Patent ID: 7119051

Claim:
A process for making bar composition comprising: (1) 25 to 85% by wt. fatty acid soap; (2) 1 to 15% C 8 to C 20 free fatty acid; (3) 0.01 to 7% protic acid salt, wherein protic acid has pKa less than that of the fatty acid component of the fatty acid soap; (4) 0.2 to 20% by wt. aluminum hydroxide; (5) 2 to 8% polyalkylene glycol; and (6) 5 to 20%% by wt. water; wherein said composition results in little or no efflorescence measured after 4 weeks of storage at about 35–45° C. and 70% relative humidity. wherein said process comprises: (i) adding fatty acid soap to a reactor; (ii) combining protic acid having a pKa lower than that of fatty acid component of said fatty acid with said fatty acid soap at about 40° C. to generate free fatty acid and alkali metal salt of said protic acid, and wherein said free fatty acid of (2) is generated from the fatty acid soap of (1); (iii) adding aluminate solution comprising water, alkali metal hydroxide and aluminate; and (iv) adding other component of soap bar solution, wherein steps (i) to (iv) may be interchangeable combined in any order of addition; and (v) cooling ingredients mixed in steps (i) to (iv) followed by formation and diminishing of bar composition.