New Commercial Cleaning Manual 1

Insider’s Secrets To The Cleaning Chemical Business

Copyright CleanChem16, 2016

Page ii

Commercial Cleaning Manual #1

Table of contents

Legal Notices & Disclaimers ................................................................................................................ 1
Introduction ........................................................................................................................................... 5
Think Positive, You Can Do It!!!........................................................................................................... 7
An Important Word Before You Begin ................................................................................................ 9
Working with Percentages .................................................................................................................12
A Word on Manufacture......................................................................................................................14
A Brief Introduction To Detergents ...................................................................................................22
Marketing .............................................................................................................................................27
Product Costing ..................................................................................................................................29
Labelling............................................................................................................................................... 30
Where to Find Raw Material Suppliers..............................................................................................32
Safety In The Laboratory or Home Workshop..................................................................................34
Government Legislation: Safety, Storage, Labelling and Handling of Dangerous Goods..........38
Product MSD Sheets...........................................................................................................................40
Emergency First Aid for Chemical Injuries ......................................................................................44
1. Economy Hand Soap ......................................................................................................................46
2. Multi-Purpose Universal Cleaner (Formula No.2) ........................................................................48
3. Urinal Cleaner (Acid based) ...........................................................................................................51
4. Toilet Bowl Cleaner (Acid Based)..................................................................................................52
5. Liquid Carpet Shampoo.................................................................................................................54
6. Air Freshener (Formula No.3) ........................................................................................................56
Basic Ingredient Catalogue................................................................................................................58
Incompatible Chemicals .....................................................................................................................66

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Insider’s Secrets To The Cleaning Chemical Business

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Insider’s Secrets To The Cleaning Chemical Business

Introduction

This series of manuals contains, simply set out, instructions for formulations of excellent
marketable products. In fact manufacturers have commented that some of these formulas are
even better than well-known brand name products in the marketplace.

The following formulations and manufacturing instructions have been specifically written in
simple terms, so that anyone with no previous experience in this business can understand them
and carry out the instructions. Although some of the terms and chemical names may look a bit
daunting and complicated at first, you will soon discover how simple each manufacturing
operation actually is.

Before any attempt is made to begin manufacturing, it is important that you thoroughly read
through this manual a few times so that you familiarise yourself with it and make sure that you
understand exactly what is involved.

Chemical formulations are composed of pigments, gums, resins, solvents, oils, greases, fats,
waxes, emulsifying agents, dyestuffs, perfumes, water, and chemicals of great diversity. To mix
certain of these with some of the others requires definite procedures, any departure from which
will inevitably result in failure. The steps for successful formulating are given with the formulas.
Follow them rigorously. If the directions require that (a) is added to (b), carry this out literally, and
do not reverse the order. The preparation of an emulsion is often quite as tricky as the making of
mayonnaise. In making mayonnaise, you add the oil to the egg, slowly, with constant and even
stirring. If you do it correctly, you get mayonnaise. If you depart from any of these details; if you
add the egg to the oil, or pour the oil in too quickly, or fail to stir regularly, the result is a complete
disappointment. The same disappointment may be expected if the prescribed procedure of any
other formulation is violated.

The next point of importance is the scrupulous use of the proper ingredients. Substitutions are
sure to result in inferior quality, if not in complete failure. Use what the formula calls for. A
formula may call for an ingredient which is difficult to obtain. In such cases substitute a similar
substance only after a preliminary experiment demonstrates its useability. There is a limit to
which this rule may reasonably be extended. In some cases, substitution of an equivalent
ingredient may be made legitimately. For example, when the formula calls for white wax
(beeswax), a yellow wax can be used, if the colour of the finished product is a matter of
secondary importance. Yellow beeswax can often replace white beeswax making due allowance
for colour, but paraffin wax will not replace beeswax, even though its light colour seems to place
it above yellow beeswax.

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Insider’s Secrets To The Cleaning Chemical Business

This leads to the third point: the use of good-quality ingredients, and ingredients of the correct
quality. Ordinary lanolin is not the same thing as anhydrous lanolin. The replacement of one with
the other, weight for weight, will give discouragingly different results. Use exactly what the
formula calls for.

Buy your chemicals from reliable sources. Many ingredients are obtainable in a number of
different grades: if the formula does not designate the grade, it is understood that the best grade
is to be used. Remember that a formula and the directions can tell you only part of the story.
Some skill is often required to attain success. Practice with a small batch in such cases until you
are sure of your technique. In the case of the use of dyestuffs for colouring lotions and the like,
dyes vary in strength; they are all very powerful in tinting value; it is not always easy to state in
quantitative terms how much to use. You must establish the quantity by carefully adding minute
quantities until you have the desired tint.

If you are completely inexperienced, you can profit greatly by experimenting. Such products such
as disinfectants, household bleach and window cleaner need little or no experience, because
they are, as a rule, merely mixtures of simple liquid and solid ingredients, which dissolve without
difficulty and the end product is a clear solution that is ready for use when mixed. However, face
creams, hand cleaner, lubricating greases, wax polishes, etc., whose formulation requires
relatively elaborate and through mixing procedures and which must have a definite final viscosity,
need some skill and may require some trial and error before achieving the desired result.

Some of the chemicals that are required in certain manufacturing processes are very dangerous.
Take care when handling and using these chemicals. You should always request a MSDS
(Materials Safety Data Sheet) from your supplier with the purchase of any chemical. Read
through the safety, handling, and storage instructions carefully and adhere to these instructions.

Remember, this manual has been specifically written for people who are "new" to the business.
Do not let complicated terms and chemical names confuse you.

All you need to do is

STRICTLY FOLLOW THE INSTRUCTIONS!

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Think Positive, You Can Do
It!!!

Have confidence in yourself. Don't sell yourself short.
Many manufactured products with national distribution
lines today were once manufactured in a small way by
people who possessed the confidence in their ability to succeed. They ^ J succeed, and there is
absolutely no reason why you can't make products as good as the finest on the market. You
must believe it!

Any product, regardless of type, has not been made that cannot be improved upon. That's the
reason why some products put out by little known manufacturers are actually superior to those
offered by the big companies. So, never be satisfied with the product you are making. Always try
to improve upon it - you don't have to be a chemist to do so. Experiment on your own - you might
be surprised at what you can do. The big companies are working 'round the clock' to improve
their products, which accounts for the constant change in the formulas of many products in the
market.

Just take a look at the evolution of the camera since Polaroid introduced its Land Camera -
supposedly the 'ultimate camera'; today digital technology has far superseded this camera. So,
regardless of how good a product may be, the possibility of improvements is always there and
should be explored at every opportunity.

Lack of finances is no barrier to success. In this business you can start up on a shoestring. The
unsuccessful person inevitably uses this as an alibi for their failures, but it is an overworked alibi.
Looking at the old saying: "it takes money to make money"; while there is nothing particularly
wrong with this statement, why is it that so many people with little or no money to speak of, have
achieved greatness in their chosen field or profession? It is because they want success strongly
enough to work for it and they have confidence in their ability to achieve it.

These people are Positive Thinkers, one of the outstanding characteristics of successful people.
Instead of looking upon a project with doubt, fear and skepticism, the positive thinker turns a deaf
ear to all the Doubting Thomases who tell him it can't be done. He goes ahead and does it!

The Negative Thinker, as much through laziness as anything else, seems to welcome negative
comments from others so he won't have to put in the effort. It gives that person a good excuse
for being a failure.

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Insider’s Secrets To The Cleaning Chemical Business

You now have in your possession TRADE SECRETS that are obtainable nowhere else. Most
successful manufacturing companies started out with unsophisticated equipment and with
nowhere near as much knowledge as you now have at your fingertips. You have a far better
chance of success than any of them ever had. Take advantage of this and use it!!!!

Some of the products described in our manuals such as Disinfectant, Fabric Softener, Household
Bleach and Window Cleaner to mention a few, are incredibly easy to make.

The products in this manual need no complicated machinery or equipment to produce. In fact
very little equipment is needed to start. Most of the equipment, >such as measuring jugs, mixing
sticks, kitchen and bathroom scales, a heat source like a portable gas burner, can be found in
and around your home or at your local supermarket or hardware store. Mixing can be done by
hand.

As your production quantities increase you may want to use mechanical apparatus to assist you.
You can make a simple mixer by using a power drill (non-arcing) and connecting a long shaft
with a blade to it, or for quantities of powders you can use a 'tumbling' device such as a portable
cement mixer. For mixing big quantities of chemicals you may want to get a clean 200 litre (44
gallon) drum. To start with, these additional items will not be necessary.

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Insider’s Secrets To The Cleaning Chemical Business

An Important Word Before You Begin

Before you start any part of the manufacturing process
read this manual thoroughly.

Acquaint yourself with all the chemicals you will be using and be familiar with how to handle
them. You should refer to the MERCK INDEX or HAWLEY'S CONDENSED CHEMICAL
DICTIONARY or similar text books which will contain this important information. These reference
books are available in most large libraries. If the book is not in your local library you can make a
request for .in 'inter library loan' of the book. Ask your local librarian for more details about this
service.

Always wear the correct personal protective equipment when dealing with chemicals.

Some of the chemicals you will be dealing with are hazardous. Take care when handling and
using these chemicals. You should always request a MSDS Materials Safety Data Sheet) from
your supplier with the purchase of each chemical. Read through the safety, handling, and
storage instructions carefully and adhere to these instructions. Your chemical supplier should be
most helpful here and will also be able to advise you on First Aid and treatments in the case of
an accident. You can also contact Safe Work Australia at:
www.safeworkaustralia.gov.au/sites/SWA.

They will be able to assist you with information and regulations concerning the safety, handling
and storage of your chemicals.

You must check on labelling requirements and other possible restrictions in your State. The
SAFE WORK AUSTRALIA will be able to help you with these requests and can give you the
contact details for your local State governing authority which will be able to advise you if the local
regulations differ from those of the SAFE WORK AUSTRALIA's. The information supplied in this
manual has been offered in good faith and does not authorise the violation of any legal
requirements or laws. Neither do we authorise the user to substitute one raw material brand for
another, in violation of any patent.

As we have no control over the quality of raw materials used and manufacturing procedure, we
cannot guarantee the finished product, although these are tried and tested products. It is
recommended that the user manufacture test samples of any product before adopting them on a
commercial scale.

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Insider’s Secrets To The Cleaning Chemical Business

Although every effort has been made to cover the many aspects in this manual, no responsibility
is accepted for errors or omissions, as the possible detail in each and every respect is almost
endless.

It is suggested that omissions and details not explained in this simplified manual be obtained
from a reference library.

References

An excellent form of reference is the MERCK INDEX as well as HAWLEY'S CONDENSED
CHEMICAL DICTIONARY. These reference books will be able to supply you with specific details
on any chemical substance. They are an excellent point of reference for chemicals and their
handling thereof.

Abbreviations

Litre = ltr
Millilitre = ml
Kilogram = kg
Gram = gr

Approximate Equivalents

1 ltr of water = 1 kg of water
1 ml of water = 1 g of water
250 ml of water = 1 cup of water
25 ml of water = 1 tablespoon of water
5 ml of water = 1 teaspoon of water
Note: 1 kg = 1,000 grams
= 1,000 ml
1 ltr

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Insider’s Secrets To The Cleaning Chemical Business

Weighing and measuring

Every one of your ingredients must be carefully weighed. Doing this isn't difficult, but because
mistakes can result in failed batches, it's important to familiarise yourself with your scales and
measuring apparatus.

These instruments are all too easy to misread. Two common mistakes are glancing at the scale
too quickly and misjudging the weight that the gradation lines represent. Different manufacturers
mark their products differently, so figure out what each line represents before you use these
instruments.

Another common error is to assume that the grams used to measure weight are equal to the litre
measurements of volume. Volume and weight are not the same! Unless otherwise specified, the
formulae in this manual refer to weight - not to volume.

IMPORTANT: The percentage figures (%) used in each formula refer to the weights, not
the volume. You will notice that even the chemicals that are in liquid form have been referred to
by their weight and not by their volume. This is due to the fact that their densities differ (ie. one
litre of a chemical by volume may not be equal to one kg of the same chemical by weight). So by
using weight and not volume as a form of measurement you will achieve the most accurate
mixing quantities. Although we have supplied some measurements for you in volume, you must
weigh all components when determining your precise mixture quantities.

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Working with Percentages

To make things clear for you we have given percentages (%) to all of our ingredients to be used
in each of our formulas.

The percentage figures in our formulations refer to the weights, not the volume. You must weigh
all components and make sure that the weight is correct before adding them to your mixture.

If this is the first time that you will be working with percentages (%), do not be confused. It is very
simple.

To make things simple for you we will explain it like this;

1% means one hundredth (1/100) of the weight of the end product.

5% means five hundredths (5/100 or 1/20) of the weight of the end product.

25% means twenty five hundredths (25/100 or ¼) of the weight of the end product.

Let's look at some examples:

Percentage To make100 kg To make 50 kg To make 25 kg To make 10 kg
given use use use use
the formula:
1% (1/100) 1 kg 0.5 (1/2) kg or 0.25 (1/4) kg or 0.1 (1/10) kg or
500 g 250 g 100 g
5% (5/100) 5 kg 2.5 kg 1.25 kg 0.5 kg
10% (10/100) 10 kg 5 kg 2.5 kg 1 kg
20% (20/100) 20 kg 10 kg 5 kg 2 kg
75% (75/100) 75 kg 37.5 kg 18.75 kg 7.5 kg

As you can see, these calculations are quite easy.
Another way of working out the amount of an ingredient is to do the following:
1. Find out what is the final weight of the product you want to manufacture.
2. Take the percentage value of each required chemical ingredient and multiply it by this

final weight.
3. The result will be the quantity of chemical ingredient you will need to add.

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Example:
35 kg is the total amount of product you wish to manufacture.
7% is the amount of chemical you need to add.
To find 7% of 35 kg:
1. Final weight is 35 kg.
2. 7% is 7/100 of the product you wish to add. So multiply 7 by 35 and divide by 100.
3. Your answer is 2.45 kg of chemical ingredient required.
Percentage Figures
The PERCENTAGE FIGURES in the formulas refer to WEIGHTS and NOT VOLUMES. WEIGH
all ingredients before adding to the mixtures.
NOTE: Where a percentage figure appears as part of the ingredient it has nothing to do with the
percentage of the ingredients that goes into the main mix. An example is SLES (28%). This
means that you should purchase SLES which has a strength of 28%. If you purchase a weaker
strength SLES (some suppliers stock SLES at a strength of 25% for example) you will have to
use a little more of it in your mixture than the amount stated in the formula.

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A Word on Manufacture

Chemical Storage

Always keep your chemicals as well as your finished product securely stored away under lock
and key and out of the reach of children and animals.

To ensure that chemicals stay in their proper state it is essential that all containers prior to being
used for storage are clean. Once they are filled they must be sealed properly. This is essential to
avoid contamination. Perfumes, acids, alcohols and oils will also evaporate if not kept tightly
sealed. It is also mandatory that all powders are kept free from moisture and so they must also
be firmly sealed. Some ingredients will need to be stored in dark containers as they deteriorate in
bright light.

You must check with your local State Government or the National Occupational Health and
Safety Commission (SAFE WORK AUSTRALIA) to determine whether you require any
dangerous goods permits for the chemicals you will be storing. Depending on where your
chemicals will be stored, there may be storage and quantity restrictions. You can contact the
www.safeworkaustralia.gov.au they will be able to assist you with information and regulations
concerning the safety, handling and storage of your chemicals.

Water

The water used in certain products must be of the purest grade possible. Water fit for human
consumption is normally satisfactory. As bacteria in water can cause problems in the
manufacturing process you will find that most products use a preservative to overcome this.

Using a Waterbath

Some manufacturing procedures call for the use of a 'Waterbath'. This is a double boiler, which
insures that the contents of the inner container are not heated to more than 100oC (boiling point
of water). This is very important when working with waxes and volatile materials. A basic
Waterbath can quite easily be made from kitchen equipment - just make sure that the inner

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Insider’s Secrets To The Cleaning Chemical Business

container is surrounded by water both at the sides as well as underneath. When filling a
waterbath take care not to allow the water to overflow into the inner container.
An illustration of a simple Waterbath:

To melt all waxes you should always use a waterbath.

Carefully adhere to the following directions:

1. Put the waxes into a metal container (the inner container).

2. Do not apply direct heat, instead half-fill the outer metal drum (container) with water.

3. Apply heat to the drum to heat the water.

4. Now float the container with the wax in the hot water.

5. Take special care not to allow the wax container to sink too deeply into the water to
permit the water to overflow into the wax container.

6. Maintain heat to the water drum until the wax in the inside drum has melted.

Checking the pH of Your Product

In the manufacture of some products you may need to acquire a certain pH level before you can
add your next ingredient, or you may need to alter the pH level in order to achieve the desired pH
of your final product.

pH stands for the power of hydrogen: the measure of the hydrogen ion in concentration in a
solution. All chemicals are either acidic, basic or neutral. Pure water is described as neutral or
having a pH of 7.

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Insider’s Secrets To The Cleaning Chemical Business

The term pH is used to measure the acidity or alkalinity of a product with pH = 7 being neutral
between the two. The number of the pH gives an indication of the strength or concentration of the
acid or alkali. If the pH of a solution is lower than 7 the solution is acidic. If the solution has a pH
which is higher than 7, the solution is alkaline.

To check for pH you will need pH paper. This can be obtained at pharmacies, swimming pool
shops and from your local chemical supplier. We recommend "Whatman pH paper" obtainable
from Merck Pty Ltd, telephone 1800 337 460.

Testing for pH

To test the pH of your product dip a section of approximately 2.5 cm of pH paper into the
solution. You will notice that the colour on the pH paper has changed. Now hold this colour next
to the colour chart that accompanied the paper and read of the current pH from the chart
according to the colour.

As an example, we will say that we are trying to achieve a neutral pH of 7. If the reading from
your test gave you a pH level of 12 then you would have to lower the pH.

To lower the pH, add small quantities of Sulphonic Acid or Citric Acid solution (± 5 ml or 1
teaspoon at a time), depending on the quantity of product you are making. Stir this in well and
then check the pH again.

If the reading you initially received was 3, then you would have to raise the pH to 7.

To raise the pH, add small quantities of Caustic Soda solution (otherwise known as Sodium
Hydroxide), (± 10 ml or 2 teaspoons at a time), depending on the quantity of product you are
making. Stir this in well and then check the pH again.

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Insider’s Secrets To The Cleaning Chemical Business

Repeat this process until you have reached a pH of 7. As the pH gets closer to 7 you should use
lesser amounts of Caustic Soda or Sulphonic Acid each time until reach 7.

If the product you are manufacturing requires a lower or higher pH than 7, just the final
suggested pH level as your goal to attain.

Nowadays you can purchase cheap electronic pH meters. If you would prefer to use one of
these, we recommend that you read its operating instructions carefully and still do a final check
on your product using conventional pH paper.

pH Levels

pH has to be at a specific level in some of the formulations. Where it is specified it is important to
make sure that this pH is attained in order for the product to be effective.

In Dishwashing Liquid, Bubble Bath and Hair Shampoos, it is important for the pH to be at a
neutral level (approximately pH 6.9 or 7) as these products come into contact with the skin and
can burn it if the pH is too far out ie. too acid or alkaline. Some detergents and cleaners that are
applied with the use of a cloth or mop and not through skin contact will have a higher pH which
makes them more effective.

pH Values

The table below shows different chemicals and their pH values.

ACIDS pH Value ALKALIS pH Value
Hydrochloric Acid 1.0 Sodium Bicarbonate 8.4
Sulphuric Acid 1.2 Borax 9.2
Phosphoric Acid 1.5 Ammonia 11.1
Acetic Acid 2.9 Sodium Carbonate 11.6
Alum 3.2 Trisodium Phosphate 12.0
Carbonic Acid 3.8 Sodium Metasilicate 12.2
Boric Acid 5.2 Lime, Saturated 12.3
Sodium Hydroxide 13.0

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Insider’s Secrets To The Cleaning Chemical Business

Mixing Machinery

All products herein have been selected for their ease of manufacture because they do not need
expensive machinery and can be mixed by hand. As your production increases though you can
begin introducing workshop aids to assist you in the mixing process.

Perfumes

Perfumes are added to most products to increase their attractiveness and to mask their raw
ingredient smell. For cleaning agents used on the food preparation surfaces in the food
preparation industry however, the agents must remain unscented. This is a mandatory
requirement of the Australian Quarantine and Inspection Service (AQIS). The reason, besides
from a health aspect, is that they do not want foodstuffs to pick up the scents left behind on
preparation surfaces by the cleaning agents. Unscrupulous companies may also try to use
overpowering scents to disguise the smell of old/rotting food. It also makes sense as people
would feel uncomfortable about buying pine scented pork!

When adding perfumes to a product it is common sense to use a scent associated with the
product colour. For example a strawberry scent is associated with a red product, not a blue or
green one. Perfumes commonly used in products are Lemon, Lime, Apple, Strawberry and Pine.
Your supplier may also stock other attractive scents.

With personal products such as shampoos and bubble baths it is best to do some research.
Study similar products on the market and ask your customers what they want.

Dyes and Pigments

There is a large range of both liquid and powder dyes available nowadays. When working with
dry powders, granules and pigments, they should always be finely ground together and then be
put through a sieve (a fine kitchen sieve is ideal) before you add any liquid components.

Always check with your raw material supplier that the dye and perfume you will be using is
compatible with the raw materials in the formulation you are making up as it is essential that the
type of dye and perfume you are using is stable in the finished product. If not, your supplier will
more likely have alternate compatible dyes and perfumes for you. If not, they will be able to
recommend a scent where you can get them.

Dyes can be very concentrated and so a small discrepancy could quite drastically change a
colour shade. This is especially the case with powder dyes. It is recommended that when adding
dyes to a product you use a small portion (5 g) and add it to a litre of water. Now add small

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quantities of this to the formula until the desired colour is achieved. By using this technique you
will be able to control your colour mixing much more accurately. To ensure the continuity of
colour shades from manufactured batch to batch, use the same measuring devices to measure
dyes and pigment each time. Usually dyes and perfumes are added towards the end of the
mixing process when the product is cool.

You should consult your supplier for particular specifications and the suggested amounts of dye
and perfume to use for their particular brand.

It is important that the dye's stability in sunlight (in the presence of ultra-violet light) be checked
with your supplier. Especially with detergents check on the stability of the dye and perfume in an
alkaline mixture. In a similar manner check on their stability in an acid solution. Your supplier will
be able to give you advice on this.

Thickening Agents

There are a number of various thickening agents available that increase the viscosity of products.
Many of these thickeners are only suitable for a certain range of products. Before using any of
these agents check its specifications with your supplier to make certain that it can be used with
your product. Examples of such agents are Acrysol ICS-1, Natrosol, Guar Gum and Salt.

Acrysol ICS-1:

This thickener is also known as PLEX 4061 D and Alcogum.

It is an alkali-soluble acrylic polymer emulsion with an unusually high aqueous thickening and
stabilising efficiency. When neutralised to a pH above 7 by adding alkali, Acrysol ICS-1 thickens
instantly. It is widely used in the following products:

Liquid detergents;
Laundry detergents
Concentrated caustic solutions
Hard surface cleaners
Liquid abrasive cleaners
Emulsion cleaners
Waterless hand cleaners
Oven cleaners
Paint strippers
Free standing gelled products
Acid metal cleaners

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Acid toilet bowl cleaners
Acrysol ICS-1 may be used as a thickener at 0,7% or less.

Natrosol:

This is a white, slightly creamy, odourless, tasteless, free-flowing powder. It must only be added
to the solution when the pH is 7 (neutral). Once added and thoroughly mixed the pH of the
solution can be adjusted to achieve its end target. Natrosol can be used in all of the above
mentioned products as well as in Fabric softener.

Guar Gum:

This is an economical thickener and can be used in a wide variety of products. It re sifted in
slowly and carefully as it is added to the solution.

Salt:

Salt is also used in certain formulae and, in combination with certain compounds (SLES is an
example), increases viscosity. With products such as shampoos and bubble baths a certain
amount of experimentation may need to be carried out to make a product with the exact
thickness that you require. Do not depart too much from the basic formula however.

The above thickeners must all be added whilst stirring (or lightly shearing) your solution.

REMEMBER:: When using a thickener always ask your supplier for their recommendations.

NON-IONIC

You will find that Non-Ionic is used in some formulas to overcome the natural face tension
between oil and water which prevents them mixing. A main function of a detergent is to break
down this surface tension to allow the water to oil to mix. A "Surface Active Agent" or "Surfactant"
as it is more usually called is a concentrated detergent. Sometimes the term "Wetting Agent" will
be used.

Different types of Surfactants are Anionic, Cationic, Non-ionic and Amphoteric.

In our formulas the term Non-Ionic (9 mole) will be found.

Ask your usual supplier for "Non-Ionic N9 or NPB" or the equivalent. Always ask for Non-Ionic in
9-mole strength.

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Q.A.C.

Q.A.C. is an abbreviation for Quaternary Ammonium Compound. This is a disinfectant/sanitizer
widely used because of its exceptional antibacterial effect. Q.A.C. is widely used in hospitals,
public toilets, homes, work situations and all places where cross-infection and contamination
must be prevented. It usually comes in a 50% concentrate.

Q.A.C. is supplied by different companies under trade names. Ask your usual supplier for the
equivalent of Q.A.C. or Bac 50.

When handling the concentrate take careful precautions. Always use face protection and rubber
gloves. The concentrate chemical can be very harmful if swallowed and can cause eye and skin
damage.

Preservatives

Most products need protection against bacterial composition. Formalin is the most commonly
used preservative another common preservative is Uniphen P-23. It is usually added to products
such as shampoos, liquid soaps and babble baths. It is usually added last in the mixing process
at a quantity no greater than 0,2%. For cosmetic products a more sophisticated preservative
called p-Hydroxy benzoate is normally used. Your preservative supplier will be able to give you
more information on this.

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A Brief Introduction To
Detergents

Detergents are chemical compounds,
which remove dirt. The primary
ingredients of cleaning agents are
detergent concentrates, which are called
"sulphonates". Detergents are
biodegradable, which means that after use they break down biologically so that they do not
pollute or kill the environment.

The main function of the detergents is to break down the natural surface tension1 that exists
between grease and water and they are referred to as "surface active agents: or "surfactants".
On dissolving detergents in the water the molecules separate into small spheres that can hold
dirt and oil particles as they escape into suspension. Manual or mechanical agitation is
necessary to obtain best results. The removed dirt comes out as soluble salts, common dirt, oils
and fats.

Surfactants are produced by different processes. The main substances that constitute the
detergents are : alcohols derived from coconut oil, sodium lauryl sulfate and petroleum fractions
combined with benzine and sulphonated with sulphuric acid. These are used combined with acid,
alkaline salts or solvents in formulas designed to meet specific needs.

Other substances used in detergents are:

 Carboxymethyl Cellulose (CMC): this is often used in laundry powders
because it is film forming and has good dirt suspending properties. It repels any dirt
likely to be redeposited in the fabric.

*Surface tension: The tendency of the surface of the liquid to behave as though covered by a skin. For example
an isolated drop of liquid occupies the smallest space possible (usually by taking the shape of a ball) because of
surface tension.

 Anti-foaming agents: because sulphonates have high foaming properties,
anti-foaming agents are required to counteract this as most washing machines have
difficulty operating when too much foam is produced.

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 Perfumes: are usually added to the detergent in order to mask the odour of the
basic ingredients and to add an illusion of cleanliness. Multi-floral and fruit scents are
very popular.

The main types of detergents are:

1. Soapless detergents or synthetic detergents

These are types of detergents are made from by-products of refining crude oil. They are
used to make many products including washing powders, shampoos and hair
conditioners. They are usually simply referred to as detergents. Soapless detergents
do not form a scum in hard water2 and lather better than soaps.

2. Washing powders

Soap or soapless detergents are used to wash clothes. They are better for fabrics than
water alone, as they make it easier to remove dirt. There are two main types of washing
powder - those used when hand-washing clothes (usually soap powders) and those
used in washing machines. The latter are mostly soapless detergents with other
substances added to keep the lather down and to brighten the appearance of the fabric.
When they also contain enzymes3 they are called "biological washing powders" or
"enzyme detergents". Enzymes help to break down proteins and loosen dirt.

3. Power alkaline cleaners

Power alkaline cleaners are blends of alkaline salts and each has a specific cleaning
property. Examples are:

 Sodium Hydroxide: otherwise known as Caustic Soda or Lye. This is
added to neutralise acidic dirt. As it is corrosive towards metal it should not be
used in the presence of aluminium.

 Sodium Perborate: when dissolved in water it releases Hydrogen
Peroxide producing small bubbles of Oxygen which remove stains without
affecting or damaging the fabric and its colour.

2 Which contains calcium and magnesium salts that have dissolved from the rocks and stones over
which the water has flowed.
3 Substances found in living things which increase the rate of reaction in natural processes

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 Sodium Silicate: this is used to disperse solids and assist cleaning.
The silicate softens the water, keeping the alkalinity high. It protects the metal
parts of washing machines from corrosion.

 Sodium Sulphate: this works as a desiccant by keeping the powder
mixture dry and granules separate to aid in easy pouring.

 Sodium Tripolyphosphate: otherwise known as STPP. This common
phosphate is largely used in laundry powders. On hydrolysis4 it produces STP
and TSPP.

 Trisodium Phosphate: it is also known as TSP. It assists in peptising5
the dirt.

 Tripolyphoshpate: it is also known as TPPP. It is a conditioner that
softens the water, assists the organic surfactant and aids in rinsability.

Colour and Smell

Traditionally colours used in detergents are blue or green. The reason being is that where minute
quantities of blue or green remains on the clothes after washing, it is translated by the brain as
being extra white. In the same way, when a minute quantity of red or yellow dye remains present,
the brain translates this is being dirty. This of course is an illusion, but you must bear it in mind
when manufacturing detergents.

Smell is also important. Remember to match any added scent to the colour. As an example you
can match a lemon scent with a green colour. Speak to your chemical supplier about
compatibility for this.

Factors determining the effectiveness of the detergents

The following factors affect the performance of the detergents:

 The smoothness of the surface. A rough surface tends to trap dirt and
therefore will be more difficult to clean compared to a smooth surface.

 The use of the appropriate surfactants to enable the water to remove the dirt.

4 Decomposition of a substance by the chemical action of water
5 Dispersing into a thick state

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 The wetability of the surface. The detergent and water needs to penetrate the
fibres in a fabric. Cotton absorbs water easily but nylon and polyester do not.
 The greater the movement between the cleaning agent and the surface the
more effectively the detergent works.
 The right temperature can assist the process of cleaning. Heat will aid in the
removal of grease and low temperature will aid in the removal of blood and protein
stains.

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Packaging

Depending on which product you are manufacturing will depend on how much you will spend on
packaging.

If you manufacture and choose to sell bulk disinfectants and cleaning agents for example then 20
litre containers are ideal for packing. If you choose to sell the same products in smaller quantities
then you will obviously need to use alternate packaging. You can get very attractive looking
high-density polyethylene (HDPE) 750 ml bottles for these products as an example. On the other
hand if you decide to go into the manufacture of cosmetics then you will be targeting a
completely different market and will be using small, attractive and more expensive glass or
plastic containers.

There are a host of companies Australia wide that carry excellent packaging ideal for your exact
needs. Your local suppliers can most conveniently be found in your immediate area just Google
them. Look them up under the column "Bottles & Jars- Wholesalers & Manufacturers". Most
companies will be happy to mail out a free product catalogue and price list to you.

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Marketing

The formulas in this manual are recommended for resale to the Industrial, Commercial and
Domestic markets.

Packaging of your product is very important as it is the first thing your customers will see. Your
packaging must compliment and draw attention to your product. An attractively packaged
product with a professional looking designed label and good name can sell just about anything.
Look at the design of your container before manufacture and not as an afterthought once you
have already manufactured your product. Always remember that your packaging must be
attractive and informative. It must be eye catching and concisely state what the product is and
what it does.

Second to your packaging is the product itself. Here the product's colour and smell are very
important as people always tend to automatically make judgments about products by sight and
smell. You will notice that when you give someone a sample they will look at the product colour,
read its label and then smell it. You should always make sure that your customers get a good
first impression of your product as first impressions always have the most memorable effect on
people.

Apart from the above, quality control is also very important. Our formulas make excellent quality

products. It is possible however to lower your raw material costs by using cheaper chemicals or

by using more water and a thickener. It is and old trick in the chemical game to "water down"

products to meet lower price demands. This is generally done by reducing the percentage of

expensive raw materials proportionately and increasing the quantity of cheaper raw materials.

You should however take care not to upset the balance of the formula, as in some cases

manufacturing difficulties can arise when trying to combine certain raw materials. An example of

this is trying to combine water based raw materials with oil based materials. You should also take

care not to dilute your product too much so that it becomes noticeably less effective.

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A good suggestion is to market the same formulation as two different products. The undiluted
product can be your "quality" brand and the diluted formulation be marketed as your "economy"
brand. You should only produce the "economy" brand as an alternative to the "quality" brand.

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Product Costing

It is not uncommon in this industry to multiply the cost of
the product's raw materials by ten (10) times to get the
selling price. In the field of cosmetics it is not unusual to
mark-up a product by thirty (30) times! As each product
is different, here are some general guidelines:

For general products use a mark-up of 10 times.

To initially gain market penetration, only mark up by 5 - 7 times as an introductory offer. It is not
advisable to market your product lower than this as people may be lead to believe that because
the product is cheap it is inferior. You will be shooting yourself in the foot. When offering pricing
for bulk orders of 200 litre or more you can, as a rule of thumb, offer a more competitive price
with mark-ups of 3 or 4 times. It is a good idea to research your particular market and find out
what are the prices of similar products. Remember though that you must compare "apples with
apples".

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Labelling

It is important to consult your local government about the specific labelling requirements in your
State.

Your label should look professional, be eye catching and large enough to be seen from a
reasonable distance. It should be neatly laid out and easily readable. Use simple typefaces as
fancy ones can be difficult to read. It is a good idea to have a look at similar products and see
how they have been labelled. This will give you an idea of how the product is currently presented
to the market.

Here are some labelling guidelines. We will use a washing powder as an example here:
 The product name: the name should also describe the product eg. "Sparkle
Washing Powder", not just "Sparkle".
 Description: where it can be used and what it does.
 Directions: areas of application and how to apply it.
 Diluting instructions, if any.
 Special features, if any.
 Cautions, hazards, warnings and first aid instructions.

An example would be as follows:

Product :Name :

Sparke Washing Powder

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Description:
Sparkle is an economical, medium granular, low bulk density laundry detergent. It contains an
entirely synthetic formula with optical brightness and a highly effective low sudsing detergent.
Directions for use :
For 12 Kg of laundry use 150 gr. of powder.
For 20 Kg of laundry use 250 gr. of powder.
For 60 Kg of laundry use 500 gr. of powder.
Special Features:

 Eliminates static electricity.
 Ideally suited for industrial applications and heavy duty washing.
 Eliminates odours, has proved highly successful in removing unpleasant
odours associated with hotels and soiled linen.
 Concentrated - it is a low bulk density powder. A small quantity can adequately
perform a clean wash where three times more fluffy powder would be required.
Cautions:
Use only as directed.
Hand and skin care: After use, wash hands thoroughly with water. People with sensitive or
damaged skin should avoid contact with the washing solution.

KEEP OUT OF THE REACH OF CHILDREN.

If swallowed, remove as much of the product as possible from the mouth. Give fluids (1-2
glasses) to dilute and seek medical advice. In case of contact with eyes flush with water for at
least 15 minutes and seek medical advice.

For medical advice phone: 13 11 26 immediately. www.chw.edu.au/poisons/

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Where to Find Raw Material Suppliers

There are literally hundreds of chemical suppliers situated throughout Australia. You will
however find that most suppliers are situated near or around the larger cities.

To find chemical suppliers near you just search with Google for the following:

"Chemical Suppliers" or "Chemicals - Industrial"

If you are having trouble sourcing a particular chemical you should ask your supplier where to
obtain it. Remember that although a particular supplier may not stock a certain chemical, being
in the industry, they will most likely know who can supply you the specific ingredient. On some
occasions you may find that your supplier does not have a particular chemical but will be able to
give you a suitable substitute or alternative.

You will find that some chemical companies only specialise in certain types of chemicals, for
example solvents, waxes, acids, alkalis, alcohols or oils. All the ingredients listed within this
manual are available in Australia.

When purchasing chemicals, be sure to always obtain high quality goods. If you use chemicals of
poor quality or low grade you will find that your end product may be affected leaving you with a
poor quality product. An inferior chemical can cause technical manufacturing problems when
mixed with other ingredients.

You will find that most suppliers of raw materials will also stock the basic dyes and perfumes that
are used in most products for their colour and scent masking.

If your supplier does not stock these they should be able to refer you to someone does.

Important note:

Some chemical names mentioned in this manual include a percentage figure or notation in
brackets. The percentage figure in the brackets after the name of the chemical is the
concentration of the raw material. You must mention this when ordering it. An example is
Phosphoric Acid (28%). This percentage figure refers to the concentration of the actual chemical
and it is necessary information for your supplier about the strength of the chemical. Do not take
any notice of this when mixing the chemical.

Similarly where the notation (9 mole) appears after some chemical names as in: Non-Ionic
(9 mole), this refers to the molecular strength. Make sure to get 9 mole (sometimes it sells under

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the name N9 or NP9) or otherwise ask for the equivalent. Although Non-Ionic comes in different
molecular strengths, in all our formulas use the 9 mole type.

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Safety In The Laboratory or Home Workshop

It is necessary to be familiar with the following procedures:

How to handle flammable solvents

How to mix acids

Common electrical hazards

First aid: Stoppage of breathing

Profuse bleeding

Chemical burns (water only)

Fire in clothing

The use of portable fire extinguishers

Storing dangerous chemicals, including alkali metals.

Chemical Hazards

A hazard may result from utilising the "raw" product or from products of a chemical reaction
between two or more substances or breakdown products developed through heating or aging.
You should have an acquaintance at least with the modes of entry, the physiological responses,
both acute and chronic, and methods of roughly assessing the hazard potential of chemicals you
are using.

Electrical Hazards and Management

The problem of handling electricity is probably one of the most ignored facets of safety. It is
important to recognise that electrical equipment can act as an ignition source to activate a fire or
explosion. Static electricity should be considered.

Hazards

High pressure apparatus such as gas cylinders, if improperly handled, can be very dangerous.
This is especially true of oxygen. Precautions are necessary in handling, transport, and in
storing. Vacuum equipment, through implosions, can be every bit as dangerous as high-pressure
explosions.

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Flammable Chemicals-Hazards

Fires and explosions account for the most dangerous and the most expensive types of accidents.
Knowledge of the flammable properties of chemicals, along with an understanding of potential
sources of ignition is extremely vital. Storage and handling of these materials also requires
special attention.

General Safety Considerations

A number of accidents and injuries could very well result from improper lifting, falls and
lacerations from improper handling of glassware. Preventive measures in these areas should be
considered.

Ventilation

The principal method of hazards control involves the effective use of ventilation, both general and
exhaust. An example of exhaust ventilation is the fume hood, which if improperly designed or
used fails to give the desired protection.

Sanitisation

Poor sanitation practices in the workplace may be the cause of contaminating potable water
supplies through temporary cross-connections. At times, poor housekeeping practices may be
dangerous because of blocking passages or by providing tripping hazards. Chemicals should not
be kept beyond their usefulness, causing containers to deteriorate and leak, or chemicals to
become unstable.

Protective Equipment

Protective equipment is a prerequisite. This may include eyewash, emergency shower, safety
glasses, eye shields, protective clothing, and respiratory protection. Knowledge of the proper
usage and limitations of such equipment is extremely important.

Reports and Records

Reports and records are necessary to any safety program and should be complete, accurate and
disseminated to the appropriate administrators.

Emergencies

The initial procedures one follows in an emergency often determines the ultimate outcome of the
accident, both to the individuals and to the installation. The rudiments of first aid, fire fighting and

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reporting are vital. You must be familiar with procedures for medical emergencies. Such
procedures are critical, especially when working alone.

Contact lenses

It is important to wear eye protection when handling and working with chemicals and especially
when wearing contact lenses.

Danger in handling acids

The heat evolution of a solution could provide sufficient thermal shock to glass and permit it to
crack. This can occur when lifted free of the counter, or setting it on a cold counter top; or a
shock in setting it down, this could also contribute to the bottom separating when the jug is lifted.

Written procedures for handling of acids should always be followed. Personal protective
equipment consisting of face protection, a rubber apron, and gloves are a necessity for this
operation.

You must have fire extinguishers

If a fire breaks out in your premises you must get out fast. Many people are killed because they
don't realise how fast a small fire can spread.

If you are caught in smoke take short breaths, breathe through your nose, and crawl to escape.
The air is better near the floor.

Always use the stairs - not the elevator. A bad fire can cut off the power to elevators. Close all
doors and windows behind you.

If you are trapped in a smoke-filled room, stay near the floor, where the air is better. If possible,
sit by a window where you can call for help.

Feel every door with your hand. If it's hot don't open it. If it's cool, make this test: open slowly and
stay behind the door. If you feel heat or pressure coming the open door, slam it shut.

If you can't get out, stay behind a closed door. Any door serves as a shield. Pick a room with a
window. Open the window at the top and bottom. Heat and smoke will go out the top. You can
breathe out the bottom.

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DON'T fight a fire yourself.

Don't jump. Many people have jumped and died without realising rescue was just a few minutes
away.

If there is a panic for the main exit, get away from the mob. Try to find another way out. Once you
are safely out, DON'T go back in. Call the Fire Department immediately. Use an alarm box or
telephone. DIAL 000. If you find smoke in an open stairway, or open hall, use another pre
planned way out.

REMEMBER: Get out fast. Don't underestimate how fast a small fire can Use stairs, not the
elevator. Close all doors behind you. Don't panic. Once you are safely out, call the Fire
Department. Dial 000 or use an alarm box. Don’t go back in.

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Government Legislation: Safety, Storage, Labelling and Handling of
Dangerous Goods

Some of the chemicals mentioned in this manual and used in the manufacture of a variety of our
formulations are classified as dangerous goods. Examples of dangerous goods are combustible
gasses such as propane, highly flammable liquids such as white spirits, corrosive substances
such as sodium hydroxide, etc.

As each individual manufacturer will produce their own specific combination of products, each
will need and use different combinations of the chemicals mentioned herein. Likewise you will
also use and store these chemicals in different volumes or quantities. As a result the multitude of
possible chemical storage and handling combinations coupled to individual manufacturing
premises are endless and exceed the scope of this manual. In order to gain a comprehensive
insight and sound understanding and knowledge into the classification, storage and handling of
these substances particular to your specific circumstances you will need to obtain the relevant
information from Standards Australia and the Safe Work Australia. It is a prerequisite to
obtain and adhere to Government Legislation concerning this particular field. The Federal
Government has compiled documents specifically outlining safety, the classification, storage and
handling of Dangerous Goods.

You can obtain copies of this legislation and these documents from Standards Australia and the
SAFE WORK AUSTRALIA. Standards Australia can be contacted on Hours: Monday to Friday 9
am to 5 pm (AEST/AEDT) Freecall within Australia or you can download all the necessary
information from the internet at the Standards Australia manual. Their manual address is
www.standards.com.au.

The following material available from Standards Australia could be relevant to you:

 Class labels for dangerous goods Code: AS1216-1995

 Packaging – Packaging of dangerous goods – General requirements
Code: AS2400.21-1986

 The storage and handling of mixed classes of dangerous goods in packages
and intermediate bulk containers Code: AS/NZS3833:1998

 The storage and handling of Class 9 (miscellaneous) dangerous goods and
articles Code: AS/NZS4681:2000

 Dangerous goods – initial emergency response guide Code: HB76:1997

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The SAFE WORK AUSTRALIA can supply you with the following necessary information that
could be relevant to you. The quickest and easiest way of obtaining this information is by going
directly to their manual and following the links listed below.

To download this info go to www.Safe Work Australia.gov.au and click on the following links:

OHS Information → SAFE WORK AUSTRALIA Publications → Model Regulations
OHS Information → SAFE WORK AUSTRALIA Publications → National Codes of Practice
OHS Information → SAFE WORK AUSTRALIA Publications → Guidance Notes
OHS Information → SAFE WORK AUSTRALIA Publications → National Standards

By clicking on the above links you will be able to obtain the following relevant documentation:

 National Model Regulations for the Control of Work Place Hazardous
Substances Code: [SAFE WORK AUSTRALIA:1005 (1994)]

 National Code of Practice for the Preparation of Material Safety Data Sheets
Code: [SAFE WORK AUSTRALIA:2011 (1994)]

 National Code of Practice for the Labelling of Workplace Substances
Code: [SAFE WORK AUSTRALIA:2012 (1994)]

 National Code of Practice for the Storage and Handling of Workplace
Dangerous Goods
Code: [SAFE WORK AUSTRALIA:2017 (2001)]

 Guidance Note Placarding Stores of dangerous Goods and Specified
Hazardous Substances
Code: [NOH SC:3009 (1990)]

 National Standard for the Storage and Handling of Workplace Dangerous
Goods
Code: [NOH SC:1015 (2001)]

An as alternative to reading through all this legislation to familiarise yourself with this is to obtain
the services of a Dangerous Goods Consultant who will be able to specifically guide and advise
you according to your particular requirements.

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Product MSD Sheets

The National Occupational Health and Safety Council
(SAFE WORK AUSTRALIA) have specific
requirements concerning the layout and format of
MSDS sheets which are reviewed from time to time.
(You can obtain a copy of their current Code of
Practice for preparing MSD sheets from the SAFE
WORK AUSTRALIA manual and links listed
previously). Each product's MSD sheet has to be
updated on a regular basis. At present the timeframe

for this is every four years.

If you manufacture products in this manual for your own personal use you are not required to
produce MSD sheets for them. If you manufacture and sell products to companies and
businesses and where staff or third parties will be using your products then you will be required
to provide MSD sheets for each specific product. As we have no way of determining that you will
be manufacturing your products strictly according to our formulations we cannot legally provide
MSD sheets with our formulations manual. Some of our customers have been known to modify
our formulas according to their own specific client requirements thus making these MSD sheets
invalid. If you are experiencing problems in getting MSDS sheets compiled for your product
range, contact us and we will be able to help.

PLEASE NOTE: The above information is intended as a guideline only. DO NOT rely solely on
what we have stated here. The information in this manual is a broad guide only. It is solely
intended to provide general understanding of the subject matter and to help people assess
whether they need more detailed information. Although every effort is made to ensure that the
material herein is up to date at the time of printing, no guarantee or warrant to the accuracy,
completeness or currency of the information is provided. Before any attempt is made to
manufacture any product contained herein, it is necessary to gain the professional services of
qualified personnel to verify that such manufacturing methods are safe and that the correct
manufacturing and safety procedures are being followed and that all necessary Government
Legislation is being adhered to. You should be aware of any laws which govern business
transactions or other business or manufacturing practices, including the manufacturing of
chemicals, their storage, transportation, packaging, labelling information, precautions, correct
chemical disposal and handling procedures in your state or territory.

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General Precautions When Working With Chemicals

The cautions mentioned in this manual should be used in conjunction with the Material Safety
Data Sheets from each chemical as well as cautions and hazards mentioned in the Merck Index.
You should also consult the SAFE WORK AUSTRALIA guidelines for safety and cautions. DO
NOT RELY SOLELY ON THE INFORMATION FOUND HERE.

Observe the following:

 Protect your workstation and the floor surrounding it by covering them with newspapers
or other protective materials. Chemicals have a way of finding tabletops and floors when
you're not prepared - so be prepared!

 Make sure that the containers you select are safe for use with acids and alkalis. Unless
they're labelled "dishwasher safe," perform the following test. Place the containers
upright in your sink and pour boiling water into them. Gently test the handles. The
pitchers should not melt or become flexible, and the handles should not weaken at all.
Acids and alkalis can reach temperatures of 77" to 93"C when mixed with other
chemicals, so don't use containers that don't pass this test with flying colours.

 When mixing acids or alkalis use mixing containers only for this specific purpose. Using
an indelible-ink pen, mark each container clearly: "Acid or Alkali mixing container! DO
NOT USE FOR ANYTHING ELSE!" Keep these containers out of sight when they're not
in use and keep them out of reach of children at all times. No one - repeat, no one -
should be able to mistake them for beverage containers!

 Read all safety precautions and MSDS on the chemical packaging before you begin. If
granules or solutions accidentally come in contact with your skin or eyes, flush
immediately with cold water. If burns ensue, consult a physician. Even dry Caustic Soda
granules can burn your skin by attracting moisture from the air.

 Always wear protective gloves and safety glasses or goggles while working with acids
and alkalis. Also wear them for clean up.

 Acids and Alkalis can corrode metals.

 Never inhale chemical fumes while you're mixing them, as the fumes may injure your
lungs.

 Place containers filled with solutions away from the edges of your work surface and out of
reach of children and pets. Make sure the containers won't be in your way as you work.

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 When you pour acids or alkalis from a container, make sure to pour slowly and evenly to
avoid splashing and the possible burns that might result.

 When handling an acid or alkali solution, always brace the bottom of the container with
one gloved hand as you grip the handle securely with the other.

 Never leave fats; oils or other chemicals unattended while you're heating them. Many of
these substances are flammable and may catch fire if they're allowed to boil over. If you
should ever have to deal with fats that have burst into flame inside the pot, first slide a
tight-fitting lid across the top of the pot and then turn the burner off. (Do not bring the lid
straight down onto the pot, or air currents will force the flames out and around to your
hand.) The fire inside the pot will go out shortly after you've deprived it of oxygen in this
fashion. Wait until the contents have cooled completely before attempting to remove the
lid or move the pot. Also keep a good, all-purpose fire extinguisher in a convenient
location and use it if necessary!

 If any of the acids or other chemicals come into contact with your skin take off any wet
clothing and rinse the skin for 15 - 20 minutes under a water tap or shower.

 If any of the acids or other chemicals come into contact with your eyes rinse the eye(s)
for 15 - 20 minutes under a water tap or shower. You should also immediately call a
doctor.

 When handling acids always use rubber gloves and a face shield as well as protective
clothing like an apron or acid-resistant overall.

 Mix all products in a well ventilated area.

 Always avoid inhaling noxious fumes, vapours and odours.

 Keep acids away from alkalis, water and other products.

 Never put an acid in a metal container.

 Keep solvents away from heat sources and open flames (eg. Xylol, alcohol, white spirits
and turpentine).

 Always keep all chemicals tightly sealed when storing them.

 Keep all chemicals safely locked away and far away from children and animals.

 Do not allow other people into your working area.

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Insider’s Secrets To The Cleaning Chemical Business

 Always keep your working area clean and tidy.
 Clearly label all chemicals for easy identification.
 Avoid skin contact with chemicals at all times.

In an emergency call the:

Poisons Control Centre on 13 11 26 or

Emergency Services on 000

Place these telephone numbers in a clearly visible area in case of an emergency. The products
listed in this manual are popular products found and used in every household. They are
extremely simple to manufacture and sell well. In each formula we will list the percentages of
each ingredient and then show you the procedure to make 25 kilograms of product. We have
used 25 kilograms as a guide to for you to follow. Should you wish to make 50 kilograms of
product, simply double the quantities. To make 100 kilograms just multiply the quantities by 4.
Remember to always make a test batch of your product to check the results before making large
quantities. Always use clean equipment to avoid contamination.
We highly recommend that you always use top quality ingredients as this will produce constant
top quality products and prevent chemical incompatibility/separation problems. If you use a
chemical substitute recommended by your supplier, always check with your supplier that it will be
suitable for the product that you are manufacturing and compatible with all the product's
ingredients. This is especially important with dyes and pigments. If you run into serious problems,
you are welcome to contact us.

Most Important: always wear personal
protective equipment when handling

and working with chemicals.

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Insider’s Secrets To The Cleaning Chemical Business

Emergency First Aid for Chemical Injuries

It is highly unlikely that you will ever come into contact with most of the chemicals listed below as
are not used in this manual but it is a good idea to have a reference to them and to know what to
do in case an emergency ever arises.

ACIDS SKIN CONTACT SWALLOWING
Acetic
Hydrochloric Immediately wash with plenty of Do not induce vomiting. Do not
Phosphoric
Sulphuric running water. Remove give anything to an unconscious
Hydroflouric Acid
Chromic Acid & contaminated clothing. Once all person by mouth. If conscious,
Dichromates
contact areas have been wash out mouth with plenty of

thoroughly washed, apply a mild water, then give milk mixed with

alkaline solution such as sodium egg whites. If this is not

bicarbonate. If eyes are available, give as much water as

involved, immediately flush with possible. Call a doctor.

warm water for at least 15

minutes. Do not induce vomiting. Give

plenty of water. Keep victim

Wash thoroughly and apply a prone: do not move.

magnesium oxide paste

immediately. Call a doctor. Hospitalise immediately. Give

sodium bicarbonate solution

Wash with 5% sodium immediately. Keep victim warm.

thiosulphate. If lesions appear, Call a doctor.

call doctor. Petrolatum in the

nasal passages will protect nose

from brief exposure.

ALKALIS SKIN CONTACT SWALLOWING

Ammonium Hydroxide Wash with large quantities of Give plenty of water mixed with
lemon juice or vinegar. Follow
Sodium Hydroxide water and neutralise with with a spoonful of salad oil. Call
a doctor.
Potassium Hydroxide vinegar.

CYANIDE SALTS SKIN CONTACT SWALLOWING

Wash thoroughly. If lesions Induce vomiting immediately.
appear, call a doctor. Give hydrogen peroxide mixed
with water. Call a doctor.

CHLORIDE SKIN CONTACT SWALLOWING
COMPOUNDS
Wash thoroughly. Induce vomiting. Give large
Ammonium Chloride amounts of water. Use Epsom
Cobalt Chloride Iron Wash thoroughly. Treat with salts as a laxative. Call a doctor.
Chloride lanolin ointment. Call doctor if
irritation occurs. Give large amounts of water.
Antimony Chloride
Call a doctor.
Nickel Chloride Tin

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Insider’s Secrets To The Cleaning Chemical Business

Chloride Cadmium
Chloride

NITRATES SKIN CONTACT SWALLOWING

Potassium Nitrate Wash thoroughly. Call doctor if Immediately give plenty of water
Mercuric Nitrate rash develops. mixed with sodium bicarbonate,
and then give non-fat milk with
Silver Nitrate Wash with salt water and treat raw eggs. Call a doctor.
for burns.
Give 3 tablespoons of salt mixed
with 500 ml of water. Induce
vomiting. Call a doctor.

SULPHATES SKIN CONTACT SWALLOWING

Aluminium, Ammonium, Wash thoroughly. Call a doctor if Give plenty of water. Call a

Cobalt, Copper, skin reaction occurs doctor if any reactions occur.

Magnesium, Nickel,

Potassium, Sodium,

Zinc, Cadmium

Sulphate

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Insider’s Secrets To The Cleaning Chemical Business

1. Economy Hand Soap

This is an "economy" product and is ideal for lightly soiled hands.

Ingredients Water To make 25 litres:
91,8% Salt 22,95 litres
0,6% CDE 150 grams
0,5% SLES 125 ml
7% Formalin 1,75 litres
0,1% Perfume and Dye as you require 25 ml

Equipment required
Plastic Drum
Plastic measuring bucket
Measuring jug
Mixing stick
Procedure
Pour half of the water into the plastic drum
Heat a portion of the remainder of the water and dissolve the 0,6% salt into it.
Now pour this salt solution into the main mixture in the drum and allow to cool.
Once cool, add the 0,5% CDE and stir in well
Add the 7% SLES and mix well
Add the remainder of the water and stir
Now add the 0,1% Formalin (preservative)
Add perfume and dye as to your requirements.

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Packing
For bulk quantities use 25 litre and 10 litre containers. For smaller units pack into 500 ml and 750
ml bottles placing a screw on hand pump as a cap for easy extraction.
Directions for use
Wet hands and work a small quantity of gel into a lather. Rinse off.
Applications
This product is ideal for use around the home, office and in public toilets.
Additional Information
CDE is an abbreviation for Coconut Diethanolamide.
SLES is an abbreviation for Sodium Laurylethersulphate
In order to get the viscosity (thickness) right you may need to do a certain amount of
experimentation with the Salt/SLES proportions.
Recommended dye colours are green and pink and scents are pine and strawberry. Ask your
supplier for more details about this.

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Insider’s Secrets To The Cleaning Chemical Business

2. Multi-Purpose Universal Cleaner (Formula No.2)

This product cleans all washable surfaces.

Ingredients To make 25 kg:

62% Hot water 15.5 litres

25% Soft soap 6.25 kg

5% Butyl Cellosolve 1.25 kg

1% Normal Propyl Alcohol 250 grams

1% EDTA 250 grams

5% Hot water 1.25 litres

1% CDE 250 grams

Equipment Required

Large metal mixing drum/container
5 litre plastic bucket
Measuring jar
Scale
Mixing stick
Heat source (Gas burner)

Procedure

Firmly place the metal drum on bricks so that the gas burner (camping type) can just fit
underneath to heat it.

Pour the 62% water into the drum and heat it.

When hot add the 25% soft soap and continue to apply heat, stirring occasionally until dissolved.

Now remove the heat source and let the ingredients cool.

As the ingredients are cooling add the 5% Butyl Cellosolve and stir it in well.

Next, add the 1% Normal Propyl Alcohol and stir in well.

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