Patent ID: 8168682

Claim:
A process for forming a personal product bar composition comprising: (1) 1% to 80% of a surfactant selected from the group consisting of anionic, nonionic, amphoteric, cationic surfactants and mixtures thereof; and (2) a structured benefit agent delivery vehicle composition consisting essentially of: (a) 0.1 to 99.9% by wt. of structured benefit agent composition comprising one or more hydrophobic benefit agents or mixtures thereof; and (b) 99.9 to 0.1% structuring material wherein said structuring material is selected from the group consisting of paraffin, victory amber wax and mixtures thereof; (3) 0.1 to 80% structuring aid and/or filler, wherein, when said structured benefit agent is separately formed and separately combined with or to a carrying composition in which the structured benefit agent will be used to deliver benefit agent onto skin, there will be provided at least a 5% increase in deposition of benefit agent to the skin relative to deposition of the same benefit agent if it were not structured or not in presence of structured benefit agent; wherein said separately formed structured benefit agent is molten, semi-molten or solid at the time of combination with the carrying composition, wherein said carrying composition with which said structured benefit agent delivery vehicle is combined comprises said surfactant of (1), said structuring aid and/or filler of (3) and optional ingredients for personal cleansing bar wherein said process comprises: (1) mixing hydrophobic benefit agent or agents and structuring material at a temperature above the melting point of the structuring material, and then either cooling to ambient temperature so that it can be combined later with the bar carrying composition, or optionally cooling to the temperature at which the carrying composition is mixed before combining with the carrying composition; (2) combining said separately prepared premix and the carrying composition, optionally with mixing; and (3) pouring the resulting mixtures into molds and cooling to room temperature; or (4) cooling the resulting mixture to flakes, and extruding flakes so formed into a billet which may be formed and stamped.