Patent Description:
Detergent manufacturers use spray-drying as a means to make detergent particles. Care needs to be taken during the spray-drying process to ensure that the bulk density and particle size of the spray-dried particle is controlled. Low bulk densities and narrow particle size distributions are preferred: such spray-dried particles have good dissolution, good residue profiles, are more aesthetically pleasing and are easier to dose. Detergent manufacturers continue to seek improvements to bulk density and particle size control during the spray-drying process.

The inventors have found that introducing low levels of polyepoxy succinic acid polymer into the anionic detersive surfactant slurry during the spray-drying process results in faster surface drying of the spray-dried particle.

The rate of surface drying is measured as the time taken to reach a rate of moisture loss of zero, which occurs when the surface of the spray-dried particle is sufficiently dried to prevent internal moisture from escaping into the surrounding environment. Having the surface of the spray-dried particles dry at such faster rates results in spray-dried particles having low bulk densities and narrow particle size distributions.

Without wishing to be bound by theory, it is believed that the internal moisture entrapped within the surface dried particle leads to lower bulk densities. Furthermore, having the particle surface dry faster reduces the chance of slurry droplet coalescence, which in turn reduces the amount of oversized spray-dried particles and narrows the particle size distribution.

The method of the present invention ensures fast surface drying of the spray-dried particle and provides spray-dried particles having good dissolution, good residue profiles, are more aesthetically pleasing and are easier to dose.

<CIT> discloses a process of spray-drying a slurry comprising LAS, water and polyepoxy succinic acid polymer.

The present invention provides a method of making a spray-dried laundry detergent particle, wherein the method comprises the steps: (a) forming an aqueous laundry detergent slurry, wherein the slurry comprises: (i) from 1wt% to 40wt% anionic detersive surfactant; (ii) from <NUM> wt% to <NUM>. 5wt% polyepoxy succinic acid polymer; and (iii) from 10wt% to 80wt% water, and (b) spray drying the slurry formed in step (a) to form a spray-dried laundry detergent particle.

The method comprises the steps: (a) forming an aqueous laundry detergent slurry, wherein the slurry comprises: (i) from 1wt% to 40wt% anionic detersive surfactant; (ii) from <NUM>. 1wt% to <NUM>. 5wt% polyepoxy succinic acid polymer; and (iii) from 10wt% to 80wt% water, and (b) spray drying the slurry formed in step (a) to form a spray-dried laundry detergent particle.

Step (a) forms an aqueous laundry detergent slurry.

Step (b) spray dries the slurry formed in step (a) to form a spray-dried laundry detergent particle.

Preferably, during step (b) the slurry is spray-dried in a spray-drying tower having an air inlet temperature of at least <NUM>, preferably at least <NUM>, or at least <NUM>, or even at least <NUM>.

The slurry comprises: (i) from 1wt% to 40wt% anionic detersive surfactant; (ii) from <NUM>. 1wt% to <NUM>. 5wt% polyepoxy succinic acid polymer; and (iii) from 10wt% to 80wt% water.

Preferably, the slurry comprises from <NUM>. 1wt% to <NUM>. 5wt%, or from <NUM>. 2wt% to <NUM>. 0wt%, or from <NUM>. 3wt% to <NUM>. 5wt%, or from <NUM>. 5wt% to <NUM>. 0wt% polyepoxy succinic acid polymer.

Preferably, the slurry comprises silicate salt. Preferably, the silicate salt is sodium silicate salt. Preferably, the slurry comprises from <NUM>. 0wt% to 20wt%, or from <NUM>. 0wt% to 15wt% silicate salt.

Preferably, the slurry comprises from 10wt% to 30wt% anionic detersive surfactant.

Preferably, the anionic detersive surfactant comprises linear alkylbenezene sulphonate.

Preferably, the slurry comprises from <NUM>. 0wt% to 40wt%, or from 10wt% to 30wt% linear alkylbenzene sulphonate.

The spray-dried particle comprises anionic detersive surfactant and polyepoxy succinic acid polymer.

Preferably, the spray-dried particle formed in step (b) has a bulk density of less than <NUM>/l, or less than <NUM>/l, or less than <NUM>/l, or less than <NUM>/l.

Preferably, the spray-dried particle formed in step (b) has a particle size distribution such that at least 90wt%, or at least 95wt%, or at least 99wt% of the particles have a particle size of not greater than <NUM> (<NUM> or less).

The spray-dried particle can be incorporated into a laundry detergent composition. Suitable laundry detergent compositions are described in more detail below.

The spray-dried particle may comprise other detergent ingredients. Suitable detergent ingredients are described in more detail below.

The polyepoxy succinic acid polymer (PESA) polymer preferably has a structure described below:
<CHM>
wherein:.

Most preferably, the polyepoxy succinic acid polymer can be represented by structure below:
<CHM>
wherein M is H or Na, and n is from <NUM>-<NUM>.

The polyepoxy succinic acid polymer maybe used as singulary or in mixture. The "n" represents an average number. In one embodiment, when polyepoxy succinic acid polymer polymer is a mixture, the polymer sample may be dominated by samples with n from <NUM>-<NUM>, more preferable from <NUM>-<NUM>.

Polymers derived from the following <NUM>-oxacyclopropane-<NUM>,<NUM>-dicarboxylic acids are suitable polyepoxy succinic acid polymers:.

Of these above acids, the most preferred are the polymers derived from <NUM>-oxacyclopropane-cis-<NUM>,<NUM>-dicarbxylic acid, with n from <NUM> to about <NUM> being most preferred.

A most preferred polyepoxy succinic acid polymer can be identified using CAS number: <NUM>-<NUM>-<NUM>, or <NUM>-<NUM>-<NUM>.

Alternative names of the preferred polymers include:.

Suitable polyepoxy succinic acid polymers are commercially available from various suppliers, such as Aquapharm Chemicals Pvt. Ltd (commercial name: Maxinol <NUM>); Shandong Taihe Water Treatment Technologies Co. , Ltd (commercial name: PESA), and Sirius International (commercial name: Briteframe PESA).

Laundry detergent composition: Suitable laundry detergents are solid, typically granular laundry detergent compositions formed from particles, more typically a solid free-flowing particulate laundry detergent composition. Typically, the solid free-flowing particulate laundry detergent composition is a fully formulated laundry detergent composition, not a portion thereof such as a spray-dried, extruded or agglomerate particle that only forms part of the laundry detergent composition. Typically, the solid composition comprises a plurality of chemically different particles, such as spray-dried base detergent particles and/or agglomerated base detergent particles and/or extruded base detergent particles, in combination with one or more, typically two or more, or five or more, or even ten or more particles selected from: surfactant particles, including surfactant agglomerates, surfactant extrudates, surfactant needles, surfactant noodles, surfactant flakes; phosphate particles; zeolite particles; silicate salt particles, especially sodium silicate particles; carbonate salt particles, especially sodium carbonate particles; polymer particles such as carboxylate polymer particles, cellulosic polymer particles, starch particles, polyester particles, polyamine particles, terephthalate polymer particles, polyethylene glycol particles; aesthetic particles such as coloured noodles, needles, lamellae particles and ring particles; enzyme particles such as protease granulates, amylase granulates, lipase granulates, cellulase granulates, mannanase granulates, pectate lyase granulates, xyloglucanase granulates, bleaching enzyme granulates and co- granulates of any of these enzymes, preferably these enzyme granulates comprise sodium sulphate; bleach particles, such as percarbonate particles, especially coated percarbonate particles, such as percarbonate coated with carbonate salt, sulphate salt, silicate salt, borosilicate salt, or any combination thereof, perborate particles, bleach activator particles such as tetra acetyl ethylene diamine particles and/or alkyl oxybenzene sulphonate particles, bleach catalyst particles such as transition metal catalyst particles, and/or isoquinolinium bleach catalyst particles, pre-formed peracid particles, especially coated pre-formed peracid particles; filler particles such as sulphate salt particles and chloride particles; clay particles such as montmorillonite particles and particles of clay and silicone; flocculant particles such as polyethylene oxide particles; wax particles such as wax agglomerates; silicone particles, brightener particles; dye transfer inhibition particles; dye fixative particles; perfume particles such as perfume microcapsules and starch encapsulated perfume accord particles, or pro-perfume particles such as Schiff base reaction product particles; hueing dye particles; chelant particles such as chelant agglomerates; and any combination thereof.

The laundry detergent composition can be incorporated in a unit dose article, such as a pouch, and may even be incorporated into a sheet or fibres.

Suitable laundry detergent compositions comprise a detergent ingredient selected from: detersive surfactant, such as anionic detersive surfactants, non-ionic detersive surfactants, cationic detersive surfactants, zwitterionic detersive surfactants and amphoteric detersive surfactants; polymers, such as carboxylate polymers, soil release polymer, anti-redeposition polymers, cellulosic polymers and care polymers; bleach, such as sources of hydrogen peroxide, bleach activators, bleach catalysts and pre-formed peracids; photobleach, such as such as zinc and/or aluminium sulphonated phthalocyanine; enzymes, such as proteases, amylases, cellulases, lipases; zeolite builder; phosphate builder; co-builders, such as citric acid and citrate; carbonate, such as sodium carbonate and sodium bicarbonate; sulphate salt, such as sodium sulphate; silicate salt such as sodium silicate; chloride salt, such as sodium chloride; brighteners; chelants; hueing agents; dye transfer inhibitors; dye fixative agents; perfume; silicone; fabric softening agents, such as clay; flocculants, such as polyethyleneoxide; suds supressors; and any combination thereof.

Suitable laundry detergent compositions may have a low buffering capacity. Such laundry detergent compositions typically have a reserve alkalinity to pH <NUM> of less than <NUM>. 0gNaOH/<NUM>. These low buffered laundry detergent compositions typically comprise low levels of carbonate salt.

Detersive Surfactant: Suitable detersive surfactants include anionic detersive surfactants, non-ionic detersive surfactant, cationic detersive surfactants, zwitterionic detersive surfactants and amphoteric detersive surfactants. Suitable detersive surfactants may be linear or branched, substituted or un-substituted, and may be derived from petrochemical material or biomaterial.

Anionic detersive surfactant: Suitable anionic detersive surfactants include sulphonate and sulphate detersive surfactants.

Suitable sulphonate detersive surfactants include methyl ester sulphonates, alpha olefin sulphonates, alkyl benzene sulphonates, especially alkyl benzene sulphonates, preferably C<NUM>-<NUM> alkyl benzene sulphonate. Suitable alkyl benzene sulphonate (LAS) is obtainable, preferably obtained, by sulphonating commercially available linear alkyl benzene (LAB); suitable LAB includes low <NUM>-phenyl LAB, other suitable LAB include high <NUM>-phenyl LAB, such as those supplied by Sasol under the tradename Hyblene®.

Suitable sulphate detersive surfactants include alkyl sulphate, preferably C<NUM>-<NUM> alkyl sulphate, or predominantly C<NUM> alkyl sulphate.

A preferred sulphate detersive surfactant is alkyl alkoxylated sulphate, preferably alkyl ethoxylated sulphate, preferably a C<NUM>-<NUM> alkyl alkoxylated sulphate, preferably a C<NUM>-<NUM> alkyl ethoxylated sulphate, preferably the alkyl alkoxylated sulphate has an average degree of alkoxylation of from <NUM> to <NUM>, preferably from <NUM> to <NUM>, preferably the alkyl alkoxylated sulphate is a C<NUM>-<NUM> alkyl ethoxylated sulphate having an average degree of ethoxylation of from <NUM> to <NUM>, preferably from <NUM> to <NUM>, more preferably from <NUM> to <NUM> and most preferably from <NUM> to <NUM>.

The alkyl sulphate, alkyl alkoxylated sulphate and alkyl benzene sulphonates may be linear or branched, substituted or un-substituted, and may be derived from petrochemical material or biomaterial.

Other suitable anionic detersive surfactants include alkyl ether carboxylates.

Suitable anionic detersive surfactants may be in salt form, suitable counter-ions include sodium, calcium, magnesium, amino alcohols, and any combination thereof. A preferred counterion is sodium.

Non-ionic detersive surfactant: Suitable non-ionic detersive surfactants are selected from the group consisting of: Cs-Cis alkyl ethoxylates, such as, NEODOL® non-ionic surfactants from Shell; C<NUM>-C<NUM> alkyl phenol alkoxylates wherein preferably the alkoxylate units are ethyleneoxy units, propyleneoxy units or a mixture thereof; C<NUM>-C<NUM> alcohol and C<NUM>-C<NUM> alkyl phenol condensates with ethylene oxide/propylene oxide block polymers such as Pluronic® from BASF; alkylpolysaccharides, preferably alkylpolyglycosides; methyl ester ethoxylates; polyhydroxy fatty acid amides; ether capped poly(oxyalkylated) alcohol surfactants; and mixtures thereof.

Suitable non-ionic detersive surfactants are alkylpolyglucoside and/or an alkyl alkoxylated alcohol.

Suitable non-ionic detersive surfactants include alkyl alkoxylated alcohols, preferably C<NUM>-<NUM> alkyl alkoxylated alcohol, preferably a C<NUM>-<NUM> alkyl ethoxylated alcohol, preferably the alkyl alkoxylated alcohol has an average degree of alkoxylation of from <NUM> to <NUM>, preferably from <NUM> to <NUM>, or from <NUM> to <NUM>, or from <NUM> to <NUM>, preferably the alkyl alkoxylated alcohol is a C<NUM>-<NUM> alkyl ethoxylated alcohol having an average degree of ethoxylation of from <NUM> to <NUM>, preferably from <NUM> to <NUM>, more preferably from <NUM> to <NUM> and most preferably from <NUM> to <NUM>. The alkyl alkoxylated alcohol can be linear or branched, and substituted or un-substituted.

Suitable nonionic detersive surfactants include secondary alcohol-based detersive surfactants.

Cationic detersive surfactant: Suitable cationic detersive surfactants include alkyl pyridinium compounds, alkyl quaternary ammonium compounds, alkyl quaternary phosphonium compounds, alkyl ternary sulphonium compounds, and mixtures thereof.

Preferred cationic detersive surfactants are quaternary ammonium compounds having the general formula:.

wherein, R is a linear or branched, substituted or unsubstituted C<NUM>-<NUM> alkyl or alkenyl moiety, R<NUM> and R<NUM> are independently selected from methyl or ethyl moieties, R<NUM> is a hydroxyl, hydroxymethyl or a hydroxyethyl moiety, X is an anion which provides charge neutrality, preferred anions include: halides, preferably chloride; sulphate; and sulphonate.

Zwitterionic detersive surfactant: Suitable zwitterionic detersive surfactants include amine oxides and/or betaines.

Polymer: Suitable polymers include carboxylate polymers, soil release polymers, anti-redeposition polymers, cellulosic polymers, care polymers and any combination thereof.

Carboxylate polymer: The composition may comprise a carboxylate polymer, such as a maleate/acrylate random copolymer or polyacrylate homopolymer. Suitable carboxylate polymers include: polyacrylate homopolymers having a molecular weight of from <NUM>,<NUM> Da to <NUM>,<NUM> Da; maleate/acrylate random copolymers having a molecular weight of from <NUM>,<NUM> Da to <NUM>,<NUM> Da, or from <NUM>,<NUM> Da to <NUM>,<NUM> Da.

Another suitable carboxylate polymer is a co-polymer that comprises: (i) from <NUM> to less than <NUM> wt% structural units derived from one or more monomers comprising carboxyl groups; (ii) from <NUM> to less than <NUM> wt% structural units derived from one or more monomers comprising sulfonate moieties; and (iii) from <NUM> to <NUM> wt% structural units derived from one or more types of monomers selected from ether bond-containing monomers represented by formulas (I) and (II):
<CHM>
wherein in formula (I), R<NUM> represents a hydrogen atom or CH<NUM> group, R represents a CH<NUM> group, CH<NUM>CH<NUM> group or single bond, X represents a number <NUM>-<NUM> provided X represents a number <NUM>-<NUM> when R is a single bond, and R<NUM> is a hydrogen atom or C<NUM> to C<NUM> organic group;
<CHM>
wherein in formula (II), R<NUM> represents a hydrogen atom or CH<NUM> group, R represents a CH<NUM> group, CH<NUM>CH<NUM> group or single bond, X represents a number <NUM>-<NUM>, and R<NUM> is a hydrogen atom or C<NUM> to C<NUM> organic group.

It may be preferred that the polymer has a weight average molecular weight of at least 50kDa, or even at least 70kDa.

Soil release polymer: The composition may comprise a soil release polymer. A suitable soil release polymer has a structure as defined by one of the following structures (I), (II) or (III):.

(I)     -[(OCHR<NUM>-CHR<NUM>)a-O-OC-Ar-CO-]d.

(II)     -[(OCHR<NUM>-CHR<NUM>)b-O-OC-sAr-CO-]e.

(III)     -[(OCHR<NUM>-CHR<NUM>)c-OR<NUM>]f.

Suitable soil release polymers are sold by Clariant under the TexCare® series of polymers, e.g. TexCare® SRN240 and TexCare® SRA300. Other suitable soil release polymers are sold by Solvay under the Repel-o-Tex® series of polymers, e.g. Repel-o-Tex® SF2 and Repel-o-Tex® Crystal.

Anti-redeposition polymer: Suitable anti-redeposition polymers include polyethylene glycol polymers and/or polyethyleneimine polymers.

Suitable polyethylene glycol polymers include random graft co-polymers comprising: (i) hydrophilic backbone comprising polyethylene glycol; and (ii) hydrophobic side chain(s) selected from the group consisting of: C<NUM>-C<NUM> alkyl group, polypropylene, polybutylene, vinyl ester of a saturated C<NUM>-C<NUM> mono-carboxylic acid, C<NUM>-C<NUM> alkyl ester of acrylic or methacrylic acid, and mixtures thereof. Suitable polyethylene glycol polymers have a polyethylene glycol backbone with random grafted polyvinyl acetate side chains. The average molecular weight of the polyethylene glycol backbone can be in the range of from <NUM>,<NUM> Da to <NUM>,<NUM> Da, or from <NUM>,<NUM> Da to <NUM>,<NUM> Da. The molecular weight ratio of the polyethylene glycol backbone to the polyvinyl acetate side chains can be in the range of from <NUM>: <NUM> to <NUM>:<NUM>, or from <NUM>: <NUM> to <NUM>:<NUM>. The average number of graft sites per ethylene oxide unit can be less than <NUM>, or less than <NUM>, the average number of graft sites per ethylene oxide unit can be in the range of from <NUM> to <NUM>, or the average number of graft sites per ethylene oxide unit can be less than <NUM>, or in the range of from <NUM> to <NUM>.

Suitable polyethylene glycol polymers are described in <CIT>.

A suitable polyethylene glycol polymer is Sokalan HP22.

Cellulosic polymer: Suitable cellulosic polymers are selected from alkyl cellulose, alkyl alkoxyalkyl cellulose, carboxyalkyl cellulose, alkyl carboxyalkyl cellulose, sulphoalkyl cellulose, more preferably selected from carboxymethyl cellulose, methyl cellulose, methyl hydroxyethyl cellulose, methyl carboxymethyl cellulose, and mixures thereof.

Suitable carboxymethyl celluloses have a degree of carboxymethyl substitution from <NUM> to <NUM> and a molecular weight from <NUM>,<NUM> Da to <NUM>,<NUM> Da. Suitable carboxymethyl celluloses have a degree of substitution greater than <NUM> and a degree of blockiness greater than <NUM>, e.g. as described in <CIT>.

Care polymers: Suitable care polymers include cellulosic polymers that are cationically modified or hydrophobically modified. Such modified cellulosic polymers can provide anti-abrasion benefits and dye lock benefits to fabric during the laundering cycle. Suitable cellulosic polymers include cationically modified hydroxyethyl cellulose.

Other suitable care polymers include dye lock polymers, for example the condensation oligomer produced by the condensation of imidazole and epichlorhydrin, preferably in ratio of <NUM>:<NUM>:<NUM>. A suitable commercially available dye lock polymer is Polyquart® FDI (Cognis).

Other suitable care polymers include amino-silicone, which can provide fabric feel benefits and fabric shape retention benefits.

Bleach: Suitable bleach includes sources of hydrogen peroxide, bleach activators, bleach catalysts, pre-formed peracids and any combination thereof. A particularly suitable bleach includes a combination of a source of hydrogen peroxide with a bleach activator and/or a bleach catalyst.

Source of hydrogen peroxide: Suitable sources of hydrogen peroxide include sodium perborate and/or sodium percarbonate.

Bleach activator: Suitable bleach activators include tetra acetyl ethylene diamine and/or alkyl oxybenzene sulphonate.

Bleach catalyst: The composition may comprise a bleach catalyst. Suitable bleach catalysts include oxaziridinium bleach catalysts, transistion metal bleach catalysts, especially manganese and iron bleach catalysts. A suitable bleach catalyst has a structure corresponding to general formula below:
<CHM>
wherein R<NUM> is selected from the group consisting of <NUM>-ethylhexyl, <NUM>-propylheptyl, <NUM>-butyloctyl, <NUM>-pentylnonyl, <NUM>-hexyldecyl, n-dodecyl, n-tetradecyl, n-hexadecyl, n-octadecyl, iso-nonyl, iso-decyl, iso-tridecyl and iso-pentadecyl.

Pre-formed peracid: Suitable pre-form peracids include phthalimido-peroxycaproic acid.

Enzymes: Suitable enzymes include lipases, proteases, cellulases, amylases and any combination thereof.

Protease: Suitable proteases include metalloproteases and/or serine proteases. Examples of suitable neutral or alkaline proteases include: subtilisins (EC <NUM>. <NUM>); trypsin-type or chymotrypsin-type proteases; and metalloproteases. The suitable proteases include chemically or genetically modified mutants of the aforementioned suitable proteases.

Suitable commercially available protease enzymes include those sold under the trade names Alcalase®, Savinase®, Primase®, Durazym®, Polarzyme®, Kannase®, Liquanase®, Liquanase Ultra®, Savinase Ultra®, Ovozyme®, Neutrase®, Everlase® and Esperase® by Novozymes A/S (Denmark), those sold under the tradename Maxatase®, Maxacal®, Maxapem®, Preferenz P® series of proteases including Preferenz® P280, Preferenz® P281, Preferenz® P2018-C, Preferenz® P2081-WE, Preferenz® P2082-EE and Preferenz® P2083-A/J, Properase®, Purafect®, Purafect Prime®, Purafect Ox®, FN3® , FN4®, Excellase® and Purafect OXP® by DuPont, those sold under the tradename Opticlean® and Optimase® by Solvay Enzymes, those available from Henkel/ Kemira, namely BLAP (sequence shown in Figure <NUM> of <CIT> with the folowing mutations S99D + S101 R + S103A + V104I + G159S, hereinafter referred to as BLAP), BLAP R (BLAP with S3T + V4I + V199M + V205I + L217D), BLAP X (BLAP with S3T + V4I + V205I) and BLAP F49 (BLAP with S3T + V4I + A194P + V199M + V205I + L217D) - all from Henkel/Kemira; and KAP (Bacillus alkalophilus subtilisin with mutations A230V + S256G + S259N) from Kao.

A suitable protease is described in <CIT> and <CIT>.

Amylase: Suitable amylases are derived from AA560 alpha amylase endogenous to Bacillus sp. DSM <NUM>, preferably having the following mutations: R118K, D183*, G184*, N195F, R320K, and/or R458K. Suitable commercially available amylases include Stainzyme®, Stainzyme® Plus, Natalase, Termamyl®, Termamyl® Ultra, Liquezyme® SZ, Duramyl®, Everest® (all Novozymes) and Spezyme® AA, Preferenz S® series of amylases, Purastar® and Purastar® Ox Am, Optisize® HT Plus (all Du Pont). A suitable amylase is described in <CIT>.

Cellulase: Suitable cellulases include those of bacterial or fungal origin. Chemically modified or protein engineered mutants are also suitable. Suitable cellulases include cellulases from the genera Bacillus, Pseudomonas, Humicola, Fusarium, Thielavia, Acremonium, e.g., the fungal cellulases produced from Humicola insolens, Myceliophthora thermophila and Fusarium oxysporum.

Commercially available cellulases include Celluzyme®, Carezyme®, and Carezyme® Premium, Celluclean® and Whitezyme® (Novozymes A/S), Revitalenz® series of enzymes (Du Pont), and Biotouch® series of enzymes (AB Enzymes). Suitable commercially available cellulases include Carezyme® Premium, Celluclean® Classic. Suitable cellulases are described in <CIT> and <CIT>.

Lipase: Suitable lipases include those of bacterial, fungal or synthetic origin, and variants thereof. Chemically modified or protein engineered mutants are also suitable. Examples of suitable lipases include lipases from Humicola (synonym Thermomyces), e.g., from H. lanuginosa (T. lanuginosus).

The lipase may be a "first cycle lipase", e.g. such as those described in <CIT> and <CIT>. In one aspect, the lipase is a first-wash lipase, preferably a variant of the wild-type lipase from Thermomyces lanuginosus comprising T231R and/or N233R mutations. Preferred lipases include those sold under the tradenames Lipex®, Lipolex® and Lipoclean® by Novozymes, Bagsvaerd, Denmark.

Other suitable lipases include: Liprl <NUM>, e.g. as described in <CIT>; and TfuLip2, e.g. as described in <CIT> and <CIT>.

Other enzymes: Other suitable enzymes are bleaching enzymes, such as peroxidases/oxidases, which include those of plant, bacterial or fungal origin and variants thereof. Commercially available peroxidases include Guardzyme® (Novozymes A/S). Other suitable enzymes include choline oxidases and perhydrolases such as those used in Gentle Power Bleach™.

Other suitable enzymes include pectate lyases sold under the tradenames X-Pect®, Pectaway® (from Novozymes A/S, Bagsvaerd, Denmark) and PrimaGreen® (DuPont) and mannanases sold under the tradenames Mannaway® (Novozymes A/S, Bagsvaerd, Denmark), and Mannastar® (Du Pont).

Zeolite builder: The composition may comprise zeolite builder. The composition may comprise from 0wt% to 5wt% zeolite builder, or 3wt% zeolite builder. The composition may even be substantially free of zeolite builder; substantially free means "no deliberately added". Typical zeolite builders include zeolite A, zeolite P and zeolite MAP.

Phosphate builder: The composition may comprise phosphate builder. The composition may comprise from 0wt% to 5wt% phosphate builder, or to 3wt%, phosphate builder. The composition may even be substantially free of phosphate builder; substantially free means "no deliberately added". A typical phosphate builder is sodium tri-polyphosphate.

Carbonate salt: The composition may comprise carbonate salt. The composition may comprise from 0wt% to 10wt% carbonate salt, or to 5wt% carbonate salt. The composition may even be substantially free of carbonate salt; substantially free means "no deliberately added". Suitable carbonate salts include sodium carbonate and sodium bicarbonate.

Silicate salt: The composition may comprise silicate salt. The composition may comprise from 0wt% to 10wt% silicate salt, or to 5wt% silicate salt. A preferred silicate salt is sodium silicate, especially preferred are sodium silicates having a Na<NUM>O:SiO<NUM> ratio of from <NUM> to <NUM>, preferably from <NUM> to <NUM>.

Sulphate salt: A suitable sulphate salt is sodium sulphate.

Brightener: Suitable fluorescent brighteners include: di-styryl biphenyl compounds, e.g. Tinopal® CBS-X, di-amino stilbene di-sulfonic acid compounds, e.g. Tinopal® DMS pure Xtra and Blankophor® HRH, and Pyrazoline compounds, e.g. Blankophor® SN, and coumarin compounds, e.g. Tinopal® SWN. Preferred brighteners are: sodium <NUM> (<NUM>-styryl-<NUM>-sulfophenyl)-<NUM>-napthol[<NUM>,<NUM>-d]triazole, disodium <NUM>,<NUM>'-bis{[(<NUM>-anilino-<NUM>-(N methyl-N-<NUM> hydroxyethyl)amino <NUM> ,<NUM>,<NUM>- triazin-<NUM>-yl)];amino}stilbene-<NUM>-<NUM>' disulfonate, disodium <NUM>,<NUM>'-bis{[(<NUM>-anilino-<NUM>-morpholino-<NUM>,<NUM>,<NUM>-triazin-<NUM>-yl)]amino} stilbene-<NUM>-<NUM>' disulfonate, and disodium <NUM>,<NUM>'- bis(<NUM>-sulfostyryl)biphenyl. A suitable fluorescent brightener is C. Fluorescent Brightener <NUM>, which may be used in its beta or alpha crystalline forms, or a mixture of these forms.

Chelant: The composition may also comprise a chelant selected from: diethylene triamine pentaacetate, diethylene triamine penta(methyl phosphonic acid), ethylene diamine-N'N'-disuccinic acid, ethylene diamine tetraacetate, ethylene diamine tetra(methylene phosphonic acid) and hydroxyethane di(methylene phosphonic acid). A preferred chelant is ethylene diamine-N'N'-disuccinic acid (EDDS) and/or hydroxyethane diphosphonic acid (HEDP). The composition preferably comprises ethylene diamine-N'N'- disuccinic acid or salt thereof. Preferably the ethylene diamine-N'N'-disuccinic acid is in S,S enantiomeric form. Preferably the composition comprises <NUM>,<NUM>-dihydroxy-m-benzenedisulfonic acid disodium salt. Preferred chelants may also function as calcium carbonate crystal growth inhibitors such as: <NUM>-hydroxyethanediphosphonic acid (HEDP) and salt thereof; N,N-dicarboxymethyl-<NUM>-aminopentane-<NUM>,<NUM>-dioic acid and salt thereof; <NUM>-phosphonobutane-<NUM>,<NUM>,<NUM>-tricarboxylic acid and salt thereof; and combination thereof.

Hueing agent: Suitable hueing agents include small molecule dyes, typically falling into the Colour Index (C. ) classifications of Acid, Direct, Basic, Reactive (including hydrolysed forms thereof) or Solvent or Disperse dyes, for example classified as Blue, Violet, Red, Green or Black, and provide the desired shade either alone or in combination. Preferred such hueing agents include Acid Violet <NUM>, Direct Violet <NUM>, <NUM> and <NUM>, Solvent Violet <NUM> and any combination thereof.

Many hueing agents are known and described in the art which may be suitable for the present invention, such as hueing agents described in <CIT>.

Suitable hueing agents include phthalocyanine and azo dye conjugates, such as described in <CIT>.

Suitable hueing agents may be alkoxylated. Such alkoxylated compounds may be produced by organic synthesis that may produce a mixture of molecules having different degrees of alkoxylation. Such mixtures may be used directly to provide the hueing agent, or may undergo a purification step to increase the proportion of the target molecule. Suitable hueing agents include alkoxylated bis-azo dyes, such as described in <CIT>, and/or alkoxylated thiophene azo dyes, such as described in <CIT> and <CIT>.

The hueing agent may be incorporated into the detergent composition as part of a reaction mixture which is the result of the organic synthesis for a dye molecule, with optional purification step(s). Such reaction mixtures generally comprise the dye molecule itself and in addition may comprise un-reacted starting materials and/or by-products of the organic synthesis route. Suitable hueing agents can be incorporated into hueing dye particles, such as described in <CIT>.

Dye transfer inhibitors: Suitable dye transfer inhibitors include polyamine N-oxide polymers, copolymers of N-vinylpyrrolidone and N-vinylimidazole, polyvinylpyrrolidone, polyvinyloxazolidone, polyvinylimidazole and mixtures thereof. Preferred are poly(vinyl pyrrolidone), poly(vinylpyridine betaine), poly(vinylpyridine N-oxide), poly(vinyl pyrrolidone-vinyl imidazole) and mixtures thereof. Suitable commercially available dye transfer inhibitors include PVP-K15 and K30 (Ashland), Sokalan® HP165, HP50, HP53, HP59, HP56K, HP56, HP66 (BASF), Chromabond® S-<NUM>, S403E and S-<NUM> (Ashland).

Perfume: Suitable perfumes comprise perfume materials selected from the group: (a) perfume materials having a ClogP of less than <NUM> and a boiling point of less than <NUM> (quadrant <NUM> perfume materials); (b) perfume materials having a ClogP of less than <NUM> and a boiling point of <NUM> or greater (quadrant <NUM> perfume materials); (c) perfume materials having a ClogP of <NUM> or greater and a boiling point of less than <NUM> (quadrant <NUM> perfume materials); (d) perfume materials having a ClogP of <NUM> or greater and a boiling point of <NUM> or greater (quadrant <NUM> perfume materials); and (e) mixtures thereof.

It may be preferred for the perfume to be in the form of a perfume delivery technology. Such delivery technologies further stabilize and enhance the deposition and release of perfume materials from the laundered fabric. Such perfume delivery technologies can also be used to further increase the longevity of perfume release from the laundered fabric. Suitable perfume delivery technologies include: perfume microcapsules, pro-perfumes, polymer assisted deliveries, molecule assisted deliveries, fiber assisted deliveries, amine assisted deliveries, cyclodextrin, starch encapsulated accord, zeolite and other inorganic carriers, and any mixture thereof. A suitable perfume microcapsule is described in <CIT>.

Silicone: Suitable silicones include polydimethylsiloxane and amino-silicones. Suitable silicones are described in <CIT>.

Process for making the solid composition: Typically, the particles of the composition can be prepared by any suitable method. For example: spray-drying, agglomeration, extrusion and any combination thereof.

Typically, a suitable spray-drying process comprises the step of forming an aqueous slurry mixture, transferring it through at least one pump, preferably two pumps, to a pressure nozzle. Atomizing the aqueous slurry mixture into a spray-drying tower and drying the aqueous slurry mixture to form spray-dried particles. Preferably, the spray-drying tower is a counter-current spray-drying tower, although a co-current spray-drying tower may also be suitable.

Typically, the spray-dried powder is subjected to cooling, for example an air lift. Typically, the spray-drying powder is subjected to particle size classification, for example a sieve, to obtain the desired particle size distribution. Preferably, the spray-dried powder has a particle size distribution such that weight average particle size is in the range of from <NUM> micrometers to <NUM> micrometers, and less than 10wt% of the spray-dried particles have a particle size greater than <NUM> micrometers.

It may be preferred to heat the aqueous slurry mixture to elevated temperatures prior to atomization into the spray-drying tower, such as described in <CIT>.

It may be preferred for anionic surfactant, such as linear alkyl benzene sulphonate, to be introduced into the spray-drying process after the step of forming the aqueous slurry mixture: for example, introducing an acid precursor to the aqueous slurry mixture after the pump, such as described in <CIT>.

It may be preferred for a gas, such as air, to be introduced into the spray-drying process after the step of forming the aqueous slurry, such as described in <CIT>.

It may be preferred for any inorganic ingredients, such as sodium sulphate and sodium carbonate, if present in the aqueous slurry mixture, to be micronized to a small particle size such as described in <CIT>.

Typically, a suitable agglomeration process comprises the step of contacting a detersive ingredient, such as a detersive surfactant, e.g. linear alkyl benzene sulphonate (LAS) and/or alkyl alkoxylated sulphate, with an inorganic material, such as sodium carbonate and/or silica, in a mixer. The agglomeration process may also be an in-situ neutralization agglomeration process wherein an acid precursor of a detersive surfactant, such as LAS, is contacted with an alkaline material, such as carbonate and/or sodium hydroxide, in a mixer, and wherein the acid precursor of a detersive surfactant is neutralized by the alkaline material to form a detersive surfactant during the agglomeration process.

Other suitable detergent ingredients that may be agglomerated include polymers, chelants, bleach activators, silicones and any combination thereof.

The agglomeration process may be a high, medium or low shear agglomeration process, wherein a high shear, medium shear or low shear mixer is used accordingly. The agglomeration process may be a multi-step agglomeration process wherein two or more mixers are used, such as a high shear mixer in combination with a medium or low shear mixer. The agglomeration process can be a continuous process or a batch process.

It may be preferred for the agglomerates to be subjected to a drying step, for example to a fluid bed drying step. It may also be preferred for the agglomerates to be subjected to a cooling step, for example a fluid bed cooling step.

Typically, the agglomerates are subjected to particle size classification, for example a fluid bed elutriation and/or a sieve, to obtain the desired particle size distribution. Preferably, the agglomerates have a particle size distribution such that weight average particle size is in the range of from <NUM> micrometers to <NUM> micrometers, and less than 10wt% of the agglomerates have a particle size less than <NUM> micrometers and less than 10wt% of the agglomerates have a particle size greater than <NUM> micrometers.

It may be preferred for fines and over-sized agglomerates to be recycled back into the agglomeration process. Typically, over-sized particles are subjected to a size reduction step, such as grinding, and recycled back into an appropriate place in the agglomeration process, such as the mixer. Typically, fines are recycled back into an appropriate place in the agglomeration process, such as the mixer.

It may be preferred for ingredients such as polymer and/or non-ionic detersive surfactant and/or perfume to be sprayed onto base detergent particles, such as spray-dried base detergent particles and/or agglomerated base detergent particles. Typically, this spray-on step is carried out in a tumbling drum mixer.

Method of laundering fabric: The method of laundering fabric comprises the step of contacting the solid composition to water to form a wash liquor, and laundering fabric in said wash liquor. Typically, the wash liquor has a temperature of above <NUM> to <NUM>, or to <NUM>, or to <NUM>, or to <NUM>, or to <NUM>. The fabric may be contacted to the water prior to, or after, or simultaneous with, contacting the solid composition with water. Typically, the wash liquor is formed by contacting the laundry detergent to water in such an amount so that the concentration of laundry detergent composition in the wash liquor is from <NUM>/l to <NUM>/l, or from <NUM>/l to <NUM>/l, or to <NUM>/l. The method of laundering fabric can be carried out in a front-loading automatic washing machine, top loading automatic washing machines, including high efficiency automatic washing machines, or suitable hand-wash vessels. Typically, the wash liquor comprises <NUM> litres or less, or <NUM> litres or less, or <NUM> litres or less, or <NUM> litres or less of water. Typically, <NUM> or less, or <NUM> or less, or <NUM> or less, or <NUM> or less of laundry detergent composition is contacted to water to form the wash liquor.

Aqueous alkaline slurry composed of sodium sulphate, water, acrylate/maleate co-polymer and miscellaneous ingredients was prepared at <NUM> in a crutcher making vessel. The aqueous slurry was essentially free from zeolite builder and essentially free from phosphate builder. The slurry was mixed for at least <NUM> minutes to ensure homogeneity of the slurry suspension and then poured into Glass Petri Dishes for Drying in an Oven.

A Slurry slab of a controlled height of <NUM> ±<NUM> and a controlled diameter of <NUM> ±<NUM> was created in a glass Petri Dish and its mass was recorded. The Petri Dish was then placed inside an Oven at <NUM>, and the mass was recorded every <NUM> minutes until <NUM> minutes of drying were completed.

The percentage of moisture loss at time t was calculated as follows: <MAT> Where t = <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> & <NUM> minutes, respectively.

Subsequently, an expression for the Rate of Moisture Loss was produced by computing the <MAT>. The time at which the Rate of Moisture Loss reaches a value of zero is reported. Low times are deemed desirable to achieve satisfactory powder quality during the spray-drying process, including high porosity and narrow particle size distribution.

Comparative and inventive detergent slurry were prepared according to composition shown in Table <NUM>. The Rate of Moisture Loss of inventive and comparative slurry was measured according to method as described herein.

Inventive detergent slurry (Detergent Slurry B) manufactured with <NUM>% of Polyepoxysuccinic Acid, Sodium Salt (with resulting <NUM>% of Polyepoxysuccinic Acid, Sodium Salt in inventive powder) reached a Rate of Moisture loss of zero <NUM>. 3X faster than the comparative slurry manufactured with equal level of Acrylate/Maleate co-polymer (Detergent Slurry A).

Inventive detergent slurry (Detergent Slurry B) manufactured with <NUM>% of Polyepoxysuccinic Acid, Sodium Salt (with resulting <NUM>% of Polyepoxysuccinic Acid, Sodium Salt in inventive powder) showed a significantly faster decline in Rate of Moisture loss than comparative slurry manufactured with <NUM>% of Polyepoxysuccinic Acid (Detergent Slurry C, with resulting <NUM>% Polyepoxysuccinic Acid, Sodium Salt in inventive powder), and comparative slurry manufactured with <NUM>% of Polyepoxysuccinic Acid (Detergent Slurry D, with resulting <NUM>% Polyepoxysuccinic Acid, Sodium Salt in inventive powder).

Claim 1:
A method of making a spray-dried laundry detergent particle, wherein the method comprises the steps:
(a) forming an aqueous laundry detergent slurry, wherein the slurry comprises:
(i) from 1wt% to 40wt% anionic detersive surfactant;
(ii) from <NUM>.1wt% to <NUM>.5wt% polyepoxy succinic acid polymer; and
(iii) from 10wt% to 80wt% water, and
(b) spray drying the slurry formed in step (a) to form a spray-dried laundry detergent particle.