Cleaning compositions for solid surfaces – auxiliary compositions – Cleaning compositions or processes of preparing – Heterogeneous arrangement
Reexamination Certificate
2001-03-19
2003-06-10
Douyon, Lorna M. (Department: 1751)
Cleaning compositions for solid surfaces, auxiliary compositions
Cleaning compositions or processes of preparing
Heterogeneous arrangement
C510S441000, C510S495000, C510S498000, C264S117000, C264S140000
Reexamination Certificate
active
06576605
ABSTRACT:
FIELD
The present invention relates to a non-tower process for producing a particulate detergent composition. The process produces a free flowing, detergent composition whose density can be adjusted for a wide range of consumer needs, and which can be commercially sold as a conventional detergent composition.
BACKGROUND
Recently, there has been considerable interest within the detergent industry for laundry detergents which are “compact” and therefore, have low dosage volumes. To facilitate production of these so-called low dosage detergents, many attempts have been made to produce high bulk density detergents, for example with a density of 600 g/l or higher. The low dosage detergents are currently in high demand as they conserve resources and can be sold in small packages which are more convenient for consumers. However, the extent to which modern detergent products need to be “compact” in nature remains unsettled. In fact, many consumers, especially in developing countries, continue to prefer a higher dosage levels in their respective laundering operations. Consequently, there is a need in the art of producing modern detergent compositions for flexibility in the ultimate density of the final composition.
Generally, there are two-.primary types of processes by which detergent granules or powders can be prepared. The first type of process involves spray-drying an aqueous detergent slurry in a spray-drying tower to produce highly porous detergent granules. In the second type of process, the various detergent components are dry mixed after which they are agglomerated with a binder such as a nonionic or anionic surfactant. In both processes, the most important factors which govern the density of the resulting detergent granules are the density, porosity and surface area, shape of the various starting materials and their respective chemical composition. These parameters, however, can only be varied within a limited range. Thus, flexibility in the substantial bulk density can only be achieved by additional processing steps which lead to lower density of the detergent granules.
There have been many attempts in the art for providing processes which increase the density of detergent granules or powders. Particular attention has been given to densification of spray-dried granules by post tower treatment. For example, one attempt involves a batch process in which spray-dried or granulated detergent powders containing sodium tripolyphosphate and sodium sulfate are densified and spheronized in a Marumerizer®. This apparatus comprises a substantially horizontal, roughened, rotatable table positioned within and at the base of a substantially vertical, smooth walled cylinder. This process, however, is essentially a batch process and is therefore less suitable for the large scale production of detergent powders. More recently, other attempts have been Is made to provide continuous processes for increasing the density of “post-tower” or spray dried detergent granules. Typically, such processes require a first apparatus which pulverizes or grinds the granules and a second apparatus which increases the density of the pulverized granules by agglomeration. While these processes achieve the desired increase in density by treating or densifying “post tower” or spray dried granules, they do not provide a process which has the flexibility of providing lower density granules.
Moreover, all of the aforementioned processes are directed primarily for densifying or otherwise processing spray dried granules. Currently, the relative amounts and types of materials subjected to spray drying processes in the production of detergent granules has been limited. For example, it has been difficult to attain high levels of surfactant in the resulting detergent composition, a feature which facilitates production of detergents in a more efficient manner. Thus, it would be desirable to have a process by which detergent compositions can be produced without having the limitations imposed by conventional spray drying techniques.
Recently, there has been considerable interest in the use of high-speed mixer/granulators for the preparation of high-bulk density detergent granules. In such process, fines that are generated during the process are usually recycled. In most cases, the fines are recycled and added with the initial powder materials.
Based on the foregoing, there is a need to ensure a balance of the amount of generated fines with the amount of recycled fines so that the over accumulation of generated fines do not shut down the process for making detergent granules.
None of the existing art provides all of the advantages and benefits of the present invention.
SUMMARY
The present invention relates to a non-tower process for preparing a granular detergent composition, the process comprising the following steps: (i) fluidising powder materials in a high-speed mixer/granulator having both a stirring action and a cutting action, the powder materials comprising: particulate solid water-soluble alkaline inorganic material in an amount in excess of that required for neutralization, optionally in admixture with one or more other particulate solids, and recycled fines, the powder materials having a total surface area; (ii) adding the liquid detersive materials to the high-speed mixer/granulator, the liquid detersive materials comprising: a liquid acid precursor, optionally in admixture with one or more other liquid materials, whereby neutralization of the acid precursor by the water-soluble alkaline inorganic material occurs; and (iii) granulating the mixture in the high-speed mixer/granulator to form detergent particles, wherein the ratio of the total surface area of the powder materials to the amount of liquid detersive materials in step (ii) is from about 0.02 to about 140.
These and other features, aspects, and advantages of the present invention will become evident to those skilled in the art from a reading of the present disclosure.
DETAILED DESCRIPTION
While this specification concludes with claims distinctly pointing out and particularly claiming that which is regarded as the invention, it is believed that the invention can be better understood through a careful reading of the following detailed description of the invention. In this specification, all percentages, ratios, and proportions are by weight, all temperatures are expressed in degrees Celsius, molecular weights are in weight average, and the decimal is represented by the point (.), unless otherwise indicated.
As used herein, “comprising” means that other steps and other ingredients which do not affect the end result can be added. This term encompasses the terms “consisting of” and “consisting essentially of”.
All cited references are incorporated herein by reference in their entireties. Citation of any reference is not an admission regarding any determination as to its availability as prior art to the claimed invention.
The present invention meets the aforementioned needs in the art by providing a process which produces a detergent composition from liquid acid precursor of anionic surfactant and alkaline inorganic materials. The present invention also meets the aforementioned needs in the art by providing a process which produces a granular detergent composition for flexibility in the ultimate density of the final composition from agglomeration (e.g., non-tower) process. The process does not use the conventional spray drying towers currently which is limited in producing high surfactant loading compositions. In addition, the process is more amenable to environmental concerns in that it does not use spray drying towers which typically emit particulates and volatile organic compounds into the atmosphere.
As used herein, the term “agglomerates” refers to particles formed by agglomerating materials with binder such as surfactants and or inorganic solutions/organic solvents and polymer solutions. As used herein, the term “granulating” refers to fluidizing agglomerates thoroughly for producing free flowing, round shape granulated-agglomerates. As used herein, the te
Bolam Brian M.
Douyon Lorna M.
Miller Steven W.
The Procter & Gamble & Company
William Zerby Kim
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