PROCESS FOR MAKING A HIGH DENSITY DETERGENT COMPOSITION BY CONTROLLING AGGLOMERATION WITHIN A DISPERSION INDEX

Abstract: A process for continuously preparing high density detergent composition is provided. The process comprises the steps of: (a) agglomerating a detergent surfactant paste and dry starting detergent material in a high speed mixer/densifier to obtain agglomerates having a Dispersion Index in a range of from about 1 to about 6, wherein Dispersion Index = A/B; A is the surfactant level in the agglomerates having a particle size of at least 1100 microns, and B is the surfactant level in the agglomerates having a particle size less than about 150 microns; (b) mixing the agglomerates in a moderate speed mixer/densifier to further densify, build-up and agglomerate the agglomerates; and (c) conditioning the agglomerates such that the flow properties of the agglomerates are improved, thereby forming the high density detergent composition.

Description: PROCESS FOR MAKING A HIGH DENSITY DETERGENT COMPOSITION BY CONTROLLING AGGLOMERATION WITHIN A DISPERSION INDEX FIELD OF THE INVENTION The present invention generally relates to a process for producing a high density laundry detergent composition More particularly, the invention is directed to a process during which high density detergent agglomerates are produced by feeding a surfactant paste and dry starting detergent material into two serially positioned mixer/densifiers and then into one or more conditioning apparatus in the form of drying, cooling and screening equipment The process is operated within a selected binder dispersion index resulting tn agglomerates havmg a more uniform distribution of bmder This also results in the production of lower amounts of oversized and undersized agglomerate particles, thereby minimizing the need for one or more recycle streams in the process While the binder can be most any liquid used to enhance agglomeration of dry ingredients, the process herein focuses on a surfactant as the binder BACKGROUND OF THE INVENTION 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 650 g 1 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 Generally, there are two primary types of processes by which detergent particles or powders can be prepared The first type of process mvolves spray-dry g an aqueous detergent slurry in a spray-drying tower to produce highly porous detergent particles 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 ofthe resulting detergent matenal are the density, porosity, particle size and surface area of the various startmg mateπals and their respective chemical composition These parameters, however, can only be varied withm a limited range Thus, a substantial bulk density increase can only be achieved by additional processmg steps which lead to densification of the detergent material There have been many attempts in the art for providing processes which mcrease the density of detergent particles or powders Particular attention has been given to densification of spray-dried particles by "post-tower" treatment For example, one attempt mvolves a batch process in which spray-dried or granulated detergent powders containing sodium tripolyphosphate and sodium sulfate are densified and spheronized in a Marumeπzer® This apparatus compπses 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 made to provide a continuous processes for increasing the density of "post-tower" or spray dried detergent particles Typically, such processes require a first apparatus which pulverizes or grinds the particles and a second apparatus which increases the density of the pulverized particles by agglomeration These processes achieve the desired increase in density only by treating or densifying "post tower" or spray dried particles However, all of the aforementioned processes are directed primarily for densifying or otherwise processing spray dried particles Currently, the relative amounts and types of materials subjected to spray drying processes in the production of detergent particles has been limited For example, it has been difficult to attain high levels of surfactant in the resultmg detergent composition, a feature which facilitates production of low dosage detergents Thus, it would be desirable to have a process by which detergent compositions can be produced without havmg the limitations imposed by conventional spray drying techniques To that end, the art is also replete with disclosures of processes which entail agglomerating detergent compositions For example, attempts have been made to agglomerate detergent builders by mixing zeolite and/or layered silicates in a mixer to form free flowing agglomerates While such attempts suggest that their process can be used to produce detergent agglomerates, they do not provide a mechanism by which startmg detergent materials in the form of pastes, liquids and dry mateπals can be effectively agglomerated into crisp, free flowing detergent agglomerates havmg a high density of at least 650 g/1 Moreover, such agglomeration processes have produced detergent agglomerates containing a wide range of particle sizes, for example "overs" and "fines" are typically produced The "overs" or larger than desired agglomerate particles have a tendency to decrease the overall solubility of the detergent composition in the washmg solution which leads to poor cleaning and the presence of insoluble "clumps" ultimately resultmg in consumer dissatisfaction The "fines" or smaller than desired agglomerate particles have a tendency to "gel" in the washing solution and also give the detergent product an undesirable sense of "dustiness " Further, past attempts to recycle such "overs" and "fines" has resulted in the exponential growth of additional undesirable over-sized and under¬ sized agglomerates smce the "overs" typically provide a nucleation site or seed for the agglomeration of even larger particles, while recycling "fines" inhibits agglomeration leading to the production of more "fines" in the process Also, the recycle streams in such processes increase the operating costs ofthe process which inevitably mcrease the detergent product cost ultimately produced Accordmgly, there remains a need in the art for a process which produces a high density detergent composition havmg improved flow and particle size properties Further, there is a need for such a process which decreases or minimizes the need for recycle streams in the process Also, there remains a need for such a process which is more efficient and economical to facilitate large-scale production of low dosage or compact detergents BACKGROUND ART The following references are directed to densifying spray-dried granules Appel et al, U S Patent No 5.133,924 (Lever), Bortolotti et al, U S Patent No 5,160,657 (Lever), Johnson et ai. British patent No 1 ,517,713 (Unilever), and Curtis, European Patent Application 451 ,894 The following references are directed to producmg detergents by agglomeration Beerse et al, U S Patent No 5,108,646 (Procter & Gamble), Capeci et al, U S Patent No 5,366.652 (Procter & Gamble), Hollingsworth et al, European Patent Application 351,937 (Unilever), and Swat ng et al, U S Patent No 5,205,958 SUMMARY OF THE INVENTION The present mvention meets the aforementioned needs m the art by providing a process which produces a high density detergent composition containing agglomerates directly from startmg detergent ingredients The process invention described herein produces agglomerates withm a selected Dispersion Index indicative ofthe uniformity ofthe surfactant level throughout the agglomerate particles It has been surprisingly found that by maintaining the agglomerates within this Dispersion Index, the process produces less particles which are oversized or "overs" (l e over 1 100 microns) and undersized or "fines" (l e less than 150 microns) This obviates the need for extensive recycling of undersized and oversized agglomerate particles resulting in a more economical process and a high density detergent composition havmg improved flow properties and a more uniform particle size Such features ultimately result in a low dosage or compact detergent product having more acceptance by consumers As used herem, the term "agglomerates" refers to particles foimed by agglomerating starting detergent ingredients (liquid and or particles) which typically have a smaller median particle size than the formed agglomerates All percentages and ratios used herein are expressed as percentages by weight (anhydrous basis) unless otherwise indicated All documents are incoφorated herein by reference All viscosities referenced herem are measured at 70°C (±5°C) and at shear rates of about 10 to 100 sec" 1 In accordance with one aspect ofthe invention, a process for continuously preparing high density detergent composition is provided The process compπses the steps of (a) agglomeratmg a detergent surfactant paste and dry startmg detergent mateπal in a high speed mixer/densifier to obtain agglomerates havmg a Dispersion Index in a range of from about 1 to about 6, wherein Dispersion Index = A/B A is the surfactant level in the agglomerates havmg a particle size of at least 1 100 microns, and B is the surfactant level m the agglomerates havmg a particle size less than about 150 microns, (b) mixing the agglomerates in a moderate speed mixer/densifier to further densify. build-up and agglomerate the agglomerates, and (c) conditioning the agglomerates such that the flow properties of the agglomerates are improved, thereby forming the high density detergent composition In accordance with another aspect of the invention, another process for preparing high density detergent composition is provided This process comprises the steps of (a) agglomeratmg a detergent surfactant paste and dry starting detergent material in a high speed mixer/densifier to obtain agglomerates having a Dispersion Index in a range of from about 1 to about 6, wherein Dispersion Index = A B A is the surfactant level in the agglomerates havmg a particle size of at least 1 100 microns, and B is the surfactant level in the agglomerates havmg a particle size less than about 150 microns, (b) mixing the agglomerates in a moderate speed mixer/densifier to further densify, build-up and agglomerate the agglomerates, (c) feeding the agglomerates into a conditioning apparatus for improving the flow properties ofthe agglomerates and for separating the agglomerates into a first agglomerate mixture and a second agglomerate mixture, wherein the first agglomerate mixture substantially has a particle size of less than about 150 microns and the second agglomerate mixture substantially has a particle size of at least about 150 microns, (d) recycling the first agglomerate mixture into the high speed mixer/densifier for further agglomeration, and (e) admixing adjunct detergent ingredients to the second agglomerate mixture so as to form the high density detergent composition Another aspect ofthe invention is directed to a high density detergent composition made according to any one ofthe embodiments of the mstant process Accordmgly, it is an object ofthe mvention to provide a process which produces a high density detergent composition containing agglomerates havmg improved flow and particle size properties It is also an object of the mvention to provide such a process which is more efficient and economical to facilitate large-scale production of low dosage or compact detergents T ese and other objects, features and attendant advantages of the present mvention will become apparent to those skilled in the art from a reading ofthe followmg detailed descπption ofthe preferred embodiment and the appended claims BRIEF DESCRIPTION OF THE DRAWING Fig 1 is a flow diagram of a process m accordance with one embodiment of the mvention in which undersized detergent agglomerates are recycled back mto the high speed mixer/densifier from the conditioning apparatus DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Reference can be made to Fig 1 for purposes of illustrating one preferred embodiment of the process invention descπbed herein Process Initially, the process 10 shown in Fig 1 entails agglomerating a detergent surfactant paste 12 and dry starting detergent material 14 in a high speed mixer/densifier 16 to obtain agglomerates 18 It is preferable for the ratio of the surfactant paste to the dry detergent material to be from about 1 10 to about 10 1 and more preferably from about 1 4 to about 4 1 The various ingredients which may be selected for the surfactant paste 12 and the dry starting detergent material 14 are described more fully hereinafter It has been surprisingly found that by agglomerating the surfactant paste 12 and the dry starting detergent material 14 in the high speed mixer/densifier 16 such that the agglomerates have a Dispersion Index is in a range from about 1 to about 6, more preferably from about 1 to about 4, and most preferably from about 1 to about 2, the actual amount of undersized and oversized agglomerate particles produced is significantly reduced In this way, the need for recycling the undersized agglomerate particles and or the oversized agglomerate particles is reduced or minimized This substantially reduces the cost of operating the process The Dispersion Index as defined herein equals A B, wherem A is the surfactant level in the agglomerates havmg a particle size at least about 1 100 microns, and B is the surfactant level in the agglomerates having a particle size of less than about 150 microns The agglomerate particles having a size over 1 100 microns generally represent the "overs" or oversized particles, while the particles having a size of less than 150 microns generally represent the "fines" or undersized particles While not intending to be bound by theory, it is believed that maintaining the index (Dispersion Index) of surfactant level m the oversized particles over (or divided by) the surfactant level in the undersized particles as close to 1 as possible results in a more uniform distribution ofthe surfactant. This inevitably leads to the production of lesser amounts of oversized and undersized agglomerate particles tn that there are less particles which are excessively "sticky" (i e high amounts of surfactant) and tend to over agglomerate into oversized particles, and less particles which are not "sticky" enough (I e. low amounts of surfactant) and tend not to be built up sufficiently causing undersized particles to be produced. Additionally, failure to maintain the Dispersion Index withm the selected range described herem results in the formation of paste droplets and powder clumps which are not agglomerated sufficiently. Thus, by operating the mstant process withm the specified Dispersion Index, the need for recycling agglomerates is minimized and the flow properties ofthe agglomerates is surprisingly enhanced Preferably, the agglomerates can be maintained at the selected Dispersion Index by controlling one or more operating parameters ofthe high speed mixer/densifier 16 and/or the temperature and flow rate ofthe surfactant paste 12 and the dry starting detergent mateπal 14 Such operatmg parameters mclude, residence time, speed ofthe mixer/densifier, and the angle and/or configuration ofthe mixing tools and shovels in the mixer/densfier It will be appreciated by those skilled in the art that one or more of these conventional operating parameters may be varied to obtain agglomerates within the selected Dispersion Index One convenient adjustment means is to control the speed ofthe high speed mixer/densifier by setting the speed in a range of from about 100 φm to about 2500 φm, more preferably from about 300 φm to about 1800 φm, and most preferably from about 500 φm to about 1600 φm Of course, those skilled in the art will understand that the aforementioned operating parameters are j ust a few of many which can be varied to obtain the desired Dispersion Index as described herein and the specific parameters will be dependent upon the other processing parameters Such varying ofthe instant process parameters is well within the scope ofthe ordinary skilled artisan The agglomerates 18 are then sent or fed to a moderate speed mixer/densifier 20 to densify and build-up further and agglomerate the agglomerates 18 It should be understood that the dry starting detergent material 14 and surfactant paste 12 are built-up mto agglomerates in the high speed mixer/densifier 16, thus resultmg in the agglomerates 18 which, in accordance with this invention, have a Dispersion Index as defined herein The agglomerates 18 are then built-up further in the moderate speed mixer/densifier 20 resulting in further densified or built-up agglomerates 22 which are ready for further processing to mcrease their flow properties By operating the high speed mixer/densifier 16 withm the selected Dispersion Index, the ultimate Dispersion Index ofthe agglomerates in the moderate speed mixer/densifier 20 is also unexpectedly maintained at the desired level In fact, the Dispersion Index of the agglomerates in the moderate speed mixer/densifier 20 is preferably from about 1 to about 4, more preferably from about 1 to about 3, and most preferably from about 1 to about 1 5 Typical apparatus used in process 10 for the high speed mixer/densifier 16 mclude but are not limited to a Lδdige Recycler CB-30 while the moderate speed mixer/densifier 20 can be a Lodige Recycler KM-600 "Ploughshare" Other apparatus that may be used include conventional twin-screw mixers, mixers commercially sold as Eiπch, Schugi, O'Brien, and Drais mixers, and combmations of these and other mixers Residence tunes ofthe agglomerates/ingredients in such mixer/densifiers will vary dependmg on the particular mixer/densifier and operating parameters However, the preferred residence time in the high speed mixer/densifier 16 is from about 2 seconds to about 45 seconds, preferably from about 5 to 30 seconds, and most preferably from about 10 seconds to about 15 seconds, while the residence time in the moderate speed mixer/densifier is from about 0 5 mmutes to about 15 mmutes, preferably from about 1 to 10 minutes Optionally, a coatmg agent can be added just before, in or after the high speed mixer/densifier 16 to control or inhibit the degree of agglomeration This optional step provides a means by which the desired agglomerate particle size can be achieved Preferably, the coating agent is selected from the group consisting of aluminosilicates, sodium carbonate, crystalline layered silicates, Na 2 Ca(C0 3 )2, K 2 Ca(C0 3 ) 2 , Na 2 Ca2(C0 3 )3, NaKCa(C0 3 ) 2 . NaKCa 2 (C0 3 ) 3 , K-)Ca 2 (Cθ3 / 3, and mixtures thereof Another optional step entails spraying a binder material into the high speed mixer/densifier 16 so as to facilitate build-up agglomeration. Preferably, the binder is selected from the group consisting of water, anionic surfactants, nonionic surfactants, polyethylene glycol, polyvinyl pyrrolidone, polyacrylates, citric acid and mixtures thereof. Another step in the process 10 entails feeding the further densified agglomerates 22 into a conditioning apparatus 24 which preferably includes one or more of a drying apparatus and a cooling apparatus (not shown individually). The conditioning apparatus 24 in whatever form (fluid bed dryer, fluid bed cooler, airlift, etc.) is included for improving the flow properties ofthe agglomerates 22 and for separating them into a first agglomerate mixture 26 and a second agglomerate mixture 28. Preferably, the agglomerate mixture 26 substantially has a particle size of less than about 150 microns (i.e. undersized particles) and the agglomerate mixture 28 substantially has a particle size of at least about 150 microns. Of course, it should be understood by those skilled in the art that such separation processes are not always perfect and there may be a small portion of agglomerate particles in agglomerate mixture 26 or 28 which is outside the recited size range. The ultimate goal of the process 10, however, is to divide a substantial portion ofthe "fines" or undersized agglomerates 26 from the more desired sized agglomerates 28 which are then sent to one or more finishing steps 30. The agglomerate mixture 26 is recycled back into the high speed mixer/densifier 16 for further agglomeration such that the agglomerates in mixture 26 are ultimately built-up to the desired agglomerate particle size. However, it has been found by operating within the Dispersion Index as mentioned previously, the amount of the agglomerate mixture 26 is unexpectedly reduced, thereby increasing the efficiency ofthe instant process. Preferably, the finishing steps 30 will include admixing adjunct detergent ingredients to agglomerate mixture 28 so as to form a fully formulated high density detergent composition 32 which is ready for commercialization. In a preferred embodiment, the detergent composition 32 has a density of at least 650 g/1. Optionally, the finishing steps 30 includes admixing conventional spray-dried detergent particles to the agglomerate mixture 28 along with adjunct detergent ingredients to form detergent composition 32. In this case, detergent composition 32 preferably comprises from about 10% to about 40% by weight of the agglomerate mixture 28 and the balance spray-dried detergent particles and adjunct ingredients. Detergent Surfactant Paste The detergent surfactant paste used in the processes 10 is preferably in the form of an aqueous viscous paste, although forms are also contemplated by the invention. This so-called viscous surfactant paste has a viscosity of from about 5,000 cps to about 100,000 cps, more preferably from about 10,000 cps to about 80,000 cps, and contains at least about 10% water, more preferably at least about 20% water. The viscosity is measured at 70°C and at shear rates of about 10 to 100 sec." 1 . Optionally, the surfactant paste can have a viscosity sufficiently high so as to resemble an extrudate or "noodle" surfactant form or particle. Furthermore, the surfactant paste, if used, preferably comprises a detersive surfactant in the amounts specified previously and the balance water and other conventional detergent ingredients. The surfactant itself, in the viscous surfactant paste, is preferably selected from anionic, nonionic, zwitterionic, ampholytic and cationic classes and compatible mixtures thereof Detergent surfactants useful herein are descπbed in U S Patent 3,664,961 , Norris, issued May 23, 1972, and in U S Patent 3,919,678, Laughlin et al , issued December 30, 1975 Useful cationic surfactants also include those described in U S Patent 4,222,905, Cockrell, issued September 16, 1980, and in U S Patent 4,239,659, Muφhy, issued December 16, 1980, both of which are also incoφorated herein by reference Of the surfactants, anionics and nonionics are preferred and anionics are most preferred Noniimiting examples ofthe preferred anionic surfactants useful in the surfactant paste include the conventional Cj j-C j g alkyl benzene sulfonates ("LAS"), primary, branched-chain and random C j ø-C 2 o alkyl sulfates ("AS"), the C jø-C j g secondary (2,3) alkyl sulfates of the formula CH 3 (CH 2 ) X (CHOS0 3 " M + ) CH 3 and CH 3 (CH 2 ) y (CHOS0 3 " M + ) CH 2 CH 3 where x and (y + 1 ) are integers of at least about 7, preferably at least about 9, and M is a water-solubihzmg cation, especially sodium, unsaturated sulfates such as oleyl sulfate, and the C j ø-C j g alkyl alkoxy sulfates ("AE X S", especially EO 1-7 ethoxy sulfates) Optionally, other exemplary surfactants useful in the paste of the invention mclude C j ø-C j g alkyl alkoxy carboxylates (especially the EO 1-5 ethoxycarboxylates), the C j Q_ j g glycerol ethers, the C j Q-C J g alkyl polyglycosides and their corresponding sulfated polyglycosides, and C ] 2 -C j g alpha-sulfonated fatty acid esters If desired, the conventional nonionic and amphoteric surfactants such as the C j 2 -C j g alkyl ethoxylates ("AE") mcludmg the so-called narrow peaked alkyl ethoxylates and C£-C| 2 alkyl phenol alkoxylates (especially ethoxylates and mixed ethoxy/propoxy), C ] -C j g betaines and sulfobetaines ("sultaines"), C j ø-C j g amine oxides, and the like, can also be mcluded m the overall compositions The C j -C i g N-alkyl polyhydroxy fatty acid amides can also be used Typical examples include the C j 2 -C j g N-methylglucamides See WO 92/06154 Other sugar-derived surfactants mclude the N-alkoxy polyhydroxy fatty acid amides, such as C ] ø-C j N-(3-methoxypropyl) glucamide The N-propyl through N-hexyl C j 2 -C j g glucamides can be used for low sudsing C j -C 2 ø conventional soaps may also be used If high sudsing is desired, the branched-chain C j ø-C j g soaps may be used. Mixtures of anionic and nonionic surfactants are especially useful Other conventional useful surfactants are listed in standard texts Dry Detergent Mateπal The starting dry detergent mateπal ofthe processes 10 preferably compπses a detergency builder selected from the group consistmg of aluminosilicates, crystalline layered silicates and mixtures thereof, and carbonate, preferably sodium carbonate The aluminosilicates or alummosilicate ion exchange mateπals used herem as a detergent builder preferably have both a high calcium ion exchange capacity and a high exchange rate Without tendmg to be limited by theory, it is believed that such high calcium ion exchange rate and capacity are a function of several mterrelated factors which derive from the method by which the alummosilicate ion exchange mateπal is produced. In that regard, the alummosilicate ion exchange materials used herem are preferably produced in accordance with Corkill et al, U S Patent No 4,605,509 (Procter & Gamble), the disclosure of which is incoφorated herein by reference Preferably, the aluminosilicate ion exchange mateπal is in "sodium" form since the potassium and hydrogen forms ofthe instant aluminosilicate do not exhibit the as high of an exchange rate and capacity as provided by the sodium form Additionally, the aluminosilicate ion exchange material preferably is in over dried form so as to facilitate production of crisp detergent agglomerates as described herein The alummosilicate ion exchange materials used herein preferably have particle size diameters which optimize their effectiveness as detergent builders The term "particle size diameter" as used herein represents the average particle size diameter of a given alummosilicate ion exchange material as determined by conventional analytical techniques, such as microscopic determination and scanning electron microscope (SEM) The preferred particle size diameter ofthe alummosilicate is from about 0 1 micron to about 10 microns, more preferably from about 0 5 microns to about 9 microns Most preferably, the particle size diameter is from about 1 microns to about 8 microns Preferably, the aluminosilicate ton exchange material has the formula Na z [( A10 2 ) z (Sι0 2 ) y ]xH 2 0 wherein z and y are integers of at least 6, the molar ratio of z to y is from about 1 to about 5 and x is from about 10 to about 264 More preferably, the aluminosilicate has the formula Na 12 [(A10 2 ) I 2 (Sι0 2 ) j2 ]xH 2 0 wherein x is from about 20 to about 30, preferably about 27 These preferred aluminosilicates are available commercially, for example under designations Zeolite A, Zeolite B and Zeolite X Alternatively, naturally-occurring or synthetically derived alummosilicate ion exchange mateπals suitable for use herem can be made as described m Krummel et al, U S Patent No 3,985,669, the disclosure of which is incoφorated herein by reference The aluminosilicates used herem are further characteπzed by their ion exchange capacity which is at least about 200 mg equivalent of CaCθ3 hardness/gram, calculated on an anhydrous basis, and which is preferably in a range from about 300 to 352 mg equivalent of CaC0 3 hardness/gram Additionally, the mstant alummosilicate ion exchange materials are still further characterized by their calcium ion exchange rate which is at least about 2 grams Ca ++ /gallon/mmute/-gram gallon, and more preferably in a range from about 2 grams Ca "M 7gallon/mιnute/-gram/gallon to about 6 grams Ca ++ /gallon/m ute/-gram gallon Adiunct Detergent Ingredients The startmg dry detergent matenal in the present process can mclude additional detergent ingredients and/or, any number of additional ingredients can be incoφorated in the detergent composition duπng subsequent steps ofthe present process These adjunct ingredients include other detergency builders, bleaches, bleach activators, suds boosters or suds suppresses, anti-tarnish and anticorrosion agents, soil suspendmg agents, soil release agents, germicides, pH adjusting agents, non-builder alkalinity sources, chelating agents, smectite clays, enzymes, enzyme-stabilizing agents and perfumes See U S Patent 3,936,537, issued February 3, 1976 to Baskerville, Jr et al , incoφorated herein by reference Other builders can be generally selected from the various water-soluble, alkali metal, ammonium or substituted ammonium phosphates, polyphosphates, phosphonates, polyphosphonates, carbonates, borates, polyhydroxy sulfonates, polyacetates, carboxylates, and polycarboxylates Preferred are the alkali metal, especially sodium, salts ofthe above Preferred for use herein are the phosphates, carbonates, jø_ j fatty acids, polycarboxylates, and mixtures thereof More preferred are sodium tripolyphosphate, tetrasodium pyrophosphate, citrate, tartrate mono- and di-succinates, and mixtures thereof (see below) In comparison with amoφhous sodium silicates, crystalline layered sodium silicates exhibit a clearly increased calcium and magnesium ion exchange capacity In addition, the layered sodium silicates prefer magnesium ions over calcium ions, a feature necessary to insure that substantially all of the "hardness" is removed from the wash water These crystalline layered sodium silicates, however, are generally more expensive than amoφhous silicates as well as other builders Accordingly, in order to provide an economically feasible laundry detergent, the proportion of crystalline layered sodium silicates used must be determmed judiciously The crystalline layered sodium silicates suitable for use herem preferably have the formula NaMSι x θ2 x+ ι yH 2 0 wherein M is sodium or hydrogen, x is from about 1 9 to about 4 and y is from about 0 to about 20 More preferably, the crystalline layered sodium silicate has the formula NaMSι 2 0 5 yH 2 0 wherein M is sodium or hydrogen, and y is from about 0 to about 20 These and other crystalline layered sodium silicates are discussed m Corkill et al, U S Patent No 4,605,509, previously incoφorated herem by reference Another very viable builder mateπal which can also be used as the coating agent in the process as described previously mclude materials havmg the formula (M x ), Ca v (Cθ3) z wherem x and I are integers from 1 to 15, y is an teger from 1 to 10, z is an integer from 2 to 25, M, are cations, at least one of which is a water-soluble, and the equation Σ, _ χ_ι 5(x x multiplied by the valence of M,) + 2y = 2z is satisfied such that the formula has a neutral or "balanced" charge Waters of hydration or anions other than carbonate may be added provided that the overall charge is balanced or neutral The charge or valence effects of such anions should be added to the πght side of the above equation Preferably, there is present a water-soluble cation selected from the group consisting of hydrogen, water-soluble metals, hydrogen, boron, ammonium, silicon, and mixtures thereof, more preferably, sodium, potassium, hydrogen, lithium, ammonium and mixtures thereof, sodium and potassium being highly preferred Nonlimitmg examples of noncarbonate anions mclude those selected from the group consistmg of chloride, sulfate, fluoride, oxygen, hydroxide, silicon dioxide, chromate, nitrate, borate and mixtures thereof Preferred builders of this type in their simplest forms are selected from the group consisting of Na 2 Ca(C0 3 ) , K 2 Ca(C0 3 )2, Na 2 Ca 2 (C03)3 NaKCa(C0 3 )2 NaKCa 2 (Cθ3)3, K Ca 2 (Cθ3)3, and combinations thereof An especially preferred material for the builder described herein is Na 7 Ca(Cθ3) 7 in any of its crystalline modifications Suitable builders of the above-defined type are further illustrated by, and include, the natural or synthetic forms of any one or combinations ofthe following minerals Afghanite, Andersonite, AshcroftineY, Beyeπte, Borcaπte, Burbankite, Butschlute, Cancπnite, Carbocemaite, Carletonite, Davyne, DonnayiteY, Fairchildite, Ferπsuπte, Franzmite, Gaudefroyite, Gaylussite, Girvasite Gregoryite, Jouravskite, KamphaugiteY, Kettneπte, Khanneshite, LepersonniteGd, Liottite, MckelveyiteY, Microsommite, Mroseite, Natrofairchildite, Nyerereite, RemonditeCe, Sacrofanite, Schrockmgerite, Shortite, Suπte, Tunisite, Tuscanite, Tyro te, Vishnevite, and Zemkoπte Preferred mineral forms include Nyereπte, Fairchildite and Shortite Specific examples of inorganic phosphate builders are sodium and potassium tripolyphosphate, pyrophosphate, polymeric metaphosphate having a degree of polymenzation of from about 6 to 21, and orthophosphates Examples of polyphosphonate builders are the sodium and potassium salts of ethylene diphosphonic acid, the sodium and potassium salts of ethane 1 -hydroxy- 1 , 1 -diphosphonic acid and the sodium and potassium salts of ethane, 1 , 1 ,2-tπphosphonιc acid Other phosphorus builder compounds are disclosed in U S Patents 3,159,581 , 3,213,030, 3,422,021 , 3,422,137, 3,400,176 and 3,400, 148, all of which are incoφorated herein by reference Examples of nonphosphorus, inorganic builders are tetraborate decahydrate and silicates having a weight ratio of SiO. to alkali metal oxide of from about 0 5 to about 4 0, preferably from about 1 0 to about 2 4 Water-soluble, nonphosphorus organic builders useful herein include the various alkali metal, ammonium and substituted ammonium polyacetates, carboxylates, polycarboxylates and polyhydroxy sulfonates Examples of polyacetate and polycarboxylate builders are the sodium, potassium, lithium, ammonium and substituted ammonium salts of ethylene diamme tetraacetic acid, nitnlotπacetic acid, oxydisuccinic acid, mel tic acid, benzene polycarboxylic acids, and citric acid Polymeπc polycarboxylate builders are set forth m U S Patent 3,308,067, Diehl, issued March 7, 1967, the disclosure of which is incoφorated herem by reference Such mateπals include the water-soluble salts of homo- and copolymers of aliphatic carboxylic acids such as maleic acid, itaconic acid, mesaconic acid, fumaric acid, aconitic acid, citraconic acid and methylene malonic acid Some of these materials are useful as the water-soluble anionic polymer as hereinafter described, but only if intimate admixture with the non-soap anionic surfactant Other suitable polycarboxylates for use herem are the polyacetal carboxylates described in U S Patent 4, 144,226, issued March 13, 1979 to Crutchfield et al, and U S Patent 4,246,495, issued March 27, 1979 to Crutchfield et al, both of which are incoφorated herem by reference These polyacetal carboxylates can be prepared by bringing together under polymerization conditions an ester of glyoxylic acid and a polymenzation initiator The resulting polyacetal carboxylate ester is then attached to chemically stable end groups to stabilize the polyacetal carboxylate against rapid depolymeπzation in alkaline solution, converted to the corresponding salt, and added to a detergent composition Particularly preferred polycarboxylate builders are the ether carboxylate builder compositions comprising a combination of tartrate monosuccinate and tartrate disuccinate described in U S Patent 4,663,071 , Bush et al , issued May 5, 1987, the disclosure of which is incoφorated herein by reference Bleaching agents and activators are described m U S Patent 4,412,934, Chung et al , issued November 1, 1983, and iπ U S Patent 4,483,781, Hartman, issued November 20, 1984, both of which are incoφorated herein by reference Chelating agents are also described in U S Patent 4,663.071 , Bush et al , from Column 17, line 54 through Column 18, lme 68, incoφorated herein by reference Suds modifiers are also optional ingredients and are described in U S Patents 3,933,672, issued January 20, 1976 to Bartoletta et al , and 4,136,045, issued January 23, 1979 to Gault et al , both incoφorated herem by reference Suitable smectite clays for use herein are described in U S Patent 4,762,645, Tucker et al, issued August 9, 1988, Column 6, lme 3 through Column 7, line 24, incorporated herein by reference Suitable additional detergency builders for use herein are enumerated in the aforementioned Baskerville patent, Column 13, lme 54 through Column 16, lme 16, and in U S Patent 4,663,071, Bush et al, issued May 5, 1987, both incoφorated herein by reference In order to make the present invention more readily understood, reference is made to the following examples, which are intended to be illustrative only and not intended to be limiting m scope EXAMPLE This Example illustrates the process ofthe mvention which produces free flowing, crisp, high density detergent composition Two feed streams of various detergent starting ingredients are continuously fed, at the several rates noted m Table II below, into a Lδdige CB-30 mixer/densifier, one of which comprises a surfactant paste containing surfactant and water and the other stream eontammg startmg dry detergent matenal containing alummosilicate and sodium carbonate The rotational speeds of the shaft in the Lddige CB-30 mixer/densifier are also given in Table II and the mean residence time is about 10 seconds The agglomerates from the Lodige CB-30 mixer/densifier are contmuously fed mto a Lδdige KM-600 mixer/densifier for further agglomeration during which the mean residence time is about 3 to 6 mmutes The resulting detergent agglomerates are then fed to conditioning apparatus mcludmg a fluid bed dryer and then to a fluid bed cooler, the mean residence time bemg about 10 mmutes and 15 mmutes, respectively The undersized or "fine" agglomerate particles (less than about 150 microns) from the fluid bed dryer and cooler are recycled back into the Lodige CB-30 mixer/densifer The composition ofthe detergent agglomerates exitmg the Lodige KM-600 mixer/densifier is set forth in Table I below TABLE I Componeπt % Weight c 14-15 alkyl sulfate 21 6 C j ? 3 linear alkylbenzene sulfonate 7 2 Aluminosilicate 32 4 Sodium carbonate 20 6 Polyethylene glycol (MW 4000) 0 5 Misc (water, unreactants, etc ) 10 1 100 0 A coating agent, aluminosilicate, is fed immediately after the Lodige KM-600 mixer/densifier but before the fluid bed dryer to enhance the flowability ofthe agglomerates The detergent agglomerates exitmg the fluid bed cooler are screened, after which adjunct detergent ingredients are admixed therewith to result in a fully formulated detergent product having a uniform particle size distribution The density ofthe agglomerates in Table I is 750 g/l and the median particle size is 700 microns Adjunct liquid detergent ingredients including perfumes, brighteners and enzymes are sprayed onto or admixed to the agglomerates/particles described above in the finishing step to result in a fully formulated finished detergent composition One or more samples ofthe agglomerates formed in Lodige CB-30 mixer/densifer are taken and subjected to standard sievmg techniques that utilize a stack of screens and a rotap machine to separate particles having a size at least 1 100 microns (oversized) and particles having a size of less than 150 microns (undersized) The level of surfactant is measured in an oversized particle and in an undersized particle by conventional titration methods In this Example, the anionic surfactant level in the agglomerate particles are determmed by conducting the well known "catS03" titration technique In particular, the agglomerate particle sample is dissolved in an aqueous solution and filtered through 0 45 nylon filter paper to remove the insolubles and thereafter, titrating the filtered solution to which anionic dyes (dimidium bromide) have been added with a cationic titrant such as Hyamine™ commercially available from Sigma Chemical Company Accordmgly, the relative amount of anionic surfactant dissolved in the solution and thus m the particular particle is determmed This technique is well known and others may be used if desired The Dispersion Index is determined by dividing the surfactant level in an oversized agglomerate particle (referenced previously as "A") by the surfactant level in an undersized agglomerate particle (referenced previously as "B") Several undersized and oversized particles can be measured for their surfactant level so as to generate several Dispersion Index values for generating statistically significant values Table II below sets forth exemplary Lodige CB-30 mixer/densifer speeds and starting ingredient flow rates which produce agglomerates with a Dispersion Index withm the selected range of 1 to 6 Operating Parameters* Dispersion Index 1542 kg/hr, 800 φm, and recycle 5 0 1329 kg/hr; 800 φm; and no recycle 4.6 1542 kg/hr; 1200 φm; and recycle 2.9 1329 kg/hr; 1200 φm; and no recycle 2.7 1542 kg/hr; 1600 φm; and recycle 3.1 1329 kg/hr; 1600 φm; and no recycle 3.1 771 kg/hr; 800 φm; and recycle 2.9 665 kg/hr; 800 φm; and no recycle 2.7 771 kg/hr; 1200 φm; and recycle 1.8 665 kg/hr; 1200 φm; and no recycle 1.9 771 kg/hr; 1600 φm; and recycle 2.2 665 kg/hr; 1600 φm; and no recycle 2.0 This includes the total flow rate of the input streams to Lodige CB-30 mixer/densifer including the surfactant paste and dry starting detergent ingredients, the speed ofthe Lδdige CB-30 mixer/densifer, and whether or not a stream of undersized particles (213 kg/hr) from the fluid bed cooler was recycled back into the Lodige CB-30 mixer/densifer during processmg. The agglomerates produced by the process described above within the recited Dispersion Index are unexpectedly crisp, free flowing, and highly dense. Having thus described the invention in detail, it will be clear to those skilled in the art that various changes may be made without departing from the scope ofthe invention and the invention is not to be considered limited to what is described in the specification. What is claimed is:

Claims: 1 A process for preparing high density detergent composition characterized by the steps of (a) agglomerating a detergent surfactant paste and dry starting detergent material in a high speed mixer/densifier to obtain agglomerates having a Dispersion Index in a range of from 1 to 6, wherem Dispersion Index = A B A is the surfactant level in said agglomerates having a particle size of at least 1 100 microns, and B is the surfactant level in said agglomerates having a particle size less than 150 microns, (b) mixing said agglomerates in a moderate speed mixer/densifier to further densify, build¬ up and agglomerate said agglomerates, and (c) conditioning said agglomerates such that the flow properties of said agglomerates are unproved, thereby forming said high density detergent composition 2 The process accordmg to claim 1 wherein said conditioning step mcludes the steps of drying and coolmg said agglomerates 3 The process according to claims 1-2 wherein the Dispersion Index is from 1 to 4 4 The process accordmg to clauns 1-3 wherein said dry starting detergent material is characterized by a builder selected from the group consistmg of aluminosilicates, crystalline layered silicates, sodium carbonate, Na 2 Ca(C0 3 ) 2 , K 2 Ca(C0 3 ) 2( Na 2 Ca 2 (Cθ3) 3 , NaKCa(C0 3 ) 2 , NaKCa 2 (C0 3 )3, K Ca 2 (C0 3 )3 and mixtures thereof 5 The process accordmg to clauns 1 -4 wherem the speed of said high speed mixer/densifier is from 100 φm to 2500 φm 6 The process accordmg to clauns 1 -5 further characterized by the step of addmg a coatmg agent after said high speed mixer/densifier, wherein said coatmg agent is selected from the group consistmg of aluminosilicates, sodium carbonate, crystalline layered silicates, Na Ca(Cθ3) 2 , K 2 Ca(C0 3 ) , Na 2 Ca 2 (C0 3 ) 3 , NaKCa(C0 3 ) 2 , NaKCa 2 (C0 3 )3, K 2 Ca 2 (C0 3 )3, and mixtures thereof 7 The process accordmg to claims 1 -6 wherein the mean residence time of said agglomerates in said high speed mixer/densifier is in a range of from 2 seconds to 45 seconds 8 The process according to claims 1 -7 wherein the mean residence time of said agglomerates in said moderate speed mixer/densifier is in a range of from 0 5 minutes to 15 minutes 9 A process for preparing high densify detergent composition characterized by the steps of (a) agglomerating a detergent surfactant paste and dry starting detergent material in a high speed mixer/densifier to obtain agglomerates having a Dispersion Index in a range of from 1 to 6, wherem Dispersion Index = A/B A is the surfactant level in said agglomerates having a particle size of at least 1 100 microns, and B is the surfactant level in said agglomerates having a particle size less than 150 microns, (b) mixing said agglomerates in a moderate speed mixer/densifier to further densify, build¬ up and agglomerate said agglomerates, (c) feeding said agglomerates into a conditioning apparatus for improving the flow properties of said agglomerates and for separating said agglomerates into a first agglomerate mixture and a second agglomerate mixture, wherein said first agglomerate mixture substantially has a particle size of less than 150 microns and said second agglomerate mixture substantially has a particle size of at least 150 microns, (d) recycling said first agglomerate mixture into said high speed mixer/densifier for further agglomeration, and (e) admixing adjunct detergent ingredients to said second agglomerate mixture so as to form said high density detergent composition 10 The process accordmg to claim 9 wherein the speed of said high speed mixer/densifier is from 100 φm to 2500 φm

Inventors: CAPECI SCOTT WILLIAM, NASSANO DAVID ROBERT, CAPECI, SCOTT, WILLIAM, NASSANO, DAVID, ROBERT
Applicants: PROCTER & GAMBLE, THE PROCTER & GAMBLE COMPANY
Application year: 1996
Main classification: C11D17
IPC codes: C11D11, C11D17