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Shampoo is the most used hair care product. One of its key advantages can be called versatility, because almost everyone uses it. Currently, there is a wide range of these products on the market, which include liquid, gel-like, dry and aerosol varieties. It should be noted that the first two of them are the most popular.
The high demand for this product allows us to say with confidence that the manufacture of shampoo as a business looks very promising, since it can bring considerable profit. Before opening this business, it is necessary to register as a legal entity or a private entrepreneur. In addition, it is necessary to register with the tax authorities.
Target Audience Selection
In general, depending on the components used, there are therapeutic, hygienic and tinted shampoos. At the same time, almost every person has his favorite type of this detergent. Before you start your own production of shampoo, you need to choose the target audience that such a business will be focused on.
As market analysis shows, recent times more and more popular are products made from natural ingredients and do not have various chemical additives. In this regard, there is every reason to believe that by occupying such a niche, one can succeed.
Raw materials and components for the manufacture of shampoo
Shampoo production occurs using water, detergents, waxes, alcohols, silicone oils, softeners, moisturizers and many other components. In addition, it often contains additives, including keratin, glycine, vitamins, various natural extracts, and so on.
It should be noted that, due to the similarity of the raw materials used and production technologies, many entrepreneurs often produce other types of cosmetic products (hair balms, liquid soap, and so on) simultaneously with shampoo.
Equipment and personnel
At the initial stage, for this type of entrepreneurial activity, it will be enough to have a small room or extension. In addition, you will need equipment for the production of shampoos. It is the most expensive part of this type of business.
It is mandatory to purchase receiving and intermediate containers, a three-layer reactor with a stirrer, a rotary pump, an automatic dosing machine, and a labeling machine. At the initial stage of development of the company, you can buy used equipment. This will allow not only to save money, but also to learn all the intricacies of making this detergent.
With regard to personnel, several operators must be hired to service the units. You can initially manage all the processes yourself. In addition, as in any other company, an accountant is needed who will deal with calculations and paperwork.
Manufacturing process
Shampoo production technology is quite simple. It lies in the fact that in the reactor in a certain proportion (it depends on the specific recipe) the components are mechanically mixed (surfactants and water-alcohol extract). Any special temperature regime and no pressure is required. Next, water that has been purified is poured. The whole mass is again mixed. Perfumes, sodium chloride and formalin are added at the final stage of the manufacturing process.
Further, the finished mass is poured into a special container with the help of a pump, where it settles for a certain time. The products are checked for compliance with the requirements of technical specifications and the state standard, after which (subject to a positive result) the shampoo is packaged in containers and labeled.
Marketing and Advertising
The production of shampoos in Russia is now a very common type of entrepreneurial activity. According to experts, this is primarily due to the relatively low costs that are required for the purchase of raw materials, as well as a fairly simple technological process in production. On the other hand, this leads to high competition in this area in the domestic market, which is considered the main problem of such a business. Proceeding from this, a competent marketing policy is necessary for the successful development of the company and its prosperity.
As practice shows, it is unlikely to attract a large number of buyers at a low price. One of the most promising areas is the production of shampoo under a contract, in other words, the acquisition of a franchise. Indeed, the use of recipes and the name of a well-known enterprise (especially foreign, with a good reputation) will allow you to return the invested funds much faster.
Capital investment and payback
As noted above, the most costly part of this type of business activity will be the purchase of equipment. The cost of a high-quality reactor with a stirrer is about 700 thousand rubles, intermediate and receiving tanks - about 100 thousand rubles, a pump - 50 thousand rubles, a labeling unit - 100 thousand rubles, a dosing machine with normal power - a little more than one million rubles. Thus, at the initial stage, it is necessary to spend about two million rubles on the purchase of equipment.
At the same time, do not forget about wages five operators required to service it. Among other things, for the manufacture of one ton of the finished product, you need to buy raw materials for an average of 13 thousand rubles, and one plastic bottle will cost approximately 5-10 rubles.
As practice shows, the initial investment required for the manufacture of 20 tons of shampoo, including packaging, is almost 3 million rubles. As for the payback period, for such a type of business as the production of shampoo, this period is two to three years.
The desire to open a business and work exclusively for themselves arises in many people, but not all of them begin to implement it. There can be many reasons for such timidity, but the most important one is the inability to choose a promising industry. In our opinion, this should be guided by the demand for the product or service that you want to produce or offer. For example, shampoo is a means of mass consumption. All people wash their hair and will wash it in the future. So why not organize a business if there is already a ready-made and well-established technology for the production of shampoos? Let's try to figure out what nuances this kind of entrepreneurship can have.
Components
Shampoo production cannot be started without a good recipe.
Among the main components of this product, it is worth highlighting:
- water (makes up 70-75% of the total shampoo);
- surface active agents (surfactants), which are necessary to remove dirt and grease. They make up about 20-25% of the total ingredients. Most often, sodium or ammonium lacryl sulfates are used as surfactants in the production of shampoos;
- detergents for the formation of foam and thickening of the shampoo;
- emollients to thicken the structure and make the hair soft;
- alcohols;
- waxes;
- additives;
- flavors.
Of course, this list of components is not exhaustive. We have included it only so that you can get a basic idea of the quantity and type of raw materials for shampoo. In every specific case the amount and type of ingredients used may vary. This is not surprising, because they are like shampoos. general use, and, for example, medicinal.
Production technology
Let's say you already have a recipe and purchased the components on the basis of which this recipe will be implemented. What's next? First of all, it is necessary to carry out quality control of the initial ingredients and complete water purification.
The production process itself begins with the supply of a mixture of alcohols and water to a special reactor, the subsequent addition of surfactants and the start of mixing. All other components are added gradually. Flavors and preservatives are added last. The finished product must be pumped out with a pump into a container designed for settling. It is from it that the analysis for quality control will be taken. If all the parameters and characteristics of the resulting product fully comply with technical standards, then you can start packaging the shampoo and sticking labels.
What equipment is needed?
Opening your own production of shampoos requires the following equipment:
- receiving and intermediate tanks;
- reactor with stirrer;
- rotary pump;
- shampoo dosing machine;
- labeling machine.
Particular attention must be paid to the choice of mixing device, since the quality of the final product depends on it.
Conventional mixing methods, when adding individual components, are not able to ensure a stable state of the resulting mixture, which is expressed in its stratification.
company GlobeCore designed that work based on the application of the injection method and hydrodynamic impact. This combination makes it possible to obtain high-quality shampoos. The produced product is characterized by increased stability and does not exfoliate for a long time.
Modern hydrodynamic (in-line) mixing plants have proven themselves in industrial operation as economical, accurate and stable means of producing shampoos with optimal cost. The achievable cost savings and increased profitability of production compared to traditional technology of mixing components in mixing tanks can accelerate the rate of return on investment by up to 60% per year and provide a return on the project for a period of up to one year or less.
The hydrodynamic mixer uses a mixing process that simultaneously feeds all components in a given recipe ratio into a common mixing manifold, through which the finished product is fed into a storage tank. The advantages of this technology are precise control of the dosing of each component, a significant reduction in the duration of the mixing cycle and the elimination of the use of mixing tanks to ensure the homogenization of the finished product. During the mixing process in an in-line mixer, the flow rate of each component is constantly adjusted in order to provide a finished product with stable quality indicators at the outlet of the mixing manifold according to a given recipe.
In conclusion, we note that it is also possible to speed up the return of the folded financial resources by using the same equipment for the production of liquid soap, toothpaste, cosmetic creams, etc.
Shampoo is a universal cleanser that also has a caring effect. According to the state of aggregation, this type of product can be divided into 5 types: powder, aerosol, cream and, the most popular types, liquid and gel. Such shampoos are the most convenient to use, in addition, they have an average cost and are suitable for all types of hair.
Shampoos from the destination are divided into 4 types:
Hygienic shampoos;
Shampoos with a tint effect;
Therapeutic and prophylactic;
And deep cleansing shampoos.
An entrepreneurial activity that is based on the production of shampoo will be a good start. This business does not require a large amount of costs, and the production process is not laborious. Most often, shampoo manufacturers are not limited to only one type of product. They are also starting to produce products that have a similar production process to shampoo.
The composition of the shampoo and its production process.
The most crucial moment in the production of shampoo is the formulation of the product. Each component has certain function and property.
Water that serves as the basis. In such an environment, the components that make up the shampoo are mixed.
Surfactants, that is, surfactants. They cleanse the hair of impurities. In this capacity, substances such as sodium or ammonium lacryl sulfate act.
Detergents, in their capacity are cocamide, cocamidopropyl betaine, as well as glyceret cocoate, decyl glucoside. These substances are also used for better foaming and moisturizing.
Emollients, they serve to thicken the structure of the shampoo and perform the function of conditioning the hair.
Silicone oils. Among them are dimethicone, cyclomethicone, which perform such functions as giving hair shine, smoothing and thickening the hair. They also make combing easier, but can cause itching and irritation.
Hair moisturizers that penetrate the hair cuticle and increase it and add shine to the hair. This category includes substances such as panthenol, nut butter and shea butter.
Alcohol cetyl, oleyl or stearyl. This product is a lubricant that facilitates combing.
A variety of waxes that improve the appearance of the shampoo and its consistency.
sodium salt citric acid maintaining a normal pH level. Also, this ingredient evens out the structure of the hair.
All kinds of supplements that care for hair. These include vitamins, components that protect the hair from the sun, and other components.
The composition also includes various flavors, preservatives and fragrances.
To start production and packaging of 20 tons of shampoo in 250 ml containers, investments in the amount of 3-3.5 million rubles are required. This amount includes the rental price. A business plan for the production of shampoo can bring good profits. The payback period for such a business is approximately 2-3 years.
The implementation of shampoo has such a problem as a high level of competition. The country has a large number of companies of foreign and Russian location that specialize in the production of cosmetic products. And trying to attract users with a low price will not be the best choice. An option that can solve this problem is the production of shampoo under contract. It is possible to choose this path: to find some representative of the brand, which has already taken its place in the market, and produce shampoo according to their recipe.
Preparation of raw materials. Raw materials received at the warehouse, before being used in production, are necessarily subjected to external inspection and laboratory analysis for compliance with the requirements provided for by this technology, after which they are fed to the reactor for unloading.
Means preparation. Shampoos are prepared by mechanical mixing of the components with water in a reactor equipped with a stirrer. The use of a specially designed agitator prevents foaming of the mass. Mixing of components is carried out at the temperature of the production room and atmospheric pressure.
Water-alcohol extract and surfactant are sequentially loaded into the reactor with the stirrer turned on, which are then mixed.
Drinking water is treated at the water treatment complex and is fed into the reactor with the agitator turned off. A sample of this water is preliminarily taken for compliance with the requirements for the quality of water for the preparation of shampoos. The water supply is controlled by a water meter. Next, the components of the shampoo are mixed with water.
Formalin and fragrance are added. Next, with the mixer turned off, a pre-prepared sodium chloride solution is poured using a pump and mixed. The finished product with the help of a pump is fed into the intermediate tank for settling. The product is settled, after which a sample is taken and an analysis is made for compliance with the specifications, and if positive results are obtained, the product is sent for packaging.
Modern shampoos are mostly multifunctional and their recipes can contain from 10 to 15 ingredients or more. These include basic surfactants, thickeners (viscosity regulators), emulsifiers and emulsion stabilizers, complexing agents (water hardness regulators), foam concentrates and foam stabilizers, conditioners, colorants, fragrances, preservatives and other functional additives.
According to the definition of shampoos, they are homogeneous single-phase or multi-phase liquids with a gel - or creamy mass without foreign impurities. According to the state of aggregation, these are coarsely dispersed systems of the emulsion class. Most emulsions belong to the direct type of oil-in-water dispersions with a low content of the dispersed "oil" phase. When preparing emulsions, the aqueous and oil phases must be dispersed one into the other. For the dispersion of shampoos, mechanical mixing of liquids using paddle and propeller mixers is most widely used (Figure 6).
Figure 6. Paddle mixers
1. Preparation of the aqueous phase
The aqueous phase of shampoo emulsions, in addition to water as a solvent, contains water-soluble ingredients: thickeners, softeners, moisturizers, basic surfactants, electrolytes. Most of of which is added to the water initially and only a small amount during mixing with the oil phase and fine-tuning the finished shampoo emulsion to a predetermined condition.
process water
According to normative documentation for washing hygienic cosmetic products in shampoos, as process water as a solvent, it is allowed to use water for household needs, demineralized and deionized. Traditionally, household water is used with the addition of sequestrants. These substances prevent the formation of an insoluble precipitate of salts of polyvalent metals Ca, Mg, Fe and others contained in water and at the same time lower the hardness of water by binding sequestrants with cations Ca 2+ , Mg 2+ , Fe 2+ into complex compounds.
Of the sequestrant substances in shampoos, ethylenediaminetetraacetic acid (ETDA) and crystalline hydrates of its disodium salt (Trilon B) are most often used.
Acid-base balance.
According to the ND, the pH value in shampoos should be in the range from 5.0 to 8.5. As a regulator of pH values in shampoos, citric acid and caustic soda are mainly used. The bulk of citric acid is introduced into the water immediately after its dosage in order to create an acidic environment in it, which ensures a high dissolution rate of many ingredients without heating the aqueous phase, and also excludes the hydrolysis of alkylolamides with the release of ammonia. Caustic soda is introduced into the aqueous phase at the end of its preparation in order to bring the pH to a predetermined value.
thickening
According to technical requirements to shampoos, their consistency with a gel or creamy mass can vary from liquid to thick. Most of the thickeners (80% of their mass) are introduced into the aqueous part initially during its preparation, the remaining part is added to the finished emulsion when it is brought to the desired viscosity.
Alkyl amides, polymeric materials, and electrolytes are used as thickeners. When alkyl amides and electrolytes are added, the viscosity of an aqueous solution of surfactants changes due to the aggregative transformation of micelles into more complex geometric shapes, which increases the stress of internal friction and viscosity, and thereby provides the effect of thickening shampoos. Alkylolamides are introduced into the shampoo at the stage of formation of the aqueous phase, and electrolytes are added to the final composition of the shampoo in order to adjust the viscosity and improve compatibility.
When adding polymeric materials (water-soluble polymers, ethoxylated polyhydric alcohols with a polyol chain). The thickening effect is based on their ability to spontaneously form dispersed systems such as jellies with a spatial grid - a framework of polymer chains with a two-dimensional or three-dimensional lattice.
haze and opalescence
Most shampoos are made opaque and have a pearlescent or opal look. Their opacity is created by introducing substances into them - opacifiers. As the latter, salts of fatty acids C 16 -C 18 (palmitates and stearates of magnesium and zinc), alkylolamides and glycerides of fatty acids, esters of ethylene glycol and polyethylene glycol (mono- and diethylene glycol monostearates), monoalkyl esters of fatty acids are used.
The mother-of-pearl effect is due to a change in the optical properties of the crystals, which partly reflect and partly refract the incident light. Different stearate crystals create different pearl effect. The pearlescent effect is also affected by the length of the alkyl group of alkylolamides: for example, coconut diethanolamide gives less shine, while lauric monoisopropanolamide has more shine. The degree of turbidity and the level of gloss are significantly affected by the magnitude of the shear rate when mixed with the aqueous phase and temperature. At high shear rates, a high degree of haze and a low level of gloss is obtained, and, conversely, at low shear rates, haze decreases and gloss increases.
Introduction of basic and auxiliary surfactants.
In the production of shampoos, sodium and ammonium salts of sulfoesters of fatty alcohols (mainly C 12 lauryl alcohol and a mixture of C 12 -C 14 fatty alcohols of coconut oil) are mainly used as base surfactants: alkyl sulfates and alkyl ethoxy sulfates with a degree of oxyethylation from 2 to 3, sulfates of mono- and triethanolamides of lauric acid and a mixture of fatty acids of coconut oil.
The concentration of basic surfactants in shampoos is determined by their formulation and consumer properties and is (wt%): in cleansing foaming shampoos from 5 to 27, and in multifunctional conditioning shampoos from 7 to 30. All of the listed surfactants are anionic and readily soluble in water (with the exception of lauryl ethoxy sulfate ).
When preparing the aqueous phase, the base surfactants are first dissolved in pure process water. The mass of this water is equal to the difference between the total mass introduced into the shampoo as a solvent according to the recipe and the mass of water consumed at the stage of thickening and turbidity, as well as in the preparation of a sodium hydroxide solution for adjusting the pH in the acid-base balance of the aqueous phase. On average, this amount of water is 50% of its total mass.
Auxiliary surfactants are introduced into shampoos to enhance foaming and improve the quality of the foam (more creamy and thicker), to impart dermatological softness to the formulation (reduce skin and eye irritation), as well as to increase the viscosity of the shampoo. As auxiliary surfactants, amphoteric surfactants are used: cocamidopropyl betaines, cocamphocarboxyglycinates, lauryl (C 12) - myristyl (C 14) - and cocdimethylamine oxides, cocamidopropyl dimethylamine oxides, decyl-, undecyl- and cocpolyglucosides. They are highly soluble in water and for cleansing foaming shampoos that do not contain an oil phase, they are introduced into the aqueous phase together with base surfactants.
Other substances
These include ingredients that improve functional and consumer properties. These can be emulsifiers, emulsion and foam stabilizers, solubilizers, preservatives, moisturizers, useful additives that determine the type of shampoo.
2. Preparation of the oil phase
The oil phase contains water-insoluble ingredients: dyes, fragrances, conditioners, preservatives, emollients, useful additives. Some of these substances may be water-soluble, but within the framework of the technology for the manufacture of shampoos, especially multifunctional conditioning ones, it is advisable to introduce them into the oil phase.
Depending on the composition and physico-chemical properties of the ingredients, the oil phase is prepared either in parts. Or completely with simultaneous loading. During the loading of the ingredients into the phase, it is continuously stirred until a homogeneous mass is obtained and, if necessary, heated to a temperature of 75-80? C to increase the dissolution rate. The finished oil phase is added to the aqueous phase with continuous stirring.
3. Adjustment of the viscosity and acid-base balance of the shampoo
The viscosity of most shampoos is adjusted by adding NaCl saline to them. The pH value is adjusted by adding sodium hydroxide solution NaOH and citric acid to the shampoo.
4. Process plant
The technological process for the production of shampoos includes the stages of weighing and dosing the ingredients, their loading and mixing, heating and cooling of the phases, and their pumping, analysis of intermediate mixtures and the final product, finishing the finished product to a given condition (pH of the medium, viscosity, density, appearance and color) and pumping it into a storage container with subsequent packaging.
Figure 7. Schematic diagram of the design of a high-efficiency double circulation mixer.
To carry out these stages, the technological installation must include: mixers, pumps, measuring tanks and dispensers, feeders, heaters / coolers, analyzers, shutoff valves.
Depending on the production plant, the working volume of the mixers ranges from 50 to 6000 liters. As mixing devices in mixers, paddle, propeller (Figure 8) and anchor-scraper mixers equipped with stationary breakwaters are used.
Modern mixers (Figure 7) are additionally equipped with autonomous system washing, which cleans the apparatus from the previous mixture after pumping out.
Figure 8. Propeller agitator.
Figure 9. Shampoo production reactor.
Figure 10. Vacuum-homogenizing apparatus for cooking
cosmetic
Figure 11. Block diagram of the process unit for the production of shampoos
Apparatus-mixers for the preparation of: aqueous phase (1), aqueous NaOH solution (2), oil phase (3.4), shampoo (5).