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Business for the production and sale of washing powder. Composition and production technology of synthetic detergents

Powder-crushing workshops (departments) of pharmaceutical enterprises, in addition to meeting the needs of their enterprise (tablet workshop, extraction preparations workshop), produce a large number of powders for pharmacies. These are mainly powders of plant origin (powders of leaves, roots, seeds, etc.), which are necessary in everyday recipes for the preparation of powders, pills, candles, etc. Along with this, enterprises produce a significant amount of complex powders according to prescriptions regulated by the Federal Tax Service , VFS or MRTU.

Features of factory production of powders

The production of powders in the factory consists of the same operations as when preparing them in a pharmacy. However, due to the large quantities and volumes of raw materials used and the specific properties (many of them), which are especially prominent when processing large quantities, the factory production of powders has its own characteristics.

powder forging

When powdering vegetable raw materials and other materials, the essential issue is the correct choice of machine. First of all, it is necessary to take into account the strength of the crushed material, understanding by it its ability to resist destruction under the action of external forces. Obviously, one effort will be required to grind rhubarb rhizomes, and others, incomparably less, to grind sugar. In the first case, runners or a hammer mill are needed for grinding, while in the second, a disintegrator or ball mill will be sufficient.

When powdering plant raw materials, it is necessary to take into account the morphological and anatomical features of the plant and the localization of active substances in it. Obviously, fibrous roots (for example, marshmallow) require one type of machine, and non-fibrous ones (rhizome and valerian roots) require another.

In the preparation of powders of plant origin, the moisture content of the crushed materials is essential. It should be borne in mind that vegetable raw materials that have a commercial moisture content provided for by GOST and pharmacopoeial articles are poorly powdered. The raw material must be dried to a residual moisture content of about 6-8% (instead of the usual 12-14%). Drying is carried out in dryers, taking into account the morphological and anatomical features of the raw material and the stability of the active ingredients contained in it.

Finally, the choice of machine depends on the degree of fineness required. When determining it, they proceed from the indication of the GFH.

Powdering of medicinal substances that form poisonous or highly irritating dust(arsenic anhydride, spanish fly, emetic root, etc.). In this case, the least dusty machines are used, most often ball mills. Powdering is carried out in separate rooms. Machines are closed with casings, cases, covers. It is necessary to take personal safety measures (respirators, overalls).

Powdering with cooling. When powdering soap, resins, gums, waxes, hard fats, cooling is necessary to increase the fragility of substances. Grinding is carried out in disintegrators and hammer mills with cold air supply after preliminary cooling in the refrigerator of the products themselves.

Powdering after preliminary degreasing. The presence of fatty oil in objects due to rancidity impairs the preservation of powders (for example, ergot). The oil is removed from the coarse powder by extraction with gasoline in Soxhlet-type apparatuses, after which the final powdering is carried out.

Powdering after preliminary softening. It is used for seeds of chilibukha and salep tubers, the tissues of which require preliminary separation (separation from each other). Chilibukha seeds are exposed to steam and hot water, after which they are cut into thin pieces, dried and then powdered in a ball mill. Salep tubers are macerated with cold water, cut, dried and then powdered.

Powdering with auxiliary substances. Substances that are difficult to powder directly are mixed with some substances that promote grinding. With the addition of solids (sugar), for example, vanilla is powdered (sugar adsorbs vanilla moisture). With the addition of liquid substances (alcohol, ether), camphor, boric acid are powdered.

Mixing. Joint grinding and mixing

The main issue in the preparation of complex powders is the uniformity of their mixing. A convenient way is joint grinding on runners, in disintegrators, dismembrators and ball mills. Along with this, the mixing is carried out in mixers. The most commonly used drum mixers. In its simplest form, it is a cylindrical or multifaceted closed drum driven in rotational motion. In ribbon mixers, mixing is carried out by steel strips (ribbons) bent along a helix, which move the materials to be mixed in a closed trough-shaped vessel from one end of the apparatus to the other. The plant material is mixed in two opposite directions due to the fact that the tapes (two) are bent along the right and left helical lines. In addition, the material lifted by the rotating belts falls back into the mixing mass in a different place from where it was taken from, which greatly contributes to homogenization. For mixing powders, Werner-Pfleider machines are also suitable, having two sigmoid-shaped blades. A substance lifted by one blade up, the other goes down.

Screening

Sifting of one-component powders is carried out on the sieve mechanisms described on p. 76. GPC for most vegetable powders regulates not only the degree of grinding, but also the maximum number of particles that do not pass through sieves with holes of established sizes.

As for complex powders, the homogeneity of the mixture during sieving can be disturbed due to the separation of the components, so the latter are sieved separately and only then mixed.

Dosing and packaging

In the factory, the operations of dosing and packaging of powders are a combined production process and are carried out on the same production line. Filling machines for powders work according to the volumetric and weight method. The simplest machine, the operation of which is based on a volumetric method, uses an auger for dosing, the speed of which regulates the volume of powder poured out. There are no valves in piston dosing machines for powders; the cylinder itself with the piston rotates.

With a volumetric method of packaging, great accuracy cannot be achieved, since with the slightest shaking of the dispenser, the mass easily changes (due to a denser packing of powder particles).

The weight method is used in automatic scales (Fig. 124). The main part of the scales is a rocker /, on one side of which a cup is suspended 2 for weights, and on the other - a dosing cup 3. Before starting the scales for work on a cup 2 put the weights and finally set the mass of the powder with the regulator 8 with mobile weights 15 and22, and also fill the hopper with powder 4. After that, the balance is actuated by the handle 17, which through the levers 6 and 7 opens the damper 10, and the powder through channel 5 begins to fill the scales 3. Once the desired weight has been reached, the arrow 18 touches the zero division of the scale - screw 21 through leverage 6 and 7 and damper 20 closes the damper 10. Simultaneously with levers 12 and 13 folds down the bottom of the cup 3 and a dose of powder is poured through the funnel 14. Under the action of the counterweight 2 / from the bottom of the cup 3 closes, the scales are out of balance, with screw 19 the flap opens again through the levers 10 and the process is repeated. Regulator and rocker oscillate on a prism 16. The speed of powder outflow from the hopper is controlled by a damper 9. The balance can be temporarily stopped with lever 11 . To stop the operation of automatic scales, use the handle. 17.

Private technology and nomenclature of powders

From complex powders the industry produces:

Complex licorice powder(Purvis Glycyrrhizae compositus). Composition (parts) according to GPC: licorice root and senna leaves - 20 each, fennel fruits and sulfur - 10 each, sugar - 40. Powders of these substances are mixed in a mixer, sieved through a sieve with holes with a diameter of 0.2 mm and mixed again.

Carlsbad salt artificial(Sal. carolinum factitium). Prepare by mixing 44 parts of dried sodium sulfate, 36 parts of sodium bicarbonate, 18 parts of sodium chloride and 2 parts of potassium sulfate.

Alkaline salt rinse(Gargarisma alcalina). Consists of 5 parts sodium chloride, 10 parts sodium bicarbonate and 15 parts sodium tetraborate.

Amikasol powder(Aspersio Amycazoli) 2 and 5%. The recipe is included in the GFH for the first time. Filler - talc (98 and 95%) - Antifungal agent; list B.

Galmanin(Galmaninum). The composition of this disinfectant and drying powder includes: salicylic acid 2 parts, zinc oxide 10 parts, starch and talc 44 parts each.

Business in the segment of cleaning products, according to experts, is considered a fairly promising area. According to surveys, this market is in constant development today, as the consumer tries to choose products that are characterized by excellent quality and good use effect. And without a doubt, powder can be attributed to this niche - they wash everything and always, despite the economic crises. These are excellent prerequisites for opening the production of washing powder in Russia.

Having decided to organize a business for the production of synthetic detergents (SMC), you need to be prepared for the fact that in the first couple of years a novice entrepreneur is unlikely to be able to “conquer” the entire niche. The fact is that the lion's share of all powders presented on store shelves belongs to foreign brands. As for domestic products, here the market is "captured" by several large manufacturers. Of course, it is unlikely to compete with them, and therefore, at first we rely on budget products, which will be produced by a mini-workshop and delivered to small retail stores in a particular region.

It is also beneficial to launch a mini plant for the production of washing powder for the following reasons:
The production technology is simplified to the maximum.

If you buy semi-finished raw materials, it will be possible to produce a wide range of products.
Mini-automatic machines are reconfigured in such a way that in the shortest possible time you can re-profil your workshop, starting to produce a completely different type of cleaning products.

And in order for the washing powder production workshop to function without failures in the future, it will not hurt to work out its business plan, which will reflect all upcoming expenses and a marketing scheme will be thought out.

Documentation of business

It is impossible to start the manufacture of washing powders until the enterprise is documented. And it's quite a hassle.

What will be required for this?

Pass an inspection by representatives of Rospotrebnadzor.
Based on the results of the check, obtain a certificate of state registration.
Through sanitary supervision, obtain a declaration for all raw materials used.
To certify products that will be manufactured within the walls of a mini-factory.
In order not to waste your own strength, you can connect a qualified lawyer to the case, who will collect all the necessary package of documents.

Washing powder manufacturing process

The technology for the production of washing powder is complex only in terms of formula development. This is what needs to be given special attention, since its detergent and cleaning properties will depend on the composition of the product. Enterprises keep their recipes in the strictest confidence, and therefore, at this stage of business planning, the services of a qualified technologist cannot be dispensed with.

Various surfactants, binders, detergents and bleaching agents are used as raw materials in the manufacturing process of washing powder.
The following main components are used here:
sulfanol powder,
surfactant,
soap bar.

Raw materials are quite expensive in price, but despite this, it is quite affordable. And it is better to choose the supplier that is closest to the factory.

The production of phosphate-free washing powder is as follows:
All ingredients are mixed.
The resulting paste is sprayed through special spray nozzles.
Dried drops of liquid instantly turn into dry powder granules.
The remaining dry ingredients are added to the powder.
The finished product is packed.

Technical equipment of the workshop

If you buy equipment for the production of washing powder, fully automated and equipped, then there should not be any problems with the implementation of the process. There are a lot of options for all kinds of workshop equipment on the market, which vary in productivity and degree of automation.
What especially pleases many novice entrepreneurs is the relatively low cost of equipment. A line with a capacity of up to 500 kg / day costs no more than 250,000 rubles. And the price of more powerful equipment (up to 1.5 tons / day) is 500,000 rubles.

Low-power equipment is equipped almost identically. And the "middle" laundry detergent production line consists of the following sections:
Area for storage of liquid and dry raw materials.
Dosing area for liquid and dry components.
Powder spraying and drying area.

To the main machine for the production of powdered SMS, you will also need to purchase a packaging machine. But this is only if it is planned to pack the finished product in separate packages. But in order to avoid additional expenses, many do it easier - they sell the powder mass by weight. But finding buyers for such products will not be easy.

Profitability of the planned business

The mini-workshop will only start to make a profit when the produced powder wins the trust of consumers. And it is still unknown how long it will take. If funds are available, advertising on TV, radio and newspapers can be considered. But it doesn't make sense for a young enterprise to invest in large-scale marketing campaigns.

Taking into account the price of equipment, raw materials and rent of premises, it will take at least 1,000,000 rubles to organize a business. The main items of expenditure will fall on the purchase of components, the development of recipes and the preparation of the premises for operation.

If we talk about the profitability of a business, then everything depends on the pricing policy of a particular region. Budget powder is supplied by retail outlets at a price of at least 50 rubles / kg. At the same time, the cost of production is less than the selling price by 30-50%. And these are good indicators of profitability.

The technological process of manufacturing products by powder metallurgy begins with the production of metal powders. A large number of methods for obtaining powders are known.

The variety of methods used is explained by the fact that the qualitative characteristics of powders and products are largely determined by the method of powder production. A powder of the same metal, depending on the method of production, drastically changes some of the properties that determine its applicability for a particular purpose.

Powder Properties

In practice, metal powders are characterized by the following properties:

  • physical;
  • chemical;
  • technological.

Physical properties of powders

On the physical properties of powders usually refer to the predominant particle shape and particle size distribution of the powder. The shape of the particles mainly depends on the production method and can be spherical, spongy, fragmented, dendritic, plate-shaped, scaly. The shape of the particles affects the density, strength and uniformity of the compact. The greatest strength of compacts is given by particles of a dendritic shape. In this case, the hardening of powders during pressing is caused by the action of cohesive forces, particle jamming, intertwining of protrusions, and branching.

The particle size of powders obtained by various methods ranges from fractions of a micrometer to fractions of a millimeter. To obtain a strong compact, a powder with certain particle sizes and a set of their fineness is required. In practice, metal powders with particles of the same size are never encountered.

The granulometric composition of the powder is the relative content of particle fractions of different sizes. In combination with other properties, it affects the specific pressing pressure required to achieve the desired mechanical properties of sintered products.

Chemical properties of powders

To the chemical properties of powders primarily include the content of the base metal, impurities and impurities. The chemical properties are also affected by the content of gases in a bound, adsorbed or dissolved state. The content of the base metal in powders is not lower than 98 - 99%, and such a purity of powder metals for most sintered products is satisfactory.

Harmful impurities for iron powder are impurities of silica, oxides of aluminum and manganese. These impurities hinder the pressing of powders and increase the wear of molds.

The presence in the powders of a significant amount of gases (oxygen, hydrogen, nitrogen, etc.) adsorbed on the surface of the particles, as well as the impurities that got inside the particles during the manufacturing process and as a result of decomposition during heating, increases the fragility of the powders, makes pressing difficult, and their intensive release during sintering may cause product distortion. Therefore, powders are sometimes subjected to vacuum treatment to strip off gases.

Technological properties of powders

Under the technological properties of powders understand:

  • bulk mass of the powder;
  • fluidity;
  • compressibility.

Bulk weight of powder

Bulk weight of powder is the mass of a unit of its volume with free filling. It is determined by the density of the powder material, the size and shape of its particles, the packing density of the particles, and the state of their surface. For example, spherical powders with a smooth surface provide a higher bulk density.

Powder flow

Powder flow is the ability to move under the influence of gravity. It is estimated by the time of expiration of a certain sample (50 g) through a calibrated hole (diameter 2.5 mm). Fluidity depends on the density of the material, particle size distribution, shape and surface condition of the particles and affects the performance of automatic presses during pressing, as it determines the time for filling the mold with powder. Fluidity deteriorates when the powder is moistened, its specific surface area and the proportion of fine fraction increase.

Powder compressibility

Powder compressibility- this is the ability of a powder under the influence of an external force to acquire and hold a certain shape and size.

Powders of the same chemical composition, but with different physical characteristics, may have different technological properties, which affects the conditions for the further transformation of powders into finished products.
Therefore, the physical, chemical and technological properties of powders are directly dependent on the method of obtaining the powder.

But not only the qualitative characteristics of the powder underlie the choice of a method for obtaining powders. When evaluating the method of powder production, economic issues are very important - the cost of the powder, the amount of investment, the cost of processing the powder into products.

All this necessitated the development and industrial development of a large number of different methods for the production of powders.

Methods for obtaining powders

All methods for obtaining powders that are encountered in modern practice can be divided into two groups:

  • mechanical methods;
  • physical and chemical.

Mechanical methods for obtaining powders

By mechanical means For the production of powders, such technological processes are considered in which the source material is crushed as a result of external forces without changing the chemical composition.

Physico-chemical methods

To physical and chemical methods include such technological processes in which the production of powder is associated with a change in the chemical composition of the feedstock as a result of deep physical and chemical transformations. In this case, the final product (powder), as a rule, differs from the starting material in terms of chemical composition.

Man has always strived for cleanliness, from ancient times, when people rinsed their clothes in rivers, to the present day, when in most cases machines take over this duty.

Of course, initially no one knew about detergents in their modern concept, they used exclusively natural products and water. Soap appeared later, and in 1876 the world's first production of washing powder was created. The manufacturer was the German factory Henkel & Cie, headed by Fritz Henkel.

Our days: powder market in Russia

Since then, many years have passed, and the number of manufacturers has increased to hundreds of thousands around the world. Among them, of course, there are leaders. And in our country they are foreign companies that occupy up to 80% of the entire Russian market.

Domestic large manufacturers of washing powder in Russia have a small share - about 10%. The remaining 10% are small firms and are ideal for entry of newcomers who want to carve out a niche in this segment of detergents.

Of course, it is not easy to fight the giants of the market, who, moreover, have long won the trust of the majority of consumers. However, it is quite possible to win some of them over to your side. To do this, you need to prove yourself from the best side according to three main criteria: efficiency, safety and availability. And you will learn how to set up a powder manufacturing business from this article.

The range of basic issues on the organization of powder production

The production of washing powder is a rather complicated process in terms of technology, therefore it requires a competent approach. This is due to the large number of different chemicals used to create it. Due to the multicomponent and the correct combination of elements, the ability of the detergent to effectively remove dirt without affecting the quality of the fabric is ensured. Thus, the main issues that need to be carefully thought out and properly organized are the technology and equipment for the production of washing powder. In addition, it is necessary:

  • choose a suitable room for the workshop / plant;
  • collect the necessary permits;
  • determine the target market and think over the marketing strategy.

Technology: how and from what to produce

The composition of the washing powder is distinguished by a variety of components. Almost all products on the market are made from the same chemicals, and the difference is due to the combination of various ingredients in certain proportions, which directly affects the quality of the finished product.

The correct percentage depends on how effectively the powder will remove stains, whether it will carefully affect the quality of fabrics, their color, etc. The role of the chemist is great in this matter. Therefore, make sure that your production has a competent and experienced specialist.

Chemical composition of washing powder: list of ingredients

As for the main components, most washing powders contain the following substances:

  • surface-active - separate dirt from fabric (synthetic substances, soap);
  • binders - eliminate the hardness of water, provide softness to fabrics, prevent the formation of scale in the washing machine (phosphates or, if these are phosphate-free washing powders, zeolites);
  • bleaching - due to the oxygen content, they give freshness to fabrics, remove plant stains on clothes (sodium perborate, etc.);
  • lipases - break down fatty contaminants, amylases - starch, alkaline proteases - protein;
  • anti-resorbents - prevent re-contamination of fabrics during washing, keeping the removed contaminants in solution;
  • auxiliary - give freshness to linen, neutralize unpleasant odors during washing.

Thus, in today's powder industry, as a rule, synthetic substances are used - permafrost. If the detergent is intended for washing children's clothes, then soap chips are usually added to its composition. It is absolutely harmless and environmentally friendly.

If the powder is intended for use in a washing machine, then defoamers are an obligatory component. These substances suppress the formation of foam during washing. Recently, phosphate-free washing powders have become more widespread, in which phosphates are replaced by zeolites, citrates and other harmless components. The result is a product that is completely safe for the environment and humans.

Raw materials for the manufacture of washing powder

Raw materials for the production of powder are not cheap, but quite affordable. The chemical industry is well developed in our country and it is not so difficult to find domestic suppliers for a plant that is starting its work. If we talk about the cost, then the average price tag in Russia is as follows (per kilogram):

  • sulfanol powder - about 100 rubles;
  • surfactants - 80 rubles;
  • soap shavings - 45 rubles.

Naturally, these are just the main components. There are many other, additional, which will also have to be purchased. However, the cost of one pack (500 grams) as a result of their combination will be low.

Production process: powder preparation steps

We talked about composition. And what is the technology for the production of washing powder? It is from its proper organization that the success of the final result will depend. As mentioned earlier, the most important difference between products from different manufacturers is not the components used, but their combination with each other. It determines the successful (or not so) composition of the powder and determines its quality characteristics. For example, some components enhance the effect of each other, while others reduce it. The process of developing the composition should take place in conjunction with competent chemists.

If we talk about the sequence of actions in the manufacture of powder, then it is as follows:

  1. The paste obtained by sulfonation of akibenzene is combined with the rest of the heat-resistant ingredients.
  2. The resulting mass is sprayed through the nozzles of the spray drying tower.
  3. The hot air dried droplets turn into powder granules.
  4. Next, the powder mass is mixed with non-heat-resistant ingredients (perborate, enzymes, etc.).
  5. As a result of all these processes, washing powder is obtained, which is sent for packaging.

The actual production of the powder is a fairly straightforward and well-defined process. The main thing is to successfully develop the composition of the detergent.

Powder compositions can be produced from metals and various alloys. They can be used in a variety of ways to protect workpieces and parts. Powder metallurgy is an actively developing area, which has a huge number of features. This direction of metallurgy appeared more than a hundred years ago.

Getting powders

For the production of powder, a variety of technologies can be used, but they are united by the following points:

  1. Profitability. Wastes from the metallurgical industry can be used as raw materials. An example is scale, which is not used anywhere today. In addition, other wastes can be used.
  2. High precision geometric shapes. Products obtained using the powder metallurgy technology under consideration have precise geometric shapes, and subsequent machining is not required. This point determines a relatively small amount of waste.
  3. High surface wear resistance. Due to the fine-grained structure, the resulting products have increased hardness and strength.
  4. Low complexity of powder metallurgy technologies.

Considering the most common powder metallurgy technologies, we note that they are divided into two main groups:

  1. Physical-mechanical methods consist in grinding raw materials, due to which the particle size becomes small. Such production processes are characterized by a combination of different loads that affect the raw materials.
  2. Chemical-metallurgical methods are used to change the phase state of the raw materials used. An example of such production is the reduction of salts and oxides, as well as other metal compounds.

In addition, we highlight the following features of powder production:

  1. The ball method involves the processing of metal scraps in a ball mill. Due to careful crushing, a fine-grained powder is obtained.
  2. The vortex method consists in the use of a special mill, which creates a strong air flow. Collision of large particles causes fine powder to be obtained.
  3. The use of crushers. The load that is created when a large mass falls causes the material to be crushed. The impact load acts with a certain frequency, due to which the composition is crushed.
  4. Atomization of raw materials in liquid form under the influence of compressed air. After obtaining a brittle composition, the metal is passed through special equipment, which grinds it to obtain a powder.
  5. Electrolysis is the process of recovering metal from a liquid composition under the influence of an electric current. By increasing the brittleness index, raw materials can be quickly ground in special crushers. This processing method makes it possible to obtain a dendritic grain.

Some of the above powder metallurgy technologies have become widespread in industry due to their high productivity and efficiency, while others are practically not used today due to the increase in the cost of the raw materials obtained.

compacting

Powder metallurgy also provides for a procedure that is based on the production of semi-finished products in the form of bars and strips. After pressing, you can get a product almost ready for use.

The features of the compaction process include the following points:

  1. A bulk substance is used as a raw material in the process under consideration.
  2. After compaction, the loose powder becomes a compact material with a porous structure. The strength of the resulting product is acquired in the course of other processing processes.

Considering the powder pressing process, we note the use of the following technologies:

  1. rolling;
  2. slip casting;
  3. isostatic pressing due to the application of pressure by a gas or liquid;
  4. pressing on one or both sides when using special metal matrices;
  5. injection method.

In order to speed up the compaction process, the product powder is exposed to high temperatures. In most cases, the distance between individual particles is reduced by high pressure. Powders made from soft metals have great strength.

sintering

The final step in powder metallurgy is the exposure to high temperatures. Virtually every powder metallurgy method involves exposure to high temperatures. Sintering is carried out to achieve the following goals:

  1. to increase the density of the product;
  2. to impart certain physical and mechanical properties.

For thermal exposure, special equipment is installed. The protective environment, as a rule, is represented by inert gases, for example, hydrogen. The sintering process can also be carried out in a vacuum to increase the efficiency of the technology used.

The induction heating method is also very popular. It involves the use of induction furnaces, which are produced or made by hand. On sale there is equipment that can combine several technological processes: sintering and pressing.

Application of powder metallurgy products

Powder metallurgy is used in aviation, electrical engineering, radio engineering and many other industries. This is due to the fact that the applied production technology makes it possible to obtain parts of complex shape. In addition, modern technologies of powder metallurgy make it possible to obtain parts that have:

  1. High strength. The dense structure determines the increased strength.
  2. Durability. The resulting products can last in harsh operating conditions for a long period.
  3. wear resistance. If you need to get a surface that does not wear out under mechanical stress, then you need to consider powder molding technology.
  4. plasticity. It is also possible to obtain blanks of increased plasticity.

Also, the spread of this technology can be associated with the low cost of the products obtained.

Advantages and disadvantages
The method of obtaining products from powders has become quite widespread due to the large number of advantages:

  1. low cost of the products obtained;
  2. the ability to produce large parts with complex surfaces;
  3. high physical and mechanical qualities.

The metallurgical powder method is also characterized by several disadvantages:

  1. The resulting structure has a relatively low strength.
  2. The structure is characterized by a lower density.
  3. The technologies under consideration involve the use of specialized equipment.
  4. If the production technology is violated, the parts are of poor quality.

Today, powder metallurgy is actively used in various industries. In addition, developments are underway that are aimed at improving the quality of the products obtained.

In conclusion, we note that when fine particles of various metals and alloys are combined, materials with special performance properties are obtained.