Patent ID: 8628706

Claim:
A process for forming a non-lathering personal care article in the form of a porous dissolvable solid structure, wherein said process comprises the steps of: (a) preparing a pre-mix comprising a substantially non-lathering surfactant, wherein the non-lathering surfactant is selected from the group consisting of non-ionic surfactant, polymeric surfactant, and mixtures thereof, dissolved polymer structurant, an active selected from the group consisting of a conditioning agent, styling agent, anti-dandruff agent and combinations thereof and a plasticizer, wherein said pre-mix has: (i) from about 15% to 40% total solids; and (ii) a viscosity of from about 2,500 cps to 30,000 cps; (b) aerating said pre-mix by introducing a gas into the pre-mix to form a wet aerated pre-mix; (c) forming the wet aerated pre-mix into a desired one or more shapes to form shaped wet pre-mix; and (d) drying the shaped wet pre-mix to a desired final moisture content, wherein the final moisture content is from about 0.1% to about 15% moisture, to form the non-lathering personal care article, wherein said non-lathering personal care article has a density of from about 0.06 g/cm 3 to about 0.15 g/cm 3 .