MULTI LAYER TOILET SOAP
FIELD OF INVENTION
This invention, in general relates to human necessities. More particularly this invention relates to noval toilet soap. LTnique feature of this invention lies in a soap having multi layer compositions directed to achieve different needs and applications.
PRIOR ART:
It is well known in the art that conventional toilet soap will have a single composition. There is a need to address the problem of the fact ^ the washing of the face and hair, and washing of different parts of the body demand different compositions. So far, such a composition of the soap having multipurpose is not known.
Prior art soap will have one composition wherein washing aspects will have one or two properties. Such as i. Fairness property, ii. 5 Moisturizing property, iii. Turmeric Property. In each soap the properties are inseparable either visible conditions or microscopic conditions but the need exists in each person for a long time for more than above said property while taking bath. But the conventional soap will not fulfill a need. Hence there is a requirement of soap for a ® person to cater a different needs. Even in the economy point of view it was not fusible to invent a noval soap. In order to over come the said bottle neck and make two different properties available and distinctly deliver from two different exposed surface of a multi layer soap is the primary object of the invention addressed to a person during the act 5 of taking single bath. Each surface will be identified with separate colour and marking so as to enable the user to identify the specific layer during use.
A foil may be placed in between the two layer for identification of the surfaces which can incorporate a brand name on the foil. As the top © layer is transparent the foil will enable identification of brand name till the exhaustion of the layer. Additionally, any ornamental indication can be used in the foil so that the soap can be distinctively identified.
The object of the invention is to address the need for an unique soap 5 which cater the needs of entire human body. Accordingly the inventor has designed a soap having multi layer, the layers having
different composition directed to the specific need of the face and the hail- , and rest of the body.
In an embodiment of invention the noval multi layer toilet soap consists of two layers. Two or three distinct properties exist in a single soap. The soap is manufactured in such a way that there will be 2 or 3 different properties in a single soap which is applicable for face and body , face and hair. The soap is demarked specifically and formed with the two layers, upper layer which is 10 - 40% of the soap meant for face or hair respectively with the appropriate functional properties , and the balance 10-70% of the soap which forms lowest portion , meant for the body.
Face application portion of the soap contains fairness property or the turmeric effect , or ultra violet screen property or with glycerin which acts as hum act ant for skin. Similarly for the body application portion of the soap contains various herbs, which are most useful for skin of the body. For hair application , properties like anti dandruff and special herbs are useful for hair growth.
On consideration of the above facts the configuration of the soaps are designed in such a way that performs two properties or more with distinct layers in a single soap with affordable pricing structure in the market
OBJECTS OF INNENTION:-
Accordingly, it is the primary object of the invention to invent a noval toilet soap having multi layer (two or more) with different composition with each surface of the layer directed to the needs of specific parts of the body.
It is an another object of the invention to invent a noval toilet soap with such properties which can be manufactured at an affordable price.
It is another object of the invention to invent a noval toilet soap with multi layer which can also be eco-friendly and non-toxic.
It is yet another object of the invention to invent a noval process of manufacturing the unique multi layer toilet soap.
Further object of the invention will be clear from the ensuing description.
Now the invention will be described in detail in the following pages of the specifications. The nature of the invention and the manner in which it is to be performed has been fully and clearly described in the following pages of description.
DETAILED DESCRIPTION OF THE INVENTION: -
The following description describes the various raw materials used in the process of manufacturing this noval multi layer toilet soap. O RAW -MATERIALS:
S.no Chemicals
1. Coconut oil 1 grade
2. Palm stearic acid
3. Caustic lye 5 4. Paraffin wax
5. Micro crystalline wax
6. Alfa olefin sulphate
7. Talc
8. Titanium dioxide β 9. Sodium silicate
10. SLS
11. Coco Betaine
12. Or any other soap ingredients synthetic or natural or any other herbs or herbal extracts. 5 The percentage of each ingredient of Raw materials used in the formulation of the noval multi layer toilet soap according to invention.
S.no Chemicals % of composi
1. Coconut oil 30% to 39%
2. Palm stearic acid 20%to 30 %
3. Caustic lye 10% to 25% 0 4. Paraffin wax 1% to 5%
5. Micro crystalline wax 1% to 3%
6. Alfa olefin sulphate l% to2%
7. Talc 2% to 4 %
8. Titanium dioxide 3% to 4%
9. Sodium silicate l% to 2%
Each of these compositions may also be varied.
THE IDEALPERCENTAGE IN THEFORMULATION:
S.no Chemicals % % ooff composition by weight
1. Coconut oil 1 grade 35%
2. Palm stearic acid 25%
3. Caustic lye 18%
4. Paraffin wax 3%
5. Micro crystalline wax 2%
6. Alfa olefin sulphate 1% 0 7. Talc 3%
8. Titanium dioxide 5%
9. Sodium silicate 1%
The special addition which are envisaged to cater different section of the society, namely, ladies , babies , views in the form of specific 5 additives to the soap are mentioned herein.
TURMERIC SOAP:
S.no Chemicals
1. Coconut oil 1 grade
2. Palm stearic acid 0 3. Caustic lye
4. Paraffin wax
5. Micro crystalline wax
6. Alfa olefin sulphate
7. Talc 5 8. Titanium dioxide
9. Sodium silicate
10. Turmeric extract
11. Turmeric oil
The turmeric extract and Turmeric oil can be added separately or ® with other herbal extracts/Synthetic ingredients or de-odarents in the same layer or in the other layer.
SANDAL WOOD SOAP:
S.no Chemicals
1. Coconut oil 1 grade
2. Palm stearic acid
3. Caustic lye
4. Paraffin wax
5. Micro crystalline wax
6. Alfa olefin sulphate
7. Talc
8. Titanium dioxide
9. Sodium silicate
10. Sandal wood oil
11. Sandal wood powder
FAIRNESS SOAP:
S.no Chemicals
1. Coconut oil 1 grade
2. Palm stearic acid
3. Caustic lye
4. Paraffin wax
5. Micro crystalline wax
6. Alfa olefin sulphate
7. Talc
8. Titanium dioxide
9. Sodium silicate
10. Saffron
11. Milk
12. Octyl methoxy cinnamate
13. U.V.A
14. U.V.B
15. Benzoplienone
MULTI LAYER COMPOSITION OF THE SOAP:
The soap has minimum 2 layers. The upper layer ill cater to the need of face and hair, the bottom layers will cater to the need of the rest of the parts of the body. The unique feature of this invention is haΛing a single soap with multiple layers. The formulation of the upper layer and the bottom layer and the method of integrating the
two layers to form a single toilet soap is described in the following description in a detailed manner.
THE COMPOSITION OF THE UPPER LAYER FOR TURMERIC SOAP:-
S.no Chemicals % of composition by weight
1. Coconut oil 1 grade 35%
2. Palm stearic acid 25%
3. Caustic lye 18%
4. Paraffin wax 3% 0 5. Micro crystalline wax 2%
6. Alfa olefin sulphate 1%
7. Talc 3%
8. Titanium dioxide 5%
9. Sodium silicate 1% 5 10. Turmeric extract 1%
11. Turmeric Oil 0.5%
THE COMPOSITION OF THE UPPER LAYER FOR THE FAIRNESS SOAP:-
S.no Chemicals % of composition by weight © 1. Coconut oil 1 grade 35%
2. Palm stearic acid 25%
3. Caustic lye 18%
5. Paraffin wax 3%
5. Micro crystalline wax 2% 5 6. Alfa olefin sulphate 1%
7. Talc 3%
8. Titanium dioxide 5%
9. Sodium silicate 1%
10. Saffron 0.01% 0 11. Milk 0.1%
12. Octyl methoxy cinnamate 1.3%
THE COMPOSITION OF THE UPPER LAYER FOR THE SANDAL WOOD SOAP:-
S.no Chemicals % of composition by weight
1. Coconut oil 1 grade 35%
2. Palm stearic acid 25%
3. Caustic lye 18%
6. Paraffin wax 3%
5. Micro crystalline wax 2%
6. Alfa olefin sulphate 1% © 7. Talc 3%
8. Titanium dioxide 5%
9. Sodium silicate 1%
10. Sandal wood oil 1%
11. Sandal wood powder 1% 5 THE COMPOSITION OF THE UPPER LAYER FOR THE BADAM SOAP:-
S.no Chemicals % of composition by weight
1. Coconut oil 1 grade 35%
2. Palm stearic acid 25% 0 3. Caustic lye 18%
4. Paraffin wax 3%
5. Micro crystalline wax 2%
6. Alfa olefin sulphate 1%
7. Talc 3% 5 8. Titanium dioxide 5%
9. Sodium silicate 1%
10. S.L.S. 1%
11. Coco Betaine 3%
12. Badam Extract 1%
THE COMPOSITION OF THE UPPER LAYER FOR THE GLYCERIN SOAP:-
S.no Ingredient % of Composition by weight a. Coconut oil 35% b. Palm stearic acid 25% c. Caustic lye 18% d. Paraffin wax 3% e. Micro crystalline wax 2% f. Alfa olefin sulphate 1% 9 g. Sodium silicate 1% h. Glycerin LP.Grade 5% i. Sugar 4% j. Cetyl alcohol 4% k. PEG 6000 D.S 7%
5 THE COMPOSITION OF THE BOTTOM LAYER:
The bottom layer either herbal based or cosmetic base.
THE HERBAL BASE WILL HAVE THE FOLLOWING COMPOSITION:
S.no Chemicals © 1. Coconut oil 1 grad
2. Palm stearic acid
3. Caustic lye
4. Paraffin wax
5. Micro crystalline wax 5 6. Alfa olefin sulphate
7. Talc
8. Titanium dioxide
9. Sodium silicate
10. Amla © 11. Henna
12. Shikakai
13. Almond
14. Bringaraj
15. Bramhi 5 16. Hard a
17. Tulsi
THE ' COMPOSITION OF THE BOTTOM LAYER FOR COSMETIC BASE:
S.no Chemicals
1, Coconut oil 1 grade
2. Palm stearic acid
3. Caustic lye
4. Paraffin wax
5. Micro crystalline wax
6. Alfa olefin sulphate
1© 7. Talc
.8. Titanium dioxide
9. Sodium silicate
The upper and lower layer of this unique soap will have almost same thickness and further the ratios between the top and bottom layers 1 ° can be varied depending of the application and market requirements.
METHOD OF MANUFACTURING MULTI LAYER TOILET SOAP:
Method of manufacturing of the toilet soap is explained with the help of flow diagram. Various steps involved in using raw materials for
20 each specific kind of soap and various steps involved in subjecting the raw materials and finally obtained the required soap.
Figure I of the drawing shows the flow diagram of the process of manufacturing this noval multi layer soap.
Figure II of the drawing shows the flow diagram of the machinery " used in the manufacturing process of this noval multi layer soap.
COMPOSITIONS: -
The composition of the soap consists of three phases.
Phase I - Fatty Oil phase Phase II - Alkali Phase 0 Phase III - After saponification addition of herbs/perfumes/special additives/Colours.
Further to these three phases the batch taken to the moulds/trace to allo for maturity and cooling. Once the soap mass are formed and the same to be taken for cutting, stamping and final packing.
Phase - 1: Contains all vegetables fatty oils like coconut oil, palm oil, rice brane oily palm stearic fatty oil, waxes etc., The above mentioned fatty oil to be mixed one after the others and heat it to the temperature between 95 degree Centigrades - 100 degree centigrades.
Phase - II: Q The required quantity of caustic lye has to be dissolved in water and heat it around 50 degree centigrade.
Phase II material has to be added to phase I materials and stir it for
10 - 15 minutes for the complete reaction and saponifaction. Allow thus the soap batch to settle without any disturbance for 15 - 20 , minutes thereby the complete process of saponification will take place.
Once the batch comes to around 60 degree centigrade the further important ingredients like herbs, special additives, perfumes and colours added accordingly on our specifications and requirements. The herbal additives soap portions are spread on the trace for ® maturity and the portion in the soap which are meant for phase and hairs are next will be poured above and allowed to fuse together at appropriate temperature and conditions.
Further to the above operations the bulk will be taken for cutting section as per the specified sizes and shapes, stamping and final 5 packing in cartons are followed accordingly.
Further to explain the flow diagram according to the drawings accompanying the description initially the fatty oils are heated and mixed in SS Tanks and the oil is heated to the specific temperature. Alkali is then added in the vessel, the alkali used in this process is 0 sodium hydroxide. After adding alkali, the content in the SS Tank is heated to 100 - 120 degrees centigrade. The saponification process takes place which results in the formation of the soap. The soap mass is cooled for a period of 1 - 1 Vi hours to reach the temperature around 60 degreed centigrade. It is to be noted as this soap being a 5 unique soap having two or more layers, and for each layer separate
soap mass is formed and further separately the soap mass is subjected to further process by adding suitable additives such that the soap mass will catter to the need of specific layer in the formation of the soap. Having thus prepared separate layer, now the process of integration of layers takes place in the manner decribed as follows:-
Initially the soap mass for the bottom layer will be spread on the specific moulds after few minutes say 1 - 60 minutes or more or within 24 - 48 hrs of the formation of the bottom layer the soap mass for the top layer will be spread evenly above the bottom layer and 0, allowed to get fused in hot temperature between 45 - 90 degrees centigrade so as to obtain an integrated soap.
The soap mass thus formed is allowed to cool to the room temperature and the soap is ready for cutting to the specific requirements, stamping and packing. 5 The entire process of manufacturing of the soap is either manual or mechanical. The system involved in the large-scale production of the said soap consists of various machineries which are shown in figure II of the drawings.
MACHINERIES INVOLVED: ® Sl.No. Description Quantity
1. Mixing Drum 5 of lOOKg capacity
(for oils) SS/MS make
2. Melting Drum 5 SS - for 50Kg capacity 6
3. MS Cutting table gear type to push bigger cake 4
4. Cutting frames 4
5. MS working table 2 Ω 6. Stamping machine 6
7. Wooden/MS packing table 2
8. Stamping Dies
Smaller soap 6
Bigger soap 6
9. MS cooling boxes or Trays 25 5 10. Plastic drums 5
11. Plastic Trays 10
12. Trays made out of MS/SS with the de-markation lines between the upper and the lower layer in 25
10 their own proportions say 30:70,
40:60, 50:50 and 20:80 or any other combination
Another process of manufacturing the soap consists of having two extruders meant for bottom layer and top layer separately. Where in
15 the extruders will run in parallel and the top and bottom layer of the soap is formed by fusing the layer obtained from both the extruders through a single exist or dies, the fusion takes place by running the soap layers integrated for a length of 1ft - 1 Vi ft at a constant temperature by means of hot water jacketed/steam with the
-20 temperature maintenance facility from 40 - lOOdegrees centigrade and even more so that a homogeneous, evenly layer soap is formed. The soap mass thus obtained is cut in to the required size and stamping and packing takes place separately.
QUALITY CONTROL REPORT:
2 5 As per the IS - 2888 (1983).
1. Total fatty matters - 60% Min.
2. Rosin Acid - 7% Max.
3. Un - saponified matters - NIL
4. Free alkali - 0.05% Max. 3 0 5. Matter insoluble is Alcohol - 6% Max.
6. Chlorides (As NaCl) - 1.5%Max.
7. Free Carbonated Alkali - 1.0% Max.
8. pH of l0% w/v - 8 to 9
COLOURS FOR THE MULTI LAYER TOILET SOAP:-
The colours for the multi layer toilet soap are suitably be selected as per the requirements and on respective applications parameters as per the below descriptions and examples. EXAMPLES a. Turmeric Soap
Top layer - Yellowish Orange - Turmeric effect-Face Application Bottom - Greenish - Herbal effect - Body application b. Fairness Soap © Top layer - White - Fairness effect - Face Application
Bottom - Green - Herbal effect - Body Application c. Shikakai Soap
Top layer - Red - Shikakai effect - Hair Application 5 Bottom - Green/ - Herbal/ - Body and Face
White De-odarant Application
Effect d. Anti-Dandruff Soap
Top layer - Sky blue - Anti - Dandruff effect - Hair application Bottom - White/ - Herbal/ - for Face&Body
Green/ Anti - Bacterial/ Application Θ Brown Anti - Fungal effect
Further to the above any other combinations and colours can be prepared on.
ADVANTAGES OF THIS INVENTION:
The salient feature of this invention is in the unique composition and unique process
Which results in the following advantages: 1. This unique toilet soap has multiple application.
2. This unique toilet soap is obtained may be by a normal process.
3. The toilet soap is economical.
4. The toilet soap is eco-friendly and non toxic. 5. The raw materials for the soap being herbs , the soap has an medicinal value.
6. The soap meets the requirements of the healthy skin complexion.
7. The soap is unique in the sense that top layer has anti-dandruff, conditioning with the specific composition which makes the hair healthier and shining and managable. When such a soap is used for hair application and bottom of the soap for the body or the face applications.