Improved acyl isethionate skin cleansing bar containing liquid polyols and magnesium soap

The present invention encompasses a personal cleansing bar comprising from 10 parts to 70 parts by bar weight of sodium cocoyl isethionate (SCI), 4.5 parts to 50 parts magnesium soap and 4 parts to 15 parts liquid polyol, wherein said polyol has at least two alcohol groups attached to separate carbon atoms in the chain, and must be water soluble and liquid at room temperature. The bars of this invention are mild, lather better, and are easier to make than corresponding bars without liquid polyol.

TECHNICAL FIELD 
The present invention relates to personal cleansing bars containing acyl 
isethionate. 
BACKGROUND OF THE INVENTION 
Sodium acyl isethionate combo bars are, per se, old in the art, e.g., mild 
sodium acyl isethionate synthetic surfactant based personal cleansing bars 
are also disclosed in U.S. Pat. No.2,894,912, Jul. 1959, to Geitz and U.S. 
Pat. No. 4,954,282, Rys, et al., Sep. 4, 1990. 
This invention relates to improved mild sodium acyl isethionate based skin 
cleansing toilet bars. In other words, this invention relates to skin 
cleansing toilet bars comprising sodium acyl isethionate as a primary 
synthetic surfactant. 
The cleansing of skin with surface-active cleansing preparations has become 
a focus of great interest. Many athletic and socially conscious people 
wash and exfoliate their skin with various surface-active preparations 
several times a day. Ideal skin cleansers should cleanse the skin gently, 
causing little or no irritation, without defatting and overdrying the skin 
or leaving it taut after frequent routine use. Most lathering soaps, 
liquids and bars included, fail in this respect. 
Synthetic detergent bars, frequently referred to as "combo bars" and/or 
"syndet bars," are known and are becoming increasingly popular. However, 
widespread replacement of soap bars by syndet bars has not so far been 
possible for a variety of reasons, primarily the poor physical 
characteristics of syndet bars as compared to soap bars, e.g., off odors, 
poor processability, stickiness, brittleness, smear or bar messiness, 
lather quality or combinations thereof. 
One object of the present invention is to deliver a bar formulation that is 
mild to the skin; another object is to deliver a bar with good lathering 
properties; and yet another is to have a formulation that is easily 
processable. 
SUMMARY OF THE INVENTION 
The present invention encompasses an improved acyl isethionate a personal 
cleansing bar comprising 10 parts-70 parts by bar weight sodium acyl 
(cocoyl) isethionate (SCI), 4.5-50 parts by bar weight of magnesium soap, 
and 4-15 parts by bar weight of liquid polyol, preferably glycerin. The 
SCI/magnesium soap/glycerin bar of this invention is very mild. It is also 
better lathering and/or is easier to make than SCI/magnesium soap bars 
without glycerin.

DETAILED DESCRIPTION OF THE INVENTION 
More specifically, the SCI bar composition of this invention comprises the 
following components set out in Table A in full range, preferred and more 
preferred parts by weight of the bar. 
TABLE A 
______________________________________ 
Bar More 
Component in Parts 
Full Range 
Preferred Preferred 
______________________________________ 
A. SCI 10 to 70 15 to 60 
20 to 50 
B. Na-Alkyl Glyceryl 
0 to 50 5 to 30 10 to 25 
Ether Sulfonate or 
lathering cosurfactant 
C. Na-soap 0 to 20 1 to 15 2 to 12 
D. Mg-soap 4.5 to 50 6 to 30 8 to 25 
E. Fatty Acid 0 to 35 3 to 25 5 to 20 
F. Paraffin or wax 
0 to 30 3 to 25 5 to 23 
G. Glycerin or polyol 
4 to 15 5 to 14 6 to 13 
H. NaCl 0 to 5 0.1 to 3 
0.2 to 2 
I. Na2SO4 0 to 5 0.1 to 3 
0.2 to 2 
J. Na-Isethionate 0 to 15 1 to 10 2 to 8 
K. Water 3 to 16 4 to 15 5 to 13 
L. Fragrance 0 to 2 0.5 to 1.5 
0.8 to 1.2 
______________________________________ 
A = Sodium Cocoyl Isethionate (SCI). This ingredient is a key to the 
present invention. The preferred SCI is "STCI" herein defined as "sodium 
topped coconut isethionate which is further defined as SCI with alkyl 
carbon chains having: 0% to 4% of highly soluble acyl groups (C.sub.6, 
C.sub.8, C.sub.10, C.sub.18:1, and C.sub.18:2); 45-65% C.sub.12, and 
30%-55% C.sub.14, C.sub.16, C.sub.18. The terms SCI and STCI are used 
interchangeably herein unless otherwise specified. 
B = Sodium Alkyl Glyceryl Ether Sulfonate (AGS) or cosurfactant. This 
ingredient can be included as a lather boosting synthetic surfactant. It 
is made from coconut fatty alcohols. Equivalent synthetic surfactants can 
be used. 
C = Sodium Soap. This is a lather booster and processing aid. 
D = Magnesium Soap. This ingredient is a key to the present invention. 
This is a nonsoil load filler and processing aid. 
E = Fatty Acid. This is a plasticizer. 
F = Paraffin. This is a plasticizer. 
G = Glycerin or polyol. This ingredient is key to the present invention. 
This is a binder, a process aid and/or lather booster. 
H = Sodium Chloride. This provides bar firmness and improves bar smear. 
I = Sodium sulfate. This provides bar firmness and improves bar smear. 
J = Sodium Isethionate. This provides bar firmness and improves bar smear 
K = Water. This is a binder. 
L = Fragrance. This is a binder and improves odor. 
The bars of the present invention comprise three key ingredients: sodium 
acyl isethionate, magnesium soap and glycerin. Some high and low levels of 
these ingredients are set out below in Table B. 
The term "Plasticizer" as used herein includes any material that is solid 
at room temperature, but is maleable at a temperature of about 35.degree. 
C. to 46.degree. C. (95.degree. F. to 15.degree. F.). This is the bar 
plodding processing temperature of the plasticizer. At least about 20 
parts by bar weight is a plasticizer excluding any synthetic surfactant 
which can provide some plasticizer benefits. 
The term "Binder" as used herein means any material that is by itself 
liquid, at room temperature and selected from water and liquid polyols. 
TABLE B 
______________________________________ 
Key Components Levels 
Key Components 
High Low Comments 
______________________________________ 
SCI - 10 parts to 70 
Brittleness 
Lather Assumes 
parts. 50 parts-70 
10 parts-20 tradeoff 
parts parts with mag- 
nesium 
soap. 
Magnesium Soap - 4.5 
Lather Brittleness 
parts to 50 parts 
40 parts-50 
4.5 parts-6 
parts parts 
Glycerin - 4 parts to 
Stickiness, 
Processability, 
15 parts (or polyol) 
Smear Lather 
12 parts-15 
4 parts-6 parts 
parts 
______________________________________ 
Referring to Table B, when the level of SCI surfactant is low, that is, 
from about 10 parts to about 20 parts by weight of the bar, the ratio of 
SCI and other lathering soaps and/or non-acyl isethionate surfactants 
described hereinafter is preferably from about 1:2 to about 1:8; 
preferably 1:3 to 1:6. This ratio is needed to provide acceptable bar 
lather. 
Referring to Table B, when the level of SCI is high, that is, from about 50 
parts to about 70 parts, the ratio of it to plasticizer (plastic materials 
defined hereinafter) is preferably from about 2.5:1 to about 3.5: 1. This 
ratio is needed to avoid unacceptable brittleness. 
The formulation of synthetic detergent-based (syndet) bars is a delicate 
balancing act. There are numerous bar use properties to take into 
consideration: lather, messiness, economy, product pH, bar firmness, etc. 
More specifically, the bars of the present invention can comprise: from 
about 10 parts to about 70 parts lathering mild synthetic surfactant; and 
wherein said lathering mild synthetic surfactant is acyl isethionate 
(SCI). Other preferred mild synthetic surfactants which can be used are 
selected from the group consisting of: C.sub.12 -C.sub.14 alkyl glyceryl 
ether sulfonate, C.sub.12 -C.sub.14 acyl sarcosinate, methyl acyl 
taurates, N-acyl glutamates, alkyl sulfosuccinates, alkyl phosphate 
esters, ethoxylated alkyl phosphate esters, trideceth sulfates, 
ethoxylated alkyl sulfates and alkyl amine oxides, betaines, sultaines, 
and mixtures thereof, and preferably as their sodium salts. At least about 
10 parts of the bar is the mild lathering, sodium acyl isethionate (SCI). 
The bars of the present invention can comprise: from 0 parts to 30 parts, 
preferably 3 parts to 25 parts, more preferably from about 5 parts to 
about 23 parts of wax, preferably paraffin, having a melting point of from 
about 130.degree. F./54.degree. C. to about 180.degree. F./82.degree. C. 
The bars of the present invention can comprise: from about 0 to 35 parts; 
preferably 3 parts to 25 parts, more preferably from about 5 parts to 
about 20 parts free fatty acid. 
The bars of the present invention can comprise: from 0 parts to about 20 
parts, preferably 1 parts to 15 parts, more preferably from about 2 parts 
to about 12 parts, sodium soap. 
The bars of the present invention can comprise: from about 0 parts to about 
15 parts, preferably 1-10 parts, more preferably 2-8 parts sodium 
isethionate. 
The bars of the present invention can comprise: from 0 parts to about 5 
parts, preferably 0.1 to 3 parts, more preferably 0.2-2 parts; sodium 
chloride. 
The bars of the present invention can comprise: from about 3 parts to 16 
parts, preferably 4 parts to 15 parts, more preferably from about 5 parts 
to 13 parts water. 
The bars of the present invention can comprise: from 0 parts to about 5 
parts of cationic polymer. 
The bars of the present invention can comprise: from 0 parts to about 2 
parts perfume; preferably 0.5 parts to 1.5 parts, more preferably, 0.8 
parts to 1.2 parts. 
The bars of the present invention can comprise: from 4.5 parts to about 50 
parts, preferably 6 parts to 30 parts and more preferably from about 8 
parts to 25 parts magnesium soap. 
The bars of the present invention can comprise: from 0-5 parts, preferably 
0.1 to 3 parts; more preferably 0.2-2 parts, sodium sulfate. 
The bars of the present invention can comprise: from 4 parts to about 15 
parts, preferably 5 parts to 14 parts and more preferably from about 6 
parts to 13 parts glycerin or polyol. 
The bar has a pH of from about 4.0 to about 9.0, preferably 5 to 8, more 
preferably from about 6.5 to 7.5. 
The bar contains by bar weight from 20 parts-60 parts; more preferably 25 
parts-55 parts; most preferably 30 parts-50 parts of plastic material 
selected from the group consisting of: wax, free fatty acid, sodium soap, 
and magnesium soap, and mixtures thereof. 
The percentages, ratios, and parts herein are on a total composition weight 
basis, unless otherwise specified. All levels and ranges herein are 
approximations, unless otherwise specified. Levels of ingredients are 
expressed herein on a bar "solids" basis, unless otherwise specified. 
Mild Synthetic Surfactants Defined 
It is noted that surfactant mildness can be measured by a skin barrier 
destruction test which is used to assess the irritancy potential of 
surfactants. In this test the milder the surfactant, the lesser the skin 
barrier is destroyed. Skin barrier destruction is measured by the relative 
amount of radio-labeled water (.sup.3 H-H.sub.2 O) which passes from the 
test solution through the skin epidermis into the physiological buffer 
contained in the diffusate chamber. This test is described by T. J. Franz 
in the J. Invest. Dermatol., 1975, 64, pp. 190-195; and in U.S. Pat. No. 
4,673,525, Small et al., issued Jun. 16, 1987, incorporated herein by 
reference, and which disclose a mild alkyl glyceryl ether sulfonate (AGS) 
suffactant based synbar comprising a "standard" alkyl glyceryl ether 
sulfonate mixture. (Barrier destruction testing surprisingly shows that 
the long chain alkyl sulfates are milder than standard AGS.) 
The sarcosinates, and glyceryl ether sulfonates may be pure chain length 
variants or those derived from commercial oils such as coconut oil. Here, 
the lauryl chain length should preferably account for at least 20 parts to 
as much as 100 parts of the weight of the given mild surfactant. 
A "high lathering surfactant" as defined herein, is one which lathers 
better than the long chain sodium cetearyl (C.sub.16 -C.sub.18) alkyl 
sulfate. 
A "mild sufactant" as defined herein is one that is milder than sodium 
dodecyl (laurel) sulfate. 
Numerous examples of other surfactants in general are disclosed in the 
patents incorporated herein by reference. They include limited amounts of 
anionic acyl sarcosinates, methyl acyl taurates, N-acyl glutamates, alkyl 
sulfosuccinates, alkyl phosphate esters, ethoxylated alkyl phosphate 
esters, trideceth sulfates, protein condensates, mixtures of ethoxylated 
alkyl sulfates and alkyl amine oxides, betaines, sultaines, and mixtures 
thereof. Included in the surfactants are the alkyl ether sulfates with 1 
to 12 ethoxy groups, especially ammonium and sodium lauryl ether sulfates. 
Alkyl chains for these other surfactants are C.sub.8 -C.sub.22, preferably 
C.sub.10 -C.sub.18. Alkyl glycosides and methyl glucoside esters are 
preferred mild nonionics which may be mixed with other mild anionic or 
amphoteric surfactants in the compositions of this invention. 
The bars of this invention can have from 0 to about 40 parts of low 
lathering, mild, essentially saturated long chain (C.sub.15 -C.sub.22) 
alkyl synthetic surfactants selected from the group consisting of: alkyl 
sulfate, alkyl sarcosinate, alkyl glyceryl ether sulfonate, and mixtures 
thereof. 
The bars of this invention can also have from 0 to about 10 parts of high 
lathering, non-mild surfactants and still maintain the preferred mildness 
requirement of the bar. Examples of these surfactants include linear alkyl 
benzene sulfonates and shorter chain or traditional (coconut) alkyl 
sulfates. 
A preferred syndet bar can contain a mixture of sodium cocoyl isethionate 
(SCI) and sodium linear alkylbenzene sulfonate in a ratio of from about 
35:1 to about 15:1, preferably from about 30:1 to about 20:1. 
Plasticizers 
The term "Plasticizer" as used herein means any material that is solid at 
room temperature, but is maleable at a temperature of about 35.degree. C. 
to 46.degree. C. (95.degree. F. to 115.degree. F.). This is the bar 
plodding processing temperature of the plasticizer. At least about 20 
parts by bar weight is a plasticizer excluding any synthetic surfactant 
which can provide some plasticizer benefits. 
The plasticizers may be comprised of solid aliphatic materials. e.g. fatty 
acids, fatty alcohols, paraffins, monoglycerides, diglycerides, 
triglycerides, alkali soaps, alkaline soaps, or high molecular weight 
(solid) hydrophilic materials, e.g. polyethylene glycols, polypropylene 
glycols, starches, sugars and/or mixtures thereof. 
Preferred plasticizers of the present invention are: (1) fatty acid 
(2)sodium soap, and (3) wax, preferably paraffin wax. 
The fatty acid material which is desirably incorporated into the present 
invention includes material ranging in hydrocarbon chain length of from 
about 10 to about 22, essentially saturated. These fatty acids can be 
highly purified individual chain lengths and/or crude mixtures such as 
those derived from fats and oils. The industry term "triple pressed 
stearic acid" comprises about 45 parts stearic and 55 parts palmitic 
acids. Thus, this is its meaning as used herein. 
The composition may include soaps derived from hydrocarbon chain lengths of 
from about 10 to about 22 (including carboxyl carbon) and are preferably 
saturated. It is preferred that the soap be the sodium salt, but other 
soluble soap can be used. Potassium, ammonium, triethanolammonium, and 
mixtures thereof, are deemed acceptable. The soaps are preferably prepared 
by the in situ saponification or ion exchange with halide salt of the 
corresponding fatty acids, but they may also be introduced as preformed 
soaps. Either some or all of the soap is preferably precomplexed with 
cationic polymer, or polymers, when polymer is used. 
"Insoluble" soaps, e.g., magnesium and zinc soaps, are not included in the 
level of "sodium soap" in the composition definition. However, insoluble 
soaps can act as non-lathering, non-soil-load diluents and processing 
aids. 
The waxes are selected from the group consisting of beeswax, spermaceti, 
carnauba, baysberry, candelilla, montan, ozokerite, ceresin, paraffin, 
synthetic waxes such as Fisher-Tropsch waxes, microcrystalline wax, and 
mixtures thereof. 
A highly preferred component of this invention is a wax, preferably 
paraffin wax having a melting point (M.P.) of from about 130.degree. F. to 
about 180.degree. F. (54.degree.-82.degree. C.), preferably from about 
140.degree. F. to about 165.degree. F. (60.degree.-74.degree. C.), and 
most preferably from about 142.degree. F. to about 160.degree. F. 
(61.degree.-71.degree. C.). "High melt" paraffin is paraffin that has a 
melting point of about 150.degree.-160.degree. F. (66.degree.-71 .degree. 
C.). "Low melt" paraffin is paraffin that has a melting point of about 
130.degree.-140.degree. F. (54.degree.-60.degree. ). A preferred paraffin 
wax is a fully refined petroleum wax which is odorless and tasteless and 
meets FDA requirements for use as coatings for food and food packages. 
Such paraffins are readily available commercially. A very suitable 
paraffin can be obtained, for example, from The National Wax Co. under the 
trade name 6975. 
As set out in Table A, herein, wax, preferably paraffin, is present in the 
bar in an amount ranging from about 3 parts to about 30 parts by weight. 
The wax ingredient is used in the product to impart skin mildness, 
plasticity, firmness, and processability. It also provides a glossy look 
and smooth feel to the bar. 
The Binder 
This invention can contain water and must contain a liquid water-soluble 
aliphatic polyol or polyethylene glycol or polypropylene glycol. The 
polyol may be saturated or contain ethylenic linkages; it must have at 
least two alcohol groups attached to separate carbon atoms in the chain, 
and must be water soluble and liquid at room temperature. If desired, the 
compound may have an alcohol group attached to each carbon atom in the 
chain. Among the compounds which are effective are ethylene glycol, 
propylene glycol, glycerin and mixtures thereof. A preferred polyol is 
glycerin, which is effective in amounts as low as 4 parts by weight, 
preferably 5 parts to about 14 parts; and more preferably from about 6 
parts to about 13 parts. 
Water-soluble polyethylene glycols, water-soluble polypropylene glycols 
useful in the present invention are those products produced by the 
condensation of ethylene glycol molecules or propylene glycol molecules to 
form high molecular weight ethers having terminal hydroxyl groups. The 
polyethylene glycol compounds may range from diethylene glycol to those 
having molecular weights as high as about 800, preferably, about 100 to 
700, more preferably, 100 to 600. Normally, polyethylene glycols having 
molecular weights up to 800 are liquid and completely soluble in water. As 
the molecular weight of the polyethylene glycol increases beyond 800, they 
become solid and less water-soluble. Such solids may be used as 
plasticizers herein when maleable at 35.degree. C.-46.degree. C. The 
polypropylene glycol compounds useful in this invention may range from 
dipropylene glycol to polypropylene glycols having molecular weights of 
about 2000, preferably less than 1500, more preferably, less than 1000. 
These are normally liquid at room temperature and are readily soluble in 
water. 
Other Ingredients 
The syndet bar of this invention may comprise from 0 parts to about 5 
parts, preferably from about 0.3 parts to about 1 parts, of a suitably 
fast hydrating cationic polymer. The polymers have molecular weights of 
from about 1,000 to about 5,000,000. 
The cationic polymer (skin conditioning agent) is selected, e.g., from the 
group consisting of: 
(I) cationic polysaccharides; 
(II) cationic copolymers of saccharides and synthetic cationic monomers, 
and 
(III) synthetic polymers selected from the group consisting of: 
(A) cationic polyalkylene imines; 
(B) cationic ethoxy polyalkylene imines; and 
(C) cationic poly N- -3-(dimethylammonio)propyl!-N'- 3-(ethyleneoxyethylene 
dimethylammonio)propyl!urea dichloride!. 
Other ingredients of the present invention are selected for the various 
applications. E.g., perfumes can be used in formulating the skin cleansing 
products, generally at a level of from about 0.1 parts to about 1.5 parts 
of the composition. Vegetable oils, such as peanut and soybean oil, can be 
added at levels up to 10 parts, preferably 2-6 parts. Alcohols, 
hydrotropes, colorants, and fillers such as talc, clay, calcium carbonate, 
oils and dextrin can also be used at appropriate levels. Preservatives, 
e.g., trisodium etidronate and sodium ethylenediaminetetraacetate (EDTA), 
generally at a level of less than 1 parts of the composition, can be 
incorporated in the cleansing products to prevent color and odor 
degradation. Antibacterials can also be incorporated, usually at levels up 
to 1.5 parts. Salts, both organic and inorganic, can be incorporated. 
Examples include sodium chloride, sodium isethionate, sodium sulfate, and 
their equivalents. 
Optional Adjunct Odor-Reducing or Odor-Controlling Materials 
The compositions and articles of this invention can also contain an 
effective, i.e., odor-controlling, amount of various additional zeolite 
and non-zeolite odor-controlling materials to further expand their 
capacity for controlling odors, as well as the range of odor types being 
controlled. Such materials include, for example, cetyl pyridinium 
chloride, zinc chloride, EDTA, etidronate, BHT, and the like. 
A preferred zeolite is substantially free of particles sized greater than 
30 microns, and in fact is substantially free of particles sized over 15 
microns for acceptable bar feel. "Substantially free" means that the 
larger particles are less than about 5 parts, preferably less than about 4 
parts, more preferably less than about 3 parts, as measured by laser light 
scattering. 
A preferred personal cleansing bar composition contains a zeolite at a 
level of from about 0.05 parts to about 5 parts by weight of the 
composition; preferably, the zeolite's (SiO.sub.2 :Al.sub.2 O.sub.3)Y 
molar ratio is from about 2:1 to about 50:1, said zeolite being in the 
protonic, sodium, potassium, ammonium, or alkylammonium form, and said 
composition contains 0 parts to about 0.5 parts perfume. 
The following patents disclose or refer to ingredients and formulations 
which may be useful in the SCI bars of this invention, and are 
incorporated herein by reference: 
______________________________________ 
U.S. Pat. No. 
Issue Date Inventor(s) 
______________________________________ 
4,234,464 11/1980 Morshauser 
4,061,602 12/1977 Oberstar et al. 
4,472,297 9/1984 Bolich et al. 
4,491,539 1/1985 Hoskins et al. 
4,540,507 9/1985 Grollier 
4,704,224 11/1987 Saud 
4,812,253 3/1989 Small et al. 
4,820,447 4/1989 Medcalf et al. 
4,954,282 9/1990 Rys et al. 
5,154,849 10/1992 Visscher, et al. 
______________________________________ 
The SCI bars of this invention have a pH of from 4 to 9 in a 1 parts 
aqueous solution. The preferred pH is from about 5 to about 8, more 
preferably about about 6.5 to about 7.5. 
______________________________________ 
A Method of Making SCI Bars 
Crutching (A, B and C are Alternative Procedures) 
______________________________________ 
A. 
1. If used, add non-SCI synthetic surfactants (50.degree.-75.degree. 
C.); begin 
agitation. 
2. If used, add NaCl, then TiO.sub.2, then EDTA, then etidronate, 
and then zeolite, and bring crutcher mixture to 85.degree. C. under 
low agitation. 
3. Add premeasured caustic and Mg(OH).sub.2, if used, and continue 
to mix slowly. 
4. Steam sparge to 85.degree. C. before adding remaining ingredients. 
5. Add fatty acid and mix for 5-10 minutes at 85.degree. C. 
6. Add the paraffin, SCI, SI and continue mixing slowly for 
approximately 15-30 minutes while maintaining the mix 
temperature at 85.degree. C. 
7. Add glycerin or liquid polyol slowly under constant agitation. 
B. 
1. Add paraffin, SCI, SI and begin agitating slowly while 
maintaining the temperature at 85.degree. C. 
2. If used, add non-SCI synthetic surfactant (50.degree.-75.degree. C.) 
and 
maintain slow agitation and recirculation. 
3. If used, add NaCl, then TiO.sub.2 then EDTA, then etidronate, 
and then zeolite, increasing the temperature in the 85.degree. C. 
range under low agitation and steam sparging. 
4. Add the premeasured caustic and Mg(OH).sub.2, if used, and 
continue to mix slowly. 
5. Add the required fatty acid and mix for another 10 minutes at 
85.degree. C. Check for uniform consistency of the crutcher batch. 
6. Add glycerin or liquid polyol slowly under constant agitation. 
C. 
1. If used, add non-SCI synthetic surfactants (50.degree.-75.degree. C.) 
to the 
crutcher and begin slow agitation. 
2. Add the paraffin, SCI, sodium isethionate (SI) and continue to 
mix with agitation and begin recirculation. 
3. If used, add NaCl, then TiO.sub.2, then EDTA, then etidronate, 
and then zeolite, increasing the temperature to 85.degree. C. while 
agitating and recirculating and steam sparging. 
4. Add the premeasured caustic and and Mg(OH).sub.2, if used, and 
continue to mix slowly. 
5. Add the required fatty acid and mix for another 10 minutes at 
85.degree. C. Check for uniform consistency of the crutcher batch 
and continue to mix until fluid and lump free. 
6. Add glycerin or liquid polyol slowly under constant 
______________________________________ 
agitation. 
Drying 
The crutcher mix is dried and cooled using a combination flash chamber and 
chill roll or chill belt. The crutcher mix is first heated to 
approximately 265.degree.-275.degree. F. (130.degree.-135.degree. C.) by a 
heat exchanger and then flash dried in a chamber above the chill roll or 
chill belt. The chill belt or chill roll provides a uniform, thin cool 
(85.degree.-95.degree. F.; 29.degree.-35.degree. C.) product in flake or 
chip form. Typical moisture for the flake is from about 3 parts to about 
15 parts, preferably from about 5 parts to about 10 parts. The way to 
regulate the moisture, in the order of preference, are: (1) increasing or 
decreasing steam pressure on the heat exchanger; (2) increasing or 
decreasing crutcher mix rate to the heat exchanger; and (3) increasing or 
decreasing crutcher mix temperature to the heat exchanger. 
Amalgamating 
The flakes are weighed and added to a batch amalgamator to obtain uniform 
flake size and a course mixture of additives that may be brought into the 
flake mixture (syndet or soap). 
(Alternative Procedures): 
A. Preweighed flakes may be amalgamated to uniform size and premeasured 
amounts of zeolite deodorizing powder and glycerin (if not added in the 
crutcher) are added into the base flakes and mixed for several minutes 
with no perfume being added. 
B. Preweighed flakes may be amalgamated to uniform size and a premeasured 
amount of optional premeasured amount of perfume and glycerin (if not 
added in the crutcher). Continue amalgamating for at least one minute to 
thoroughly mix together the ingredients. 
Milling 
The 3-roll soap mills are set up with the first roll at .about.120.degree. 
F. (49.degree. C.), the second roll at .about.100.degree. F. (38.degree. 
C.), and the final roll at .about.68.degree. F. (20.degree. C.). The 
material is passed through the mills several times to provide a 
homogeneous mixture of perfume and dried flakes. Typically the milled 
material has a temperature of 44.degree. to 54.degree. C. 
Plodding and Stamping 
The plodder is set up with the barrel temperature at about 11 5.degree. F. 
(46.degree. C.) and the nose temperature at 114.degree.-122.degree. F. 
(45.degree.-50.degree. C.). The ideal plodder is a dual stage plodder that 
allows use of a vacuum of about 15-25 inches (38-64 cm) of Hg. The plugs 
should be cut in 5 inch (13 cm) sections and stamped with a cold die block 
using die liquor such as alcohol, if appropriate. 
Laboratory Assessment of Bar 
The critical bar performance attributes are smear, lather, odor and 
processability. 
Smear Test Procedure 
Equipment: 
1. #2-202C Fisher Brand Hexagonal Polystyrene weighing dishes 
(4".times.3"). 
2. #14-366A Fisher Brand Spatula. 
3. Balance capable of weighing to two decimal points. 
4. 120.degree. F. (49.degree. C.) Temperature Room. 
5. Timer. 
Test Method 
1. Label and weigh the number of weighing dishes needed (two weighing 
dishes per sample, one labeled M for mush dish, one labeled S for soak 
dish). 
2. Weigh the original bar and record the weight. Place bar in preweighed 
dish labeled S. 
3. Add 30 mls room temperature city water to the dish containing the bar 
prototype (pour water down side of weighing dish). Add 30 mls room 
temperature city water to the dish containing the control bar. When 
placing the bars in the dish make sure the bars are not touching the sides 
of the dishes. 
4. Allow bars to soak in weighing dishes at room temperature for 2 hours 
undisturbed. 
5. After 2 hours of soaking, pick bar up carefully and allow to drain into 
the same dish for 15 seconds. 
6. After 15 seconds, invert bar and place in preweighed dish labeled M. 
7. Weigh soaked bar and record. 
8. Scrape the wet surface or mush from the bar, with a spatula, into the 
same preweighed dish labeled M, weigh and record, this is the "wet smear" 
grade. Let the mush and soak water dry overnight, weigh and record. This 
is the "dry smear" grade. Best results for scraping are seen when the 
spatula is held loose in hand being careful not to gouge the bar or to 
scrape too deeply. When the surface of the bar no longer appears to look 
wet or shiny, scraping is completed. To eliminate variability of scraping 
from person to person, results from each test will be reported relative to 
the control placed in that test. 
All series of testing should include control, and all samples should be run 
in duplicates. A maximum of 7 products (6 plus a control) can be tested at 
one time, and an interval of 10 minutes between every 4 samples should be 
allotted for the addition of water as to not allow any products a lag time 
for soaking longer than 2 hours. 
Bar Soap Handwash Lather Volume Test 
The handwash lather test is used to provide in-use lather volume 
measurements for the lather performance of skin cleansing bars. The test 
measures both the ultimate lather volume generated and the volume which is 
generated after a very short lathering period (to reflect lathering ease). 
The lather volumes are generated under soil-loaded conditions. 
Synthetic soil is used for the soil-loaded lather volume test reported in 
the literature; see Small, et al., supra. 
Grading Scale 
Soil Loaded 
7--Exceptional 
6--Very much higher than target 
5--Higher than target (See Example 4) 
4--Target volume (See Example 3) 
3--Slightly lower than target 
2--Lower than target 
Assessment of Processability: The Mill Test 
Mill Test Procedure 
1. A standard three-roll mill is employed with the take-up roll set at 
120.degree. F. (48.degree. C.), the transfer roll at 110.degree. F. 
(43.degree. C.) and the discharge roll at 80.degree. F. (26.degree. C.). 
2. Final flake thickness is about 0.010 inches. 
3. After the third mill pass, the material is evaluated as described below. 
______________________________________ 
Mill Grade Assessment (See Examples Herein) 
Grade Product Flake Appearance Coming Off Mill 
______________________________________ 
10 Like Standard Soap (50/50 T/C) 
9 Non-Sticky; less than four compaction layers; no 
build-up. 
8 Non-Sticky; less than four compaction layers; 
0.010 in. (0.25 millimeters) build-up. 
7 Slightly sticky; about eight compaction layers; 
0.010 in.-0.016 in. build-up (See Example 2) 
6 Slightly sticky; large chunks; bridging; &gt;0.016" 
build-up. (See EE. 3) 
5 More sticky; sheeting; &gt;0.016" build-up. 
4 Increasing stickiness; sheeting; bridging; dough- 
like; high build-up. 
1-3 Extremely sticky; very difficult to process. 
______________________________________ 
Mill Force Assessment of Processability 
As the material is removed from the discharge roll it impacts a sheet metal 
plate so that the 0.010 inch (0.25 millimeters) thick sheet of material 
gathers into compressed chunks. The force which the material exerts on the 
sheet metal plate is an indication of the cohesiveness and brittleness of 
the material. This force is recorded as the mill force gauge reading. A 
more cohesive, less brittle material is less processable on typical 
bar-making equipment. A large force gauge reading indicates a more 
cohesive, less brittle and therefore, a less processable formula. 
EXAMPLES AND FORMULAS 
The following examples and formulas are illustrative and are not intended 
to limit the scope of the invention. The methods of making milled bars are 
well known. All levels and ranges, temperatures, results, etc. used herein 
are approximations unless otherwise specified. Therefore, the percentages 
do not necessarily add up to 100 parts. All component levels are 
percentages based on weight. 
Experimental Example 1 (E.E.1) vs. Example 2 
These examples illustrate the ability to achieve better lather, and better 
processability via using 8 parts glycerin in a SCI/magnesium soap matrix 
(see Tables 1A -1C). 
TABLE 1A 
______________________________________ 
Component E.E. 1 Ex. 2 
______________________________________ 
Na-Topped Cocoyl Isethionate 
21 20 
Na-Alkyl Glyceryl Ether Sulfonate (AGS) 
21 20 
Mg-soap** 21 21 
Fatty Acid** 1 1 
Glycerin 8 
Paraffin 21 20 
NaCl 0.5 0.5 
Na2SO4 1 1 
Na-Isethionate 1 1 
Water 7 5 
Fragrance 1 1 
Miscellaneous* Balance Balance 
Total 100 100 
______________________________________ 
*Miscellaneous includes unreacted feedstocks and products of secondary 
side reactions. 
TABLE 1B 
______________________________________ 
Component 
Chainlengths of SCI - Acyl Isethionate: 
E.E. 1 Ex. 2 
______________________________________ 
C8 0 0 
C10 0 0 
C12 60 60 
C14 23 23 
C16 10 10 
C18 7 7 
C18:1 1 1 
Total Isethionite 100 100 
______________________________________ 
**Soap and Fatty Acid Chainlengths: 
Mgsoap and fatty acid chainlengths are representative of a blend of about 
5 parts coconut, 10 parts lauric, 5 parts myristic and 80 parts triple 
pressed stearic acid or salts thereof. 
The bar characteristics are set out in Table 1 c. 
TABLE 1C 
______________________________________ 
E.E. 1 
Ex. 2 
______________________________________ 
Processability 
Mill Grade 6.5 7 
Mill Force Gauge - lbs. force 
9 7 
Bar Performance - Smear 
Wet Mush Smear 1.1 1.2 
Dry Mush Smear 1.5 1.7 
Bar Performance - Lather 
Flash Soil Lather 1.5 3.5 
Ultimate Soil Lather 3 4 
______________________________________ 
Experimental Example 1 (E.E. 1 ) is an acyl isethionate/magnesium soap bar 
that also contains sodium alkyl glyceryl ether sulfonate (AGS). AGS is 
known to make personal cleansing compositions difficult to process on 
milled bar systems. Referring to Table 1 C, E.E. 1 has a Mill Grade of 6.5 
and Mill Force Gauge reading of 9. The lather grades of E.E. 1 are 1.5 and 
3. 
Example 2 is similar in composition to E.E. 1 but also contains 8 parts 
glycerin. Example 2 has better processability than E.E. 1 based on its 
larger Mill Grade of 7 and smaller Mill Force Gauge reading of 7. Example 
2 also has better lather than E.E. 1 based on its greater lather grades of 
3.5 and 4. 
Example 2, based on its processability (7/7) and its outstanding lathers 
(3.5 and 4), is currently the best mode example. 
Not shown is another preferred bar which is similar to Example 2 but with a 
0.5 parts to 1.5 parts of polymeric skin feel aid. 
Experimental Example 3 (E.E3) vs. Example 4 
Tables 2A, 2B and 2C illustrate the ability to achieve better lather, and 
better processability via using 8 parts glycerin in an SCI/magnesium soap 
matrix. 
TABLE 2A 
______________________________________ 
Component E.E. 3 Ex. 4 
______________________________________ 
Na-Topped Cocoyl Isethionate 
30 28 
Na-Alkyl Glyceryl Ether Sulfonate (AGS) 
16 15 
Na-soap** 4 4 
Mg-soap** 9 8 
Fatty Acid** 11 9 
Glycerin 8 
Paraffin 13 12 
NaCl 0.5 0.5 
Na2SO4 1 1 
Na-Isethionate 3 3 
Water 6 6 
Fragrance 1 1 
Miscellaneous* Balance Balance 
Total 100 100 
______________________________________ 
*Miscellaneous includes unreacted feedstocks and products of secondary 
side reactions. 
TABLE 2B 
______________________________________ 
Acyl Isethionate Chainlengths (Same as Table 1B): 
______________________________________ 
**Soap and Fatty Acid Chainlengths: 
Na-soap, Mg-soap and fatty acid chainlengths are representative of 
a blend of about 5 parts coconut, 26 parts lauric, 6 parts myristic, 
and 63 parts triple pressed stearic acid or salts thereof. 
______________________________________ 
TABLE 2C 
______________________________________ 
E.E. 3 
Ex. 4 
______________________________________ 
Processability 
Mill Grade 6 6.5 
Mill Force Gauge - lbs. force 
19 5 
Bar Performance - Smear 
Wet Mush Smear 1.1 1.6 
Dry Mush Smear NA NA 
Bar Performance - Lather 
Flash Soil Lather 2 4.5 
Ultimate Soil Lather 4 5 
______________________________________ 
NA not available 
Experimental Example 3 (E.E. 3) is an acyl isethionate/magnesium soap bar 
that also contains sodium alkyl glyceryl ether sulfonate (AGS). E.E. 3 has 
a Mill Grade of 6 and Mill Force Gauge reading of 19. The lather grades of 
E.E. 3 are 2 and 4. 
Example 4 is similar in composition to E.E. 3 but also contains 8 parts 
glycerin. Example 4 has better processability than E.E. 3 based on its 
larger Mill Grade of 6.5 and smaller Mill Force Gauge reading of 5. 
Example 4 also has better lather than E.E. 3 based on its greater lather 
grades of 4.5 and 5. 
Examples 5 and 6 
These examples illustrate the improvement of processability by increasing 
the glycerin level from 8 parts to 12 parts in a SCI/magnesium soap matrix 
(see Tables 3A-3C). 
TABLE 3A 
______________________________________ 
Component Ex. 5 Ex. 6 
______________________________________ 
Na-Topped Cocoyl Isethionate 
38 36 
Na-soap** 4 4 
Mg-soap** 20 19 
Glycerin 8 12 
Paraffin 10 10 
Na2SO4 0.5 0.5 
Na-Isethionate 2 2 
Water 12 12 
Fragrance 1 1 
Miscellaneous* Balance Balance 
Total Parts 100 100 
______________________________________ 
*Miscellaneous includes unreacted feedstocks and products of secondary 
side reactions. 
TABLE 3B 
______________________________________ 
Acyl Isethionate Chainlengths (See Table 1B): 
______________________________________ 
**Soap and Fatty Acid Chainlengths: 
Na-soap, Mg-soap and fatty acid chainlengths for Examples 5 and 
6 are representative of a blend of about 8 parts coconut, 21 parts 
lauric, 9 parts myristic and 62 parts triple pressed stearic acid or 
salts thereof 
______________________________________ 
. 
TABLE 3C 
______________________________________ 
Ex. 5 
Ex. 6 
______________________________________ 
Processability 
Mill Grade 7 10 
Mill Force Gauge - lbs. force 
2.5 0 
Bar Performance - Lather 
Flash Soil Lather 3 2.5 
Ultimate Soil Lather 3.5 3 
______________________________________ 
Example 5 is an acyl isethionate/magnesium soap bar that contains 8 parts 
glycerin. Example 5 has a Mill Grade of 7 and Mill Force Gauge reading of 
2.5. The lather grades of Example 5 are 3 and 3.5. 
Example 6 is similar in composition to Example 6 but contains 12 parts 
glycerin. Example 4 has better processability than Example 5 based on its 
larger Mill Grade of 10 and smaller Mill Force Gauge reading of 0. Example 
4 has lather grades of 2.5 and 3. The lower lathers for both these 
examples indicate a need for more lather-boosting surfactant. 
Experimental Examples 7 and 8 (E.E. 7 and E.E. 8) 
These examples illustrate the criticality of the magnesium soap level of 
this invention. The improvement of processability is not present upon the 
addition of glycerin when the magnesium soap level is at or below 4 parts 
(see Tables 4A-4C). 
TABLE 4A 
______________________________________ 
Component E.E. 7 E.E. 8 
______________________________________ 
Na-Topped Cocoyl Isethionate 
21 20 
Na-Alkyl Glyceryl Ether Sulfonate (AGS) 
21 20 
Mg-soap** 4 4 
Glycerin 8 
Paraffin 38 39 
NaCl 1 1 
Na2SO4 1 1 
Na-Isethionate 1 1 
Water 6 4 
Fragrance 1 1 
Miscellaneous* Balance Balance 
Total 100 100 
______________________________________ 
*Miscellaneous includes unreacted feedstocks and products of secondary 
side reactions. 
TABLE 4B 
______________________________________ 
Acyl Isethionate Chainlengths (Same as Table 1B): 
______________________________________ 
Soap Fatty Acid Chainlengths: 
Mg-soap fatty acid chainlengths used in E.E. 7 and 8, are 
representative of a blend of about 10 parts coconut, 53 parts 
lauric, 22 parts myristic, and 15 parts triple pressed stearic acid or 
salts thereof. 
______________________________________ 
TABLE 4C 
______________________________________ 
E.E. 7 
E.E. 8 
______________________________________ 
Processability 
Mill Grade 8 7 
Mill Force Gauge - lbs. force 
7 7 
Bar Performance - Smear 
Wet Mush Smear 0.6 0.8 
Dry Mush Smear 0.8 1.2 
Bar Performance - Lather 
Flash Soil Lather 1.5 1.5 
Ultimate Soil Lather 2.5 3 
______________________________________ 
Experimental Example 7 (E.E. 7) is an acyl isethionate/magnesium soap bar. 
Note that the magnesium soap level is 4 parts. E.E. 7 has a Mill Grade of 
8 and Mill Force Gauge reading of 7. The lather grades of E.E. 7 are 
1.5/2.5. 
Experimental Example 8 (E.E. 8) is similar in composition to E.E. 7 but 
also contains 8 parts glycerin. E.E. 8 has poorer processability than E.E. 
7 based on its smaller Mill Grade of 7. This contrasts previous examples 
wherein the addition of glycerin improves processability. All previous 
examples that show the improvement in processability have greater than 4 
parts magnesium soap. 
Experimental Example 1 is a comparative to Example 2. Experimental Example 
3 is comparative to Example 4. Examples 5 and 6 are alternative 
formulations of this invention. Experimental Examples 7 and 8 illustrate 
the criticality of the magnesium soap level. The bars containing glycerin 
are improvements over comparable bars made without glycerin. The glycerin 
improvements improved processability and/or improved lather.