JP2012184295A - Production method of soap - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for producing soap in a cold process in a shorter time than by a conventional method.SOLUTION: The production method of soap includes steps of: preparing an emulsified product 15 by mixing fat and oil 11 with an alkali 12; filling a package container 16 with the emulsified product 15 while the emulsified product 15 is in a fluid state; and saponifying the emulsified product 15 in the package container 16. A heat insulating container is preferably used as the package container 16. The emulsified product 15 is preferably prepared at 60°C or lower. After the package container 16 is filled with the emulsified product 15, the package container 16 is preferably sealed.

Description

  The present invention relates to a method for manufacturing soap.

  The mainstream of soap manufacturing technology using the saponification method is a so-called hot process, and this process is widely industrialized. In the hot process, saponification is performed while mixing oil and fat and alkali, and salting out is performed by adding saline to a mixture of soap and glycerin generated by saponification. As a result, glycerin is separated, and only soap is extracted to obtain high-quality soap. Therefore, industrially made soap does not contain glycerin. On the other hand, in a soap manufacturing method called a so-called cold process, heat more than necessary is not applied during saponification. Moreover, since the mixture produced by saponification is solidified as soap as it is, the soap is in a state containing glycerin, a fat-soluble vitamin and the like as a moisturizing component. Thus, since the soap obtained by the cold process is gentle to the skin, it has been put on the market as a relatively high-grade product in recent years.

  FIG. 2 schematically shows a soap manufacturing process by a cold process. As shown in FIG. 2 (a), in the cold process, firstly, fats and oils and sodium hydroxide aqueous solution are put into the saponification vessel 100 and stirred until the saponification reaction is completed. Next, as shown in FIG.2 (b), the produced | generated saponified material is poured into the mold 101, and the saponified material is solidified by molding and cooling. Since soap containing a lot of moisture is soft and cannot be removed from the mold 101, it is necessary to remove the moisture. It takes several to tens of days to remove moisture. When soap is obtained by removing moisture, the soap is removed from the mold 101 and cut into a desired size as shown in FIG. The cut individual soap 102 is dried at room temperature to remove moisture as shown in FIG. Finally, as shown in FIG. 2 (e), the soap 102 is packaged to obtain a final product.

  However, in the conventional cold process, the viscosity of the reaction product gradually increases with the progress of the saponification reaction in the state shown in FIG. In this case, when there is little moisture, a viscosity will rise too much and it will become a bowl shape. In order to prevent this, it is necessary to increase the amount of water. However, increasing the amount of water causes a dilute saponification reaction and increases the time spent for saponification. That is, there is an inconvenience that the occupying time of the saponification kettle becomes long. Further, the steps of FIGS. 2B to 2D are disadvantageous in that many manual steps are required and a space for storing intermediate products is required. Thus, the conventional cold process is not economical compared to the hot process.

  In addition to the general cold process shown in FIG. 2, as another cold process, for example, in Patent Document 1, a saponification is performed by mixing a fatty acid source and an alkali using a special mixing vessel, so that less than 20%. A method for producing soap granules having a moisture content is described. This granule is extruded or stamped into a desired shape in the subsequent steps.

  In Patent Document 2, for the purpose of shortening the soap production time by cold pressing, saponification reaction of fat, water and sodium hydroxide is performed under the condition that the water / fat weight mixing ratio is 50% or more and less than 100%. Has been proposed.

International Publication No. 83/00502 Pamphlet JP 2006-225429 A

  However, since the technique described in Patent Document 1 requires a step of forming granular soap in order to obtain soap having a desired shape, the manufacturing time is increased correspondingly, and the conventional general cold process is required. Compared to, manufacturing time can not be significantly reduced. In the technique described in Patent Document 2, the time for the saponification step may be shortened, but the time required for the subsequent solidification step and drying step is not different from that of a conventional general cold process.

  Therefore, the subject of this invention is providing the manufacturing method of the soap which can eliminate the fault which the prior art mentioned above has.

  As a result of intensive studies to solve the above-mentioned problems, the present inventors have found that saponification proceeds uniformly even in the container by emulsifying oil and fat and filling the emulsion with the emulsion. .

  The present invention has been made on the basis of the above-mentioned knowledge. An oil and fat and an alkali are mixed to prepare an emulsion, and the emulsion is filled in a packaging container while the emulsion is in a fluid state. The above-mentioned problems are solved by providing a method for producing soap having a step of saponification therein.

  According to the present invention, it is possible to produce a soap by a cold process in a much shorter time than conventional. In addition, there is no need for storage space for intermediate products that was required in the conventional cold process.

FIG. 1A to FIG. 1C are schematic views showing each step in an embodiment of the production method of the present invention. FIG. 2 is a schematic diagram showing a method for producing soap by a conventional cold process method.

  Hereinafter, the present invention will be described based on preferred embodiments thereof. In the production method of the present invention, oils and fats and alkalis are used as in the conventional method for producing soap by a cold process. As fats and oils, the same oils and fats as those conventionally used as raw materials for soap production can be used. For example, natural fats and oils such as palm oil, palm kernel oil, sweet almond oil, avocado oil, beef tallow, coconut oil, olive oil, soybean oil, cottonseed oil, rice bran oil, rapeseed oil, peanut oil, and the like can be used. These fats and oils can use 1 type (s) or 2 or more types. On the other hand, sodium hydroxide, potassium hydroxide, sodium carbonate, or the like can be used as the alkali.

  The production method of the present invention is characterized in that an emulsion is obtained by vigorously mixing fats and oils, alkalis and water. As described above, the present inventors have surprisingly found that when oils and fats and alkalis are emulsified and the emulsion is filled in the container, saponification proceeds uniformly in the container. Therefore, according to the production method of the present invention, it is not necessary to provide an intentional saponification step, and therefore, unlike the conventional cold process, the compounding pot is not occupied for a long time. As a result, the target soap can be manufactured in a short time.

  The emulsification of fats and oils can be performed using an emulsifier that can apply a high shearing force. The emulsification may be performed in a batch system or may be performed in a continuous system. When emulsifying in a batch system, for example, emulsification with a paint shaker using a media mill or emulsification using CLEARMIX (trade name) manufactured by M Technique Co., Ltd. can be performed. On the other hand, when emulsification is carried out continuously, emulsification using a milder (trade name) manufactured by Taiheiyo Kiko Co., Ltd. can be mentioned. Of course, the emulsifier is not limited to these, and various emulsifiers used in the technical field of emulsification may be used.

  In emulsification, an emulsifier such as a surfactant may be used in combination, but it is preferable to emulsify only by applying a high shear force without using an emulsifier, from the viewpoint of the quality of the obtained soap.

  The emulsion obtained by emulsification becomes O / W type or W / O type depending on the ratio of fat and oil. In the present invention, it is preferable to prepare a W / O emulsion.

  When solid fat is used as the fat, it is preferable to heat the fat to make it liquid during emulsification. Correspondingly, it is also preferable to heat the aqueous alkali solution. However, since the saponification reaction between fat and alkali is an exothermic reaction, excessive heating of the fat and alkali aqueous solution may cause significant expansion due to heat generation after the emulsion is filled in the container. As such, it is advantageous not to overheat. From this viewpoint, the temperature for preparing the emulsion is preferably suppressed to 60 ° C. or less, and particularly preferably 55 ° C. or less, on condition that the oil or fat becomes a liquid temperature or higher.

  The usage-amount of the alkali with respect to fats and oils is set so that it may not exceed the saponification value of the fats and oils to be used. Further, the amount of water used is preferably in a range different from that of the conventional cold process from the viewpoint of eliminating the drying step in the present production method. Specifically, the amount of water used is preferably set such that the amount of water relative to the fat is in the range of 10 to 30% by mass in relation to the amount of fat used.

  1A to 1B schematically show each step in an embodiment of the production method of the present invention. In the manufacturing method of this invention, as shown to Fig.1 (a), the fats and oils 11 and the alkaline aqueous solution 12 with which tank 10a, 10b was filled are supplied to the emulsifier 13, and emulsification is performed. The tanks 10a and 10b can be heated. As described above, the oil and fat 11 and the alkaline aqueous solution 12 are heated to a predetermined temperature. In the figure, the symbol P represents a pump. The pump P is used to send the oil 11 and the alkaline aqueous solution 12 from the tanks 10a and 10b to the emulsifier 13. The fats and oils 11 and the alkaline aqueous solution 12 fed by the pump P may be directly introduced into the emulsifier 13 or, alternatively, introduced into the emulsifier 13 via the mixer 14 as shown in FIG. Also good. For example, a dynamic mixer or a static mixer can be used as the mixer 14.

  When the emulsion is prepared, the emulsion 15 is filled in the container 16 as shown in FIG. The emulsion 15 can be filled in a mold used in a conventional cold process, but is preferably filled individually and directly into a container 16 which is complementary to the shape of the target soap. This eliminates the need for a formwork and saves space in the soap production facility. Further, the individual filling of the emulsion 15 into the container 16 is an operation that can be easily automated using a filling machine, and thus contributes to labor saving.

  Filling the container 16 with the emulsion 15 is performed while the emulsion 15 is in a fluid state. In this specification, that the emulsion 15 is in a fluid state means that saponification does not proceed excessively in the emulsion 15. As saponification proceeds in the emulsion 15, the amount of saponification gradually increases and the fluidity of the emulsion 15 becomes poor. Even if it is going to fill the emulsion 15 in the container 16 in such a state, it cannot be filled successfully or has a long time for filling. Therefore, in this production method, the emulsion 15 is filled in the container 16 in a highly fluid state before the saponification in the emulsion 15 proceeds excessively.

  Saponification in the emulsion 15 has progressed before the emulsion 15 is filled into the container 16, but saponification continues after the container 16 has been filled. Thus, in this manufacturing method, since saponification is performed in the container 16 that is a part of the final product, it is necessary to secure time and space for increasing the hardness of the soap unlike the conventional cold process. There is no advantage. Moreover, since the emulsion 15 can be formed into the shape of the final product simply by filling the container 16, unlike the conventional cold process, the soap taken out from the mold is cut and the surface is ground. Is unnecessary, and the manufacturing time can be greatly reduced.

  As the container 16, the thing similar to what was conventionally used for the packaging of soap can be especially used without a restriction | limiting. For example, a synthetic resin container 16 can be used. In particular, it is preferable to use a heat insulating container as the container 16. The reason for this is that in the present production method, the saponification of the emulsion 15 proceeds in the container 16, but when the temperature of the emulsion 15 in the container 16 decreases, the speed of saponification decreases. This is because it may take time to reach the desired degree of saponification. From this point of view, when using a heat insulating container, the heat conductivity of the constituent material of the container 16 is 0.03 to 0.42 W / (m · K), particularly 0.03 to 0.19 W / (m · K). Is preferably used.

  If the emulsion 15 can be filled in the container 16, as shown in FIG.1 (c), the container 16 will be stored in predetermined temperature and saponification of the emulsion 15 will be advanced. Prior to this, after the filling of the emulsion 15 is completed, as shown in FIG. 1 (b), the opening of each container 16 is sealed with a sealing member 17, and the inside of the container 16 is kept airtight. It is preferable to break the contact between the emulsion 15 and the outside air. The reason is to prevent sodium carbonate from precipitating on the surface of the target soap. Specifically, the emulsion 15 contains sodium hydroxide or the like as an alkali component. This sodium hydroxide may react with carbon dioxide in the air to produce sodium carbonate, which may precipitate on the surface of the soap. In order to prevent this precipitation, it is advantageous to cut off the contact between the emulsion 15 in the container 16 and the outside air. For this purpose, the container 16 is preferably sealed after the emulsion 15 is filled.

  The saponification of the emulsion 15 in the container 16 is performed at room temperature or a temperature higher than room temperature. When an insulated container is used as the container 16, saponification can be performed at room temperature because the temperature drop of the emulsion 15 is small due to the balance between reaction heat generated by saponification and heat dissipated to the outside. When an insulated container is not used, the heat dissipated to the outside may increase more than the heat of reaction caused by saponification, and the temperature of the emulsion 15 tends to decrease. It is preferable to keep above. For example, it is preferable to maintain the environment in which the container 16 is stored at 25 to 60 ° C., particularly 30 to 40 ° C.

The saponification of the emulsion 15 in the container 16 depends on the volume of the container 16, but the container 16 having a volume of about 40 to 50 cm ³ is used for at least 24 hours from the completion of the filling of the emulsion 15. Completed and the final product packaged soap 18 is obtained. Thus, according to this manufacturing method, the time required from the mixing of fats and oils to the packaged soap 18 is about 48 hours at most. On the other hand, since the manufacturing time of the soap by the conventional cold process is about 1 to 2 months, it is understood how the soap can be manufactured in a short time by the cold process according to the present manufacturing method.

  As mentioned above, although this invention was demonstrated based on the preferable embodiment, this invention is not restrict | limited to the said embodiment. For example, as the shape of the container 16, an appropriate shape can be selected according to the specific use of the target soap. Moreover, the emulsion 15 of fats and oils may be filled in a temporary stock tank, and the emulsion 15 may be extracted from the tank and filled in the container 16.

  Hereinafter, the present invention will be described in more detail with reference to examples. However, the scope of the present invention is not limited to such examples. Unless otherwise specified, “%” and “part” mean “% by mass” and “part by mass”, respectively.

[Example 1]
Palm kernel oil was used as the fat. A 48% aqueous sodium hydroxide solution was used as the alkali. In a polyethylene bottle with a lid of 250 cm ³ , 100 g of palm kernel oil was put, and this bottle was bathed at 51 ° C. to melt the palm kernel oil. Separately from this, 35 g of the sodium hydroxide solution and 13 g of semen water were mixed, and the mixture was bathed at 37 ° C. After putting the water-soaked mixed solution in the bottle and capping, emulsification was performed using a paint shaker (PAINT SHAKER manufactured by TOYO SEIKI). The operating conditions of the paint shaker were set to normal conditions without special shift control. Emulsification with a paint shaker was carried out for 10 minutes. The emulsion thus obtained was transferred to another container (thermal conductivity: 0.17 to 0.19 W / (m · K), volume 200 cm ³ ), and this container was placed in a constant temperature bath at 40 ° C. Left to stand. The saponification was allowed to stand for 48 hours in this thermostatic bath to obtain soap.

[Example 2]
Palm kernel oil was used as the fat. A 48% aqueous sodium hydroxide solution was used as the alkali. 100 g of palm kernel oil was put in a container and bathed at 50 ° C. to melt the palm kernel oil. Separately from this, 35 g of the sodium hydroxide solution and 13 g of semen water were mixed, and this mixed solution was bathed at 50 ° C. This mixed liquid was put into the said container, and it emulsified using the emulsifier (Clea mix (brand name) CLM-1.5S by M technique Co., Ltd.). The rotation speed of the emulsifier was 1000 rpm. The clearance between the rotor and the screen was set to 0.2 mm. Emulsification was performed for 2 minutes to obtain an emulsion. Thereafter, a soap was obtained in the same manner as in Example 1.

[Evaluation]
It was confirmed by the following method whether the soap obtained in Examples 1 and 2 has the same composition as the soap obtained by the cold process. Among the soap components, the mass fraction of moisture, pure soap, and petroleum ether soluble matter was measured according to the soap measurement method of JIS K3304. However, pure soap was calculated as a sodium salt. The mass fraction of glycerin is the amount of moisture, pure soap, and petroleum ether solubles from the whole because soap (containing water) and glycerin are produced in the saponification reaction with fats and alkalis. The subtracted value was calculated, and this value was defined as the mass fraction of glycerin. The results are shown in Table 1.

表１に示す組成は、油脂とアルカリとのけん化反応において、約９０％の石けんと約１０％のグリセリン等が生成する事実と合致している。また、石油エーテル可溶分に着目すると、その質量分率（乾燥質量比）が実施例１で０.４％、実施例２で０.９％と僅かであり、化粧浴用石けんのＪＩＳ規格である３％をクリアしていることから、けん化反応がほぼ完了し、コールドプロセスで得られた石けんと同等の組成を有する石けんが生成したことが確認された。

The composition shown in Table 1 is consistent with the fact that about 90% soap, about 10% glycerin and the like are produced in the saponification reaction between fats and oils and alkalis. Further, when focusing on petroleum ether-soluble matter, the mass fraction (dry mass ratio) is as low as 0.4% in Example 1 and 0.9% in Example 2. Since 3% was cleared, it was confirmed that the saponification reaction was almost completed and a soap having the same composition as the soap obtained by the cold process was produced.

Example 3
Palm kernel oil was used as the fat. A 48% aqueous sodium hydroxide solution was used as the alkali. Palm kernel oil was charged into the first tank heated to 40 ° C. In addition, a sodium hydroxide solution and purified water were charged into a second tank heated to 40 ° C. at a mass ratio of 72.9: 27.1. The liquid with which each tank was prepared was sent using the liquid feeding pump, and they were supplied to the emulsifier (Milder (trade name) manufactured by Taihei Koki Co., Ltd.). The amount of liquid fed was 48 parts of the amount of liquid in the second tank with respect to 100 parts of palm kernel oil in the first tank. In this emulsifier, fats and oils and alkali were continuously emulsified. The rotation speed of the emulsifier was 6000 to 10000 rpm. The exit temperature of the emulsifier for the emulsion produced by emulsification was 50 to 60 ° C. Thereafter, a soap was obtained in the same manner as in Example 1. When the composition of the obtained soap was analyzed by the same method as in Example 1, it was confirmed that it had a composition equivalent to the soap obtained by the cold process.

10a, 10b Tank 11 Oil 12 Oil 12 Alkaline aqueous solution 13 Emulsifier 14 Mixer 15 Emulsified 16 Container 17 Sealing member 18 Packaged soap

Claims (5)

  A method for producing soap, comprising preparing an emulsion by mixing fats and oils and an alkali, filling the emulsion into a packaging container while the emulsion is in a fluid state, and saponifying the packaging container.   The method for producing soap according to claim 1, wherein an insulating container is used as the packaging container.   The method for producing soap according to claim 1 or 2, wherein the emulsion is prepared at 60 ° C or lower.   The method for producing soap according to any one of claims 1 to 3, wherein the soap generated by saponification is not dried after the emulsion is filled in the packaging container.   The method for producing soap according to any one of claims 1 to 4, wherein the packaging container is sealed after the emulsion is filled in the packaging container.

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