PROCESS FOR MAKING A LOW DENSITY DETERGENT COMPOSITION BY CONTROLLING AGGLOMERATION VIA PARTICLE SIZE

Abstract: A process for preparing low density detergent agglomerates is provided. The process involves the step of: (a) agglomerating a detergent surfactant paste or precursor thereof and dry starting detergent material having a median particle size in a range from about 5 microns to about 70 microns in a first high speed mixer to obtain detergent agglomerates having a median particle size of from about 100 microns to about 250 microns; (b) mixing the detergent agglomerates with a binder in a second high speed mixer to obtain built-up agglomerates having a median particle size in a range of from about 140 microns to about 350 microns; and (c) feeding the built-up agglomerates into a fluid bed dryer in which the built-up agglomerates are agglomerated with another binder and dried to form detergent agglomerates having a median particle size in a range of from about 300 microns to about 700 microns and a density in a range about 300 g/l to about 550 g/l.

Description: PROCESS FOR MAKING A LOW DENSITY DETERGENT COMPOSITION BY CONTROLLING AGGLOMERATION VIA PARTICLE SIZE FIELD OF THE INVENTION The present invention generally relates to a process for producing a low density detergent composition. More particularly, the invention is directed to a process during which low density detergent agglomerates are produced by feeding a surfactant paste or liquid acid precursor of anionic surfactant and dry starting detergent mateπal sequentially into two high speed mixers followed by a fluid bed dryer. The process produces a free flowing, low density detergent composition which can be commercially sold as a conventional non-compact detergent composition or used as an admix in a low dosage, "cpmpact" detergent product. BACKGROUND OF THE INVENTION Recently, there has been considerable interest withm 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/1 or higher The low dosage detergents are currently in high demand as they conserve resources and can be sold m small packages which are more convenient for consumers. However, the extent to which modern detergent products need to be "compact" m 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-drymg 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 no onic 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 mateπals and their respective chemical composition. These parameters, however, can only be vaπed within a limited range. Thus, flexibility m 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 m 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 batch process m which spray-dπed or granulated detergent powders containing sodium tπpolyphosphate and sodium sulfate are densifϊed and spheromzed in a Marumeπzer® This apparatus compπses a substantially hoπzontal, roughened, rotatable table positioned withm 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 continuous processes for increasing the density of "post-tower" or spray dπed detergent granules Typically, such processes require a first apparatus which pulveπzes or gπnds the granules and a second apparatus which increases the density of the pulveπzed granules by agglomeration While these processes achieve the desired increase in density by treating or densifying "post tower" or spray dπed granules, they do not provide a process which has the flexibility of providing lower density granules using an agglomeration process or other non-tower process. Moreover, all of the aforementioned processes are directed pπmaπly for densifying or otherwise processing spray dπed granules Currently, the relative amounts and types of mateπals 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. 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 conventional starting detergent mateπals in the form of surfactant pastes or precursors thereof, liquids and dry mateπals can be effectively agglomerated into cπsp, free flowing detergent agglomerates having low densities rather than high densities. In the past, attempts at producing such low density agglomerates involves a nonconventional detergent ingredient which is typically expensive, thereby adding to the cost of the detergent product One such example of this involves a process of agglomerating with inorganic double salts such as Burkeite to produce the desired low density agglomerates. Accordingly, there remains a need in the art to have a process for producing a low density detergent composition directly from starting detergent ingredients without the need for relatively expensive specialty ingredients. Also, there remains a need for such a process which is more efficient, flexible and economical to facilitate large-scale production of detergents of low as well as high dosage levels. 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 al, Bπtish patent No. 1,517,713 (Unilever); and Curtis, European Patent Application 451,894. The following references are directed to producing 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); Holhngsworth et al, European Patent Application 351,937 (Unilever); and Swat ng et al, U.S. Patent No. 5,205,958. The following references are directed to inorganic double salts: Evans et al, U.S. Patent No. 4,820,441 (Lever); Evans et al, U.S. Patent No. 4,818,424 (Lever); Atkinson et al, U.S. Patent No. 4,900,466 (Lever); and France et al, U.S. Patent No. 5,576,285 (Procter & Gamble); and Dhalewadika et al, PCT WO 96/04359 (Unilever). SUMMARY OF THE INVENTION The present invention meets the aforementioned needs in the art by providing a process which produces a low density (below about 600 g/1) detergent composition directly from starting ingredients without the need for certain relatively expensive specialty ingredients. The process does not use the conventional spray drying towers currently used and is therefore more efficient, economical and flexible with regard to the vaπety of detergent compositions which can be produced in the process. Moreover, 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. In essence, the process involves agglomerating a surfactant paste or precursor thereof and dry detergent ingredients in a high speed mixer followed by another high speed mixer to form agglomerates which have been built-up or glued together via controlled particle size growth such that the resulting agglomerates are highly porous and have a very low density. The built-up low density agglomerates are further agglomerated in this fashion and dried in a fluid bed dryer to produce the final low density detergent agglomerates. As used herein, the term "agglomerates" refers to particles formed by agglomerating detergent granules or particles which typically have a smaller median particle size than the formed agglomerates. All percentages used herein are expressed as "percent-by- weight" on an anhydrous basis unless indicated otherwise. In accordance with one aspect of the invention, a process for preparing low density detergent agglomerates is provided The process comprises the steps of (a) agglomerating a detergent surfactant paste or precursor thereof and dry starting detergent material having a median particle size m a range from about 5 microns to about 70 microns in a first high speed mixer to obtain detergent agglomerates having a median particle size of from about 100 microns to about 250 microns, (b) mixing the detergent agglomerates with a first binder m a second high speed mixer to obtain built-up agglomerates having a median particle size in a range of from about 140 microns to about 350 microns; and (c) feeding the built-up agglomerates into a fluid bed dryer m which the built-up agglomerates are agglomerated with a second binder and dπed to form detergent agglomerates having a median particle size m a range of from about 300 microns to about 700 microns and a density in a range from about 300 g/1 to about 550 g/1 In accordance with another aspect of the invention, another process for prepanng low density detergent agglomerates is provided The process compπses the steps of (a) agglomerating a first liquid acid precursor of an anionic surfactant and dry starting detergent mateπal having a median particle size in a range from about 5 microns to about 50 microns in a first high speed mixer to obtain detergent agglomerates having a median particle size of from about 100 microns to about 250 microns; (b) mixing the detergent agglomerates with a second liquid acid precursor of an anionic surfactant in a second high speed mixer to obtain built-up agglomerates having a median particle size in a range of from about 140 microns to about 350 microns; and (c) feeding the built-up agglomerates into a fluid bed dryer in which the built-up agglomerates are agglomerated with a third liquid acid precursor of an anionic surfactant and dπed to form detergent agglomerates having a median particle size in a range of from about 300 microns to about 700 microns and a density in a range from about 300 g/1 to about 550 g/1. The detergent products made m accordance with any of the process embodiments descπbed herein are also provided. Accordmgly, it is an object of the invention to provide a process for producing a low density detergent composition directly from starting detergent ingredients which does not include relatively expensive specialty ingredients. It is also an object of the invention to provide such a process which is more efficient, flexible and economical so as to facilitate large-scale production of detergents of low as well as high dosage levels. These and other objects, features and attendant advantages of the present invention will become apparent to those skilled in the art from a reading of the following detailed descπption of the preferred embodiment and the appended claims. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT The present invention is directed to a process m which low density agglomerates are produced by controlling the median particle size of the detergent ingredients in every step of the process By "median particle size", it is meant the particle size diameter value above which 50% of the particles have a larger particle size and below which 50% of particles have a smaller particle size The process forms free flowing, low density detergent agglomerates which can be used alone as the detergent product or as an admixture with conventional spray-dried detergent granules and/or high density detergent agglomerates in a final commercial detergent product It should be understood that the process descπbed herein can be operated continuously or in a batch mode depending upon the particularly desired application One major advantage of the present process is that it utilizes equipment currently used to make high density or compact detergent products However, the process descπbed herein produces low density detergent compositions from such similar equipment by selectively adjusting and modifying certain unit operations and parameters as detailed herein. In this way, a single large-scale commercial detergent manufactuπng facility can be built to produce high or low density detergent compositions depending upon the local consumer demand and its inevitable fluctuations between compact and non-compact detergent products. Process In the first step of the process, a detergent surfactant paste or precursor thereof as set forth m more detail hereinafter and dry starting detergent mateπal having a selected median particle size is inputted and agglomerated in a high speed mixer. Unlike previous processes in this area, the dry starting mateπal can include only those relatively inexpensive detergent mateπals typically used in modern granular detergent products. Such ingredients, include but are not limited to, builders, fillers, dry surfactants, and flow aides. Preferably, the builder includes aluminosihcates, crystalline layered silicates, phosphates, carbonates and mixtures thereof which is the essential dry starting detergent ingredient withm the scope of the current process. Relatively expensive mateπals such as Burkeite (Na2Sθ4»Na2Cθ3) and the vaπous silicas are not necessary to achieve the desired low density agglomerates produced by the process. Rather, it has been found that by judiciously controlling the median particle size of the inputted dry mateπals, particle buildup can be achieved in manner which produces agglomerates having a high degree of "lntraparticle" or "mtragranule" or "intraagglomerate" porosity, and therefore are low in density. The terms "mtraparticle" or "mtragranule" or "intraagglomerate" are used synonmously herein to refer to the porosity or void space inside the formed built-up agglomerates produced at any stage of the process. Accordingly, in the first step of the process, the median particle size of the dry detergent mateπal is preferably m a range from about 5 microns to about 70 microns, more preferably from about 10 microns to about 60 microns, and most preferably from about 10 microns to about 50 microns. It is also preferable to include from 1% to about 40% by weight of recycled undersized detergent particles or "fines" in the first step of the process This can be conveniently accomplished by screening the detergent particles formed subsequent to the fluid bed dryer to a median particle size range of from about 10 microns to about 150 microns and feeding these "fines" back into the first high speed mixer The high speed mixer can be any one of a variety of commercially available mixers such as a Lodige CB 30 mixer or similar brand mixer. These types of mixers essentially consist of a hoπzontal, hollow static cylinder having a centrally mounted rotating shaft around which several shovel and rod-shaped blades are attached which have a tip speed of from about 5 m/s to about 30 m/s, more preferably from about 6 m/s to about 26 m/s At the scale of a Lodige CB 30, the shaft rotates at a speed of from about 100 rpm to about 2500 rpm, more preferably from about 300 rpm to about 1600 rpm. At other mixer scales, the preferred rotation speed is adjusted to maintain tool tip speed equivalent to that of the Lodige CB 30 The tip speed is calculated by multiplying the radius from the center of the shaft to the tool tip by 2πN, wherein N is the rotation speed. Preferably, the mean residence time of the detergent ingredients m the high speed mixer is preferably m range from about 2 seconds to about 45 seconds, and most preferably from about 5 seconds to about 15 seconds. This mean residence time is conveniently measured by dividing the weight of the mixer at steady state by throughput (kg/hr) flow. Another suitable mixer is any one of the vanous Flexomix models available from Schugi (Netherlands) which are vertically positioned high speed mixers. This type of mixer is preferably operated at a Froude Index of from about 13 to about 32. See U.S. Patent 5,149,455 to Jacobs et al (issued September 22, 1992) for a detailed discussion of this well-known Froude Index which is a dimensionless number that can be optimally selected by those skilled m the art. In a preferred embodiment of the process invention, a liquid acid precursor of an anionic surfactant is inputted with the dry starting detergent mateπal which at least includes a neutralizing agent such as sodium carbonate. The preferred liquid acid surfactant precursor is C\ 1_1 g linear alkylbenzene sulfonate surfactant ("HLAS"), although any acid precursor of an anionic surfactant may be used in the process. A more preferred embodiment involves feeding a liquid acid precursor of Cj2-14 linear alkylbenzene sulfonate surfactant with a Ci ø_ι g alkyl ethoxylated sulfate ("AES") surfactant into the first high speed mixer, preferably in a weight ratio of from about 5: 1 to about 1 :5, and most preferably, m a range of from about 1 : 1 to about 3 : 1 (HLAS : AS). The result of such mixmg is a "dry neutralization" reaction between the HLAS and the sodium carbonate embodied m the dry starting detergent mateπal, all of which forms agglomerates. It is preferable to add the HLAS before the addition of other surfactants such as AES or alkyl sulfate ("AS") surfactants so as to insure optimal mixing and neutralization of the HLAS in the first high speed mixer. Preferably, after agglomeration in the first high speed mixer, detergent agglomerates having a median particle size of from about 100 microns to about 250 microns, more preferably from about 80 microns to about 140 microns, and most preferably from about 90 microns to about 120 microns, are formed The rate of particle size growth can be controlled in a vaπety of ways, including but not limited to, varying the residence time, temperature and mixing tool speed of the mixer, and controlling amount of liquid or binder inputted into the mixer In this regard, the particular parameter controlled is not cπtical, but only that the median particle size falls within the ranges set forth previously In this way, the smaller particle sized starting detergent mateπal is gradually built-up in a controlled fashion such that the agglomerates have a large degree of mtragranule porosity, thereby resulting in a low density detergent composition Stated differently, the smaller sized starting detergent material is gently "glued" or "stuck" together to form porous built-up agglomerates, all of which is controlled so as to retain or increase the porosity by solidifying the particle bonds without consolidation or collapse of the agglomerates. In the second step of the process, the detergent agglomerates formed in the first step are inputted into a second high speed mixer and agglomerated with a atomized liquid binder The second high speed mixer can be the same piece of equipment as used in the first step or a different type of high speed mixer For example, a Lodige CB mixer can be used in the first step while a Schugi mixer is used in the second step In this second process step, the agglomerates having a median particle size as noted previously are mixed and built-up further in a controlled fashion such that detergent agglomerates exiting the second high speed mixer have a median particle size of from about 140 microns to about 350 microns, more preferably from about 160 microns to about 250 microns, and most preferably from about 180 microns to about 220 microns. As in the first step of the process, the agglomerates are agglomerated m a very controlled fashion such that they have a median particle size withm the aforementioned ranges. Again, the mtragranule porosity of the particles is mcreased by "sticking" together smaller sized particles with a high degree of porosity between the particles (i.e., lnterparticle porosity). In this step, this is achieved by operating the high speed mixer with sufficient binder atomization and spray coverage to produce only agglomerates in the aforementioned median particle size ranges. In this regard, an appropπate binder is added to facilitate formation of the desired agglomerates in this step. Typical binders include liquid sodium silicate, a liquid acid precursor of an anionic surfactant such as HLAS, nomonic surfactant, polyethylene glycol or mixtures thereof. In the next step of the process, the built-up agglomerates are inputted into a fluid bed dryer in which the agglomerates are dπed and agglomerated to a median particle size of from about 300 microns to about 700 microns, more preferably from about 325 microns to about 450 microns The density of the agglomerates formed is from about 300 g/1 to about 550 g/1, more preferably from about 350 g/1 to about 500 g/1, and even more preferably from about 400 g/1 to about 480 g/1 All of these densities are generally below that of typical detergent compositions formed of dense agglomerates or most typical spray-dπed granules Preferably, m those process embodiments involving aqueous binders, the inlet air temperature of the fluid bed dryer is maintained in a range of from about 100°C to about 200°C so as to enhance formation of the desired agglomerates While not wishing to be bound by theory, it is believed that this relatively high temperature insures rapid moisture evaporation to solidify the wet bonds of the built-up agglomerates so as to retain a high degree of mtragranule porosity As with the first and second steps of the process, the agglomerates are built-up from smaller sizes to large sized particles having a high degree of mtragranule porosity The degree of mtragranule porosity is preferably from about 20% to about 40%, and most preferably from about 25% to about 35% The mtragranule porosity can be conveniently measured by standard mercury porosimetry testing Optionally, a binder as descπbed previously may be added duπng this step at more than one location such as at each end of the fluid bed dryer so to enhance formation of the desired agglomerates The net result of this process embodiment involves addition of a binder in the second high speed mixer and at each end (i.e., the mlet port and exit port) of the fluid bed, thus totaling three binder addition points in the process which provides supeπor low density agglomerates Particularly preferred binders m this regard are liquid sodium silicate and HLAS. Other optional steps contemplated by the present process include screening the oversized detergent agglomerates in a screening apparatus which can take a vaπety of forms including but not limited to conventional screens chosen for the desired particle size of the finished detergent product. Other optional steps include conditioning of the detergent agglomerates by subjecting the agglomerates to additional drying and/or cooling by way of apparatus discussed previously. Another optional step of the instant process entails finishing the resulting detergent agglomerates by a vaπety of processes including spraying and/or admixing other conventional detergent ingredients. For example, the finishing step encompasses spraying perfumes, bπghteners and enzymes onto the finished agglomerates to provide a more complete detergent composition. Such techniques and ingredients are well known in the art. Detergent Surfactant Paste or Surfactant Acid Precursor As mentioned, a liquid acid precursor of anionic surfactant is used m the first step of the process as well as in the second and third essential steps of the process as a bmder This liquid acid precursor will typically have a viscosity as measured at 30°C of from about 500 cps to about 5,000 cps. The liquid acid is a precursor for the anionic surfactants descπbed m more detail hereinafter. A detergent surfactant paste can also be used in the process and is preferably in the form of an aqueous viscous paste, although other 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%o water. The viscosity is measured at 70°C and at shear rates of about 10 to 100 sec.'l. Furthermore, the surfactant paste, if used, preferably compπses 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, nomonic, zwitteπonic, ampholytic and catiomc classes and compatible mixtures thereof. Detergent surfactants useful herein are described in U.S. Patent 3,664,961, Norπs, issued May 23, 1972, and m U.S. Patent 3,919,678, Laughlin et al., issued December 30, 1975, both of which are incorporated herein by reference. Useful catiomc 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, Murphy, issued December 16, 1980, both of which are also incorporated herein by reference. Of the surfactants, aniomcs and noniomcs are preferred and anionics are most preferred. Nonlimiting examples of the preferred anionic surfactants useful in the surfactant paste, or from which the liquid acid precursor described herein derives, include the conventional Ci -C\ g alkyl benzene sulfonates ("LAS"), primary, branched-chain and random C10-C20 alkyl sulfates ("AS"), the Cjo-Cjg secondary (2,3) alkyl sulfates of the formula CH 3 (CH2) x (CHOS0 3 " M + ) CH3 and CH3 (CH 2 )y(CHOSθ3 " 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-solubilizing cation, especially sodium, unsaturated sulfates such as oleyl sulfate, and the Cio-Cjg alkyl alkoxy sulfates ("AE X S"; especially EO 1-7 ethoxy sulfates). Optionally, other exemplary surfactants useful in the paste of the invention include and Ci Q -Ci g alkyl alkoxy carboxylates (especially the EO 1-5 ethoxycarboxylates), the C 1 n_ g glycerol ethers, the C \ Q-C 1 g alkyl polyglycosides and their corresponding sulfated polyglycosides, and Cj2-Cιg alpha-sulfonated fatty acid esters. If desired, the conventional nonionic and amphoteric surfactants such as the C12-C1 g alkyl ethoxylates ("AE") including the so-called narrow peaked alkyl ethoxylates and alkyl phenol alkoxylates (especially ethoxylates and mixed ethoxy/propoxy), C12-C1 g betaines and sulfobetaines ("sultaines"), Ci Q -C^ amine oxides, and the like, can also be included m the overall compositions. The CJQ-CI g N-alkyl polyhydroxy fatty acid amides can also be used. Typical examples include the C 1 2-C1 g N-methylglucamides. See WO 9,206,154. Other sugar-derived surfactants include the N-alkoxy polyhydroxy fatty acid amides, such as C i ø-C i g N-(3 -methoxypropyl) glucamide The N-propyl through N-hexy 1 C \ 2-C g glucamides can be used for low sudsmg C10-C20 conventional soaps may also be used If high sudsmg is desired, the branched-chain C^Q-C^g soaps may be used Mixtures of anionic and nomonic surfactants are especially useful Other conventional useful surfactants are listed in standard texts Dry Detergent Mateπal The starting dry detergent mateπal of the present process preferably compnses a builder and other standard detergent ingredients such as sodium carbonate, especially when a liquid acid precursor of a surfactant is used as it is needed as a neutralizing agent m the first step of the process Thus, preferable starting dry detergent mateπal includes sodium carbonate and a phosphate or an alummosihcate builder which is referenced as an alummosihcate ion exchange mateπal A preferred builder is selected from the group consisting of alummosihcates, crystalline layered silicates, phosphates, carbonates and mixtures thereof. Preferred phosphate builders include sodium tπpolyphosphate, tetrasodium pyrophosphate and mixtures thereof. Additional specific examples of inorganic phosphate builders are sodium and potassium tπpolyphosphate, pyrophosphate, polymeπc metaphosphate having a degree of polymeπzation 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-l, 1 -diphosphonic acid and the sodium and potassium salts of ethane, 1,1,2-tπphosphomc acid. Other phosphorus builder compounds are disclosed m 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 incorporated herein by reference. The alummosihcate ion exchange mateπals used herein as a detergent builder preferably have both a high calcium ion exchange capacity and a high exchange rate. Without intending to be limited by theory, it is believed that such high calcium ion exchange rate and capacity are a function of several interrelated factors which deπve from the method by which the alummosihcate ion exchange mateπal is produced. In that regard, the alummosihcate ion exchange mateπals used herein are preferably produced in accordance with Corkill et al, U.S. Patent No. 4,605,509 (Procter & Gamble), the disclosure of which is incorporated herein by reference. Preferably, the alummosihcate ion exchange mateπal is in "sodium" form since the potassium and hydrogen forms of the instant alummosihcate do not exhibit the as high of an exchange rate and capacity as provided by the sodium form. Additionally, the alummosihcate ion exchange matenal preferably is in over dπed form so as to facilitate production of cπsp detergent agglomerates as descπbed herein. The alummosihcate ion exchange mateπals 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 alummosihcate ion exchange mateπal as determined by conventional analytical techniques, such as microscopic determination and scanning electron microscope (SEM). The preferred particle size diameter of the alummosihcate 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 alummosihcate ion exchange mateπal 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 alummosihcate has the formula Na 12 [(A10 2 ) 1 2.(Siθ2)i2]xH2θ 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-occurπng or synthetically deπved alummosihcate ion exchange mateπals suitable for use herein can be made as descπbed in Krummel et al, U.S. Patent No. 3,985,669, the disclosure of which is incorporated herein by reference. The aluminosilicates used herein are further characterized by their ion exchange capacity which is at least about 200 mg equivalent of CaC03 hardness/gram, calculated on an anhydrous basis, and which is preferably in a range from about 300 to 352 mg equivalent of CaC03 hardness/gram. Additionally, the instant alummosihcate ion exchange materials are still further characteπzed by their calcium ion exchange rate which is at least about 2 grams Ca ++ /gallon/minute/-gram gallon, and more preferably in a range from about 2 grains Ca ++ /gallon/minute/-gram/gallon to about 6 grams Ca ++ /gallon/minute/-gram/gallon . Adjunct Detergent Ingredients The starting dry detergent mateπal in the present process can include additional detergent ingredients and/or, any number of additional ingredients can be incorporated in the detergent composition during subsequent steps of the present process. These adjunct ingredients include other detergency builders, bleaches, bleach activators, suds boosters or suds suppressors, anti-tarnish and anticorrosion agents, soil suspending 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 , incorporated herein by reference Other builders can be generally selected from the various borates, polyhydroxy sulfonates, polyacetates, carboxylates, citrates, tartrate mono- and di-succmates, and mixtures thereof Preferred are the alkali metal, especially sodium, salts of the above In compaπson with amorphous 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 amorphous 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 determined judiciously The crystalline layered sodium silicates suitable for use herein preferably have the formula NaMSι x 0 2x+ 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 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 incorporated herein by reference. Examples of nonphosphorus, inorganic builders are tetraborate decahydrate and silicates having a weight ratio of SιO~ 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 vaπous 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 diamine tetraacetic acid, nitπlotπacetic acid, oxydisuccinic acid, melhtic acid, benzene polycarboxyhc acids, and citπc acid. Polymeπc polycarboxylate builders are set forth m U.S. Patent 3,308,067, Diehl, issued March 7, 1967, the disclosure of which is incorporated herein by reference. Such mateπals include the water-soluble salts of homo- and copolymers of aliphatic carboxyhc acids such as maleic acid, ltacomc acid, mesaconic acid, fumaπc acid, aconitic acid, citracomc acid and methylene malomc acid. Some of these matenals are useful as the water-soluble anionic polymer as hereinafter descπbed, but only if m intimate admixture with the non-soap anionic surfactant. Other suitable polycarboxylates for use herein 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 incorporated herein by reference. These polyacetal carboxylates can be prepared by bringing together under polymerization conditions an ester of glyoxyhc acid and a polymerization initiator. The resulting polyacetal carboxylate ester is then attached to chemically stable end groups to stabilize the polyacetal carboxylate against rapid depolymerization in alkaline solution, converted to the corresponding salt, and added to a detergent composition. Particularly preferred polycarboxylate builders are the ether carboxylate builder compositions compnsing a combination of tartrate monosuccinate and tartrate disuccmate descπbed in U.S. Patent 4,663,071, Bush et al., issued May 5, 1987, the disclosure of which is incorporated herein by reference. Bleaching agents and activators are described in U.S. Patent 4,412,934, Chung et al., issued November 1, 1983, and in U.S. Patent 4,483,781, Hartman, issued November 20, 1984, both of which are incorporated 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, line 68, incorporated 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 incorporated herein 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, line 3 through Column 7, line 24, incorporated herein by reference. Suitable additional detergency builders for use herein are enumerated in the Baskerville patent, Column 13, line 54 through Column 16, lme 16, and in U.S. Patent 4,663,071, Bush et al, issued May 5, 1987, both incorporated herein by reference. In order to make the present invention more readily understood, reference is made to the following example, which is intended to be illustrative only and not intended to be limiting in scope. EXAMPLE This Example illustrates the process invention in which a low density agglomerated detergent composition is prepared. A Lodige CB 30 high speed mixer is charged with a mixture of powders, namely sodium carbonate (median particle size 15 microns) and sodium tripolyphosphate ("STPP") with a median particle size of 25 microns. A liquid acid precursor of sodium alkylbenzene sulfonate surfactant (Cj 2H25-C6H4-SO3- H or "HLAS" as noted below) and a Ci ø_ιg alkyl ethoxylated sulfate aqueous surfactant paste (EO = 3, 70% active "AES") are also inputted into the Lodige CB 30 mixer, wherein the HLAS is added first. The mixer is operated at 1600 rpm and the sodium carbonate, STPP, HLAS and AES are formed into agglomerates having a median particle size of about 1 10 microns after a mean residence time in the Lodige CB 30 mixer of about 5 seconds. The agglomerates are then fed to a Schugi (Model # FX160) high speed mixer which is operated at 2800 rpms with a mean residence time of about 2 seconds. A HLAS binder is inputted into the Schugi (Model # FX160) mixer during this step which results in built-up agglomerates having a median particle size of about 180 microns being formed. Thereafter, the built-up agglomerates are passed through a four-zone fluid bed dryer wherein two spray nozzles are positioned in the first and fourth zone of the fluid bed dryer. The fluid bed is operated at an air mlet temperature of about 125°C. In the amounts and particle size specified below, fines are also added to the Lodige CB 30 mixer. In the first and fourth zones of the fluid bed dryer, liquid sodium silicate is fed into the fluid bed dryer resulting in the finished detergent agglomerates having a density of about 485 g/1 and a median particle size of about 360 microns. Unexpectedly, the finished agglomerates have excellent physical properties in that they are free flowing as exhibited by their supeπor cake strength grades. The composition of the agglomerates are given below in Table I. TABLE I (% weight) Component I LAS (Na) 15.8 AES (EO = 3) 4.7 Sodium carbonate 48.0 STPP 22.7 Sodium Silicate 5.5 Water 100.0 The agglomerates embody about 14% of the fines (less than 150 microns) mentioned previously which are recycled from the fluid bed back into the Lodige CB 30 to enhance production of the agglomerates produced by the process. Having thus described the invention in detail, it will be clear to those skilled m the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is descπbed in the specification.

Claims: WHAT IS CLAIMED IS: 1. A process for preparing a low density detergent composition characterized by the steps of: (a) agglomerating a detergent surfactant paste or precursor thereof and dry starting detergent material having a median particle size in a range from 5 microns to 70 microns in a first high speed mixer to obtain agglomerates having a median particle size of from 100 microns to 250 microns; (b) mixing said detergent agglomerates wim a first binder in a high speed mixer to obtain built-up agglomerates having a median particle size in a range of from 140 microns to 350 microns; and (c) feeding said built-up agglomerates and a binder into a fluid bed dryer in which built-up agglomerates are agglomerated with a second binder and dried to form detergent agglomerates having a median particle size in a range of from 300 microns to 700 microns and a density in a range from 300 g/1 to 550 g 1. 2. The process of claim 1 wherein said first binder is sodium silicate. 3. The process of claim 1 wherein said first binder and said second binder are a liquid acid precursor of an anionic surfactant. 4. The process of claim 1 wherein in said step (c) said second binder is added at each end or said fluid bed dryer. 5. The process of claim 1 wherein the intragranule porosity of said detergent agglomerates is from 20% to 40%. 6. The process of claim 1 wherein said first binder and said second binder are sodium silicate. 7. The process of claim 1 wherein said step (a) includes agglomerating a liquid acid precursor of Cπ-iβ linear alkylbenzene sulfonate surfactant and a Cio-iβ alkyl ethoxylated sulfate surfactant. 8. The process of claim 1 wherein said step (c) includes maintaining the temperature of said fluid bed dryer to be in a range of from 100°C to 200°C. 9. The process of claim 1 wherein said dry starting material comprises a builder selected from the group consisting of aluminosilicates, crystalline layered silicates, phosphates, carbonates and mixtures thereof. 10. A detergent composition made in accordance with the process of claim 1.

Inventors: BEER ALLEN DALE, JONES RICCI JOHN, MORT PAUL III, SULLIVAN MILLARD, BEER, ALLEN, DALE, JONES, RICCI, JOHN, MORT, PAUL, III, SULLIVAN, MILLARD
Applicants: BEER ALLEN DALE, JONES RICCI JOHN, MORT PAUL III, PROCTER & GAMBLE, SULLIVAN MILLARD, BEER, ALLEN, DALE, JONES, RICCI, JOHN, MORT, PAUL, III, SULLIVAN, MILLARD, THE PROCTER & GAMBLE COMPANY
Application year: 1998
Main classification: C11D11
IPC codes: C11D11, C11D17