Patent ID: 7579311

Claim:
A no-strip process for producing a bar base having about 20-70% by wt. final bar acyl isethionate and about 15-35% by wt. free fatty acid and wherein the bar has lather of at least 80 ml lather volume as measured by the Bar Lather Appraisal Method and bar has grit of no more than 10 grit particle at 35° C. as measured by Bar wash Down Procedures, wherein said process comprises: (1) producing a directly esterified fatty acid isethionate (DEFI) by reacting fatty acid with alkali metal isethionate or ammonium isethionates in a reactor according to reaction shown: RCO 2 H+HOR′SO 3 M→(isethionate) RCO 2 R′SO 3 M+H 2 O+unreacted fatty acid and isethionate (acyl isethionate) wherein M is alkali metal or ammonium ion; R is C 5 -C 24 straight chain or unsaturated alkyl group and R′ is divalent, aliphatic hydrocarbon atoms having 2 to 4 carbons, wherein conversion rate to acyl isethionate is > about 60%; wherein the DEFI coming out of the reactor is a molten DEFI solution having a temperature about 220° to 240° C.; (2) adding solution of a neutralizing agent to said molten DEFI solution at a temperature of about 25° C., said agent being selected from the group consisting of metal hydroxides, metal oxides and mixtures thereof in an amount sufficient to neutralize 10 to 90% of unreacted fatty acid and form in-situ soap, RCO 2 M; wherein said solution of neutralizing agent both reacts with unreacted fatty acid to form soap as noted and cools reaction to temperature of about 100 to 150° C. where DEFI can be mixed with other ingredients prior to transferring to such mixer; (3) transferring acyl isethionate solution (comprising acyl isethionate, fatty acid, in-situ soap and metal isethionate) to container holding one or more ingredients which will be in base bar composition besides what is in acyl isethionate solution; (4) cooling reactants of (3) to form base bar chips.