Sodium perborate

This acts as a high bleach and also retains the colours of the clothes. In addition it also
breaks up the dirt particles.

Perfume

Perfumes and aromatic mixture are used in detergent to subside the intense smell of
detergent ingredients. Major perfumes used in detergent powders are P Methoxy, P Methyle,
Di-Oxide, Musk Ketone etc.

Colour.

Instead of white, coloured detergents are the preferred ones. Majorly, copper
phthalocyamine is used for this purpose because it also blocks light and temperature.

Lather producing chemical

This chemical is required to produce lather and also enhances the cleaning capacity of the
detergent.
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Detergent Making Machines.

Detergent manufacturing machines include systems and equipment that can be used to produce
detergents in various forms of powder, liquid and gel.
With advancements in technology, the manufacturing techniques have changed a lot and a variety of
sophisticated machines are available to produce effective detergents for different cleaning
applications.

Some of the common detergent making machines used in the industry is -

 Detergent Cake Making Plant

 Detergent Mixing Machine
 Rotary Sealing Machine.

Design

Machines for detergent manufacturing are designed keeping the various operations, processes and
stages of soap manufacturing in mind. For example, a detergent making machine should support the
batch as well as continuous processes of detergent manufacturing. Some of the salient features that
should be there in a detergent making machine are -

 Easy to operate and maintain

 Sturdy design
 Durable
 Efficiently supports that different functions of detergent making
 Less power consumption.

Buying Tips - Detergent making Machines

While buying a detergent making machine, it is important that one has to know his requirement, so
that one can purchase a right machine for your specific need. Different types of machines are
available in industry that designed for manufacturing a particular type of detergent like powder
detergent manufacturing machine, liquid detergent machine, etc. Hence it important that one buys a
machine as per one's need. Generally one should prefer a machine with a sturdy and robust
structure as durability is the most important factor.

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Detergent Powder Manufacturing License & Registration

 First of all, determination of form of business. And accordingly, register the business.

 Apply for the Trade License from the Municipal Authority.

 Additionally, apply for MSME Udyog Aadhaar online registration.

 Apply for the ‘Consent to Establish’ from the Pollution Control Board.

 Obtain the GST registration.

 Apply for BIS certification.

 Choice of a brand name of the product and secure the name with Trademark

Implementation Schedule

The project can be implemented in 3 months' time as detailed below:

Sr. No. Activity Time Required

(in months)
1 Acquisition of premises 1
2 Construction (if applicable)
3 Procurement & installation of Plant & Machinery 1
4 Arrangement of Finance 1
5 Recruitment of required manpower 1
Total time required (some activities shall run concurrently) 3

Quality Control & Standards

In order to manufacture good quality detergent, it is utmost urgent to purchase good quality of
raw material from only the established and renowned suppliers. Before putting the raw material
into operation all those has got to be tested for their chemical properties at the gate testing
facilities and after the finished product. Quality means the producer has to satisfy the desire and
urge of uses. Keeping in view the demand of people from quality point of view it is necessary to
adopt better technique of manufacturing and good quality of raw material. To manufacture a
detergent of good quality, specific BIS standard can be followed

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 Pollution Control

There might be some pollution in the manufacturing of detergent powder. However, the producer
is advised to adopt and follow the prescribed norms by the pollution control board. Before
switching over to manufacturing, NOC from the concerned State Authority is very much required in
this case. To minimize the pollution some control measures and monitors can be installed.

Energy Conservation

To conserve the energy required thickness of vessels should be taken. Only necessary
machinery and equipment and jig jags should be purchased. Proper space is given to proper flow
for manufacturing raw material and finished products. Control is maintained over consumption of
electricity light and fuel so that extravagance expenditure can be checked.

Project Financials
Basis & Presumptions:
The basis for calculation of production capacity has been taken of single shift basis, working of 25 days per
Month on 75% efficiency.

The maximum capacity utilization on single shift basis for 300 days a year.

Interest rate for Fixed and Working capital of the project has been taken at an average rate of 12 %

Land and Building is owned and Cost of Plant and Machinery has been taken as per prices
Prevailing in the market.

The wages for skilled workers are taken as per prevailing rates in this type of industry.

The essential production machinery and test equipment required for the project have been indicated.

The unit can achieve its full capacity utilization during the 2nd year of operation.

Financial Assistance required from Bank/ Financial Institutions :

Term Loan : 476,000.00
Working Capital : 950,000.00

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CERTIFICATE:
I Nitin Jaat student of XII-B of ,hereby certify that the
investigatory project "Manufacturing of toilet soap"is an
authentic and original piece of work undertaken by me. This
project has been completed as part of the academic requirements
for the subject Chemistry.I confirm that the information and
content presented in this project are based on my own research
and understanding, and all references and sources used have
been duly acknowledged in the project.

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ACKNOWLEDGEMENT:
I would like to express my sincere gratitude to all those who
supported and guided me throughout the course of my
investigatory project on "Manufacturing of detergent and its
uses"
Firstly, I would like to extend my heartfelt thanks to Mr.
Gyaneshwar Singh, my project guide, for their invaluable
guidance, constant encouragement, and constructive
suggestions, which helped me in the successful completion of
this project. Their expertise and insights provided a solid
foundation for my research and helped me deepen my
understanding of the topic.
Last but not least, I would like to acknow-ledge the various
authors, researchers, and institutions whose work and
publications were instrumental in completing this project.
Thank you all for your unwavering support.
THANK
YOU