Method for producing detergent or detergent dispensing unit

Abstract

The invention relates to a method for producing a detergent or detergent dispensing unit, comprising the following steps: i) providing a mould having at least one mould cavity; ii) supplying a first water-soluble film to the mold cavity; iii) molding a first water-soluble film into the mold cavity to form a receiving chamber; iv) filling the receiving chamber with at least one washing or cleaning active composition to form an at least partially filled receiving chamber; v) supplying a second water-soluble film; vi) sealing the at least partially filled receiving chamber with a second water-soluble film to form a detergent or detergent dispensing unit containing a water-soluble wrap; vii) conveying the detergent or detergent dispensing unit through the shrinkage tunnel by means of a conveying device and shrinking the water-soluble film of the detergent or detergent dispensing unit in the shrinkage tunnel to form a pre-shrunk detergent or detergent dispensing unit; viii) cooling the pre-shrunk detergent or detergent dispensing unit on a cooling section outside the first shrinkage tunnel; and (ix) conveying the pre-shrunk detergent or detergent dispensing unit through a shrinking tunnel by means of a conveying device, and shrinking the water-soluble film of the pre-shrunk detergent or detergent dispensing unit in the shrinking tunnel to form a shrunk detergent or detergent dispensing unit.

Description

[0001] The present invention relates to a method for producing detergent or cleaning agent portioning units encapsulated with a water-soluble film. In particular, the present application relates to a multi-stage production method in which the water-soluble film is repeatedly shrunk.

[0002] The demands placed on the packaging and product formats of detergents and cleaning agents are constantly changing. For a long time, the main focus has been on convenient dosing of detergents and cleaning agents for consumers and on simplifying the work steps required to carry out washing or cleaning methods. Solutions have been provided by pre-packaged detergents and cleaning agents, such as film pouches with one or more receiving compartments for solid or liquid compositions. A particular focus has been on the development and production of liquid or gel detergents suitable for packaging in water-soluble film pouches.

[0003] To be commercially successful, detergent or cleanser dispensing units must satisfy the interests of consumers as effectively as possible. Essential for conveying product quality and product claims is the look and feel of the dispensing unit. This applies particularly to water-soluble film pouches, whose soluble films are typically transparent and allow a clear view of the solid or liquid detergent or cleanser they contain. Particularly in the case of multiphase detergents or cleansers, conveying product quality and product claims is supported by clear phase boundaries within the dispensing unit and by essentially identical structural designs and visual impressions of identical dispensing units. The film pouches also preferably have a secure grip and low mechanical deformation, i.e., they do not sag.

[0004] Detergent or cleaning agent portion packing units with water-soluble film packaging are usually produced by means of a sequential process, during which the water-soluble film and the ingredients of the detergent are combined with one another to form the portion packing unit.

[0005] International patent application WO 2002 / 16205 A1 describes a process for producing detergents and cleaning agents in the form of tightly filled, water-soluble film bags.

[0006] Granted European patent EP 2 944 578 B1 describes a method for coating detergent or cleaning agent tablets using a heat-treated water-soluble film.

[0007] The object of the present application is to provide an efficient process for producing detergent or cleaning agent dispensing units, the products of which are characterized by an attractive look and feel.

[0008] This object is achieved by a method for producing a detergent or cleaning agent dispensing unit, comprising the following steps:

[0009] i) providing a mold having at least one mold cavity;

[0010] ii) supplying a first water-soluble film to the mold cavity;

[0011] iii) molding the first water-soluble film into the mold cavity to form a receiving chamber;

[0012] iv) filling the receiving compartment with at least one detergent-active composition or cleaning-active composition to form an at least partially filled receiving compartment;

[0013] v) supplying a second water-soluble film;

[0014] vi) sealing the at least partially filled receiving chamber with a second water-soluble film to form a detergent or cleaning agent dispensing unit containing a water-soluble wrapper;

[0015] vii) conveying the detergent or cleaning agent dispensing unit through a shrinking tunnel by means of a conveying device, and shrinking the water-soluble film of the detergent or cleaning agent dispensing unit in the shrinking tunnel to form a pre-shrinked detergent or cleaning agent dispensing unit;

[0016] viii) cooling the pre-shrunk detergent or cleaning agent dispensing unit in a cooling section outside the first shrink tunnel;

[0017] ix) transporting the pre-shrinked detergent or cleaning agent dispensing unit through a shrinking tunnel by means of a transport device, and shrinking the water-soluble film of the pre-shrinked detergent or cleaning agent dispensing unit in the shrinking tunnel to form a shrunken detergent or cleaning agent dispensing unit.

[0018] The method according to the present invention is used to efficiently produce detergent and cleaning agent dispensing units with an attractive look and feel. The dispensing units are characterized by a secure grip. The outer surface of the encapsulating water-soluble film is smoother than that of dispensing units produced by alternative methods.

[0019] In step i) of the method, a mold having at least one mold cavity is provided. Due to the high efficiency and good reproducibility of the deep drawing method for water-soluble films, the mold and the mold cavity are preferably a deep drawing mold having at least one cavity.

[0020] The deep drawing die itself can be designed in the form of a horizontal rotating belt or in the form of a drum. Preferably, a deep drawing die having at least one cavity based on a horizontal rotating conveyor belt is used.

[0021] In step ii) of the method, a first water-soluble film is supplied to the mould cavity.In a preferred embodiment, a thermoplastic water-soluble film is supplied in step ii).

[0022] The water-soluble film can be supplied continuously or discontinuously. A continuous process is preferred to improve the efficiency of the method. In a particularly preferred embodiment of the method, the first water-soluble film is continuously conveyed in step ii). For the sake of cost-effectiveness and safety of the method, the first water-soluble film is preferably supplied in step ii) at a speed of 0.04 m / s, preferably greater than 0.08 m / s.

[0023] The water-soluble film may comprise one or more structurally different water-soluble polymers. Suitable water-soluble polymer(s) for the first water-soluble film are in particular polymers from the group of (optionally acetalized) polyvinyl alcohol (PVAL) and copolymers thereof.

[0024] The water-soluble film used to produce the packaging unit is preferably based on polyvinyl alcohol or a polyvinyl alcohol copolymer, the molecular weight of which is preferably between 10,000 and 1,000,000 gmol. -1 , preferably 20,000 to 500,000 gmol -1 , particularly preferably 30,000 to 100,000 gmol -1 , especially 40,000 to 80,000 gmol -1 Preferred water-soluble films comprise at least 30% by weight, preferably at least 50% by weight, in particular at least 70% by weight of polyvinyl alcohol or a polyvinyl alcohol copolymer.

[0025] The production of polyvinyl alcohol and polyvinyl alcohol copolymers generally involves the hydrolysis of the intermediate polyvinyl acetate. Preferred polyvinyl alcohol and polyvinyl alcohol copolymers have a degree of hydrolysis of 70 to 100 mol %, preferably 80 to 90 mol %, particularly preferably 81 to 89 mol %, in particular 82 to 88 mol %.

[0026] In addition to vinyl alcohol, preferred polyvinyl alcohol copolymers also contain ethylenically unsaturated carboxylic acids, or salts or esters thereof. In addition to vinyl alcohol, such polyvinyl alcohol copolymers particularly preferably contain sulfonic acids (such as 2-acrylamido-2-methyl-1-propanesulfonic acid (AMPS)), acrylic acid, methacrylic acid, acrylic acid esters, methacrylic acid esters, or mixtures thereof; among these esters, C 1-4 Alkyl esters or hydroxyalkyl esters. Ethylenically unsaturated dicarboxylic acids (for example, itaconic acid, maleic acid, fumaric acid, and mixtures thereof) are possible as additional monomers.

[0027] Suitable water-soluble membranes for use in the dispensing units according to the invention are those sold by MonoSol LLC, for example under the names M8630, M8720, M8310, C8400 or M8900. Other suitable membranes include those sold by Aicello Chemical Europe GmbH under the name PT, GA, KC or membranes from KL; or VF-HP membranes from Kuraray; and the Hi-Selon series from Mitsubishi Chemical Corporation.

[0028] The first water-soluble film supplied in step ii) preferably has a thickness of 60 to 2000 μm, preferably 60 to 800 μm, in particular 60 to 200 μm.

[0029] The water-soluble film can be molded into the mold cavity in a manner known to those skilled in the art in step iii). Both cold forming and hot forming can be used. The film can also be molded into the mold cavity under the influence of force (e.g., its weight, punching force, or vacuum). Due to the advantageous method results achieved, it is preferred that the first water-soluble film is molded under the influence of heat in step iii). It is possible to reproducibly achieve good results, particularly by heating the first film and subsequent vacuum deformation thereof.

[0030] The film is optionally pretreated with heat and / or solvent prior to molding.The water-soluble film can then be molded into the cavity as described with the aid of a tool, the action of a vacuum, the action of compressed air, and / or the action of its own weight.

[0031] Among a range of deep drawing methods, preferred methods are those in which a water-soluble film is conveyed above the cavity of a deep drawing die, where it is pressed into a recess in the die by the action of compressed air on the upper side of the film or by the action of vacuum on the lower side of the film, particularly preferably by the simultaneous action of compressed air and vacuum. Particularly advantageous methods are characterized in that the film is pretreated by the action of heat and / or a solvent before the pressing.

[0032] The effect of heat and / or solvent on the water-soluble film promotes its plastic deformation. The film can be heated, for example, by thermal radiation, hot air, or particularly preferably by direct contact with a hot plate. The duration of the thermal treatment and the temperature of the thermal radiation, hot air or hot plate surface used certainly depend on the type of shell material used. For water-soluble or water-dispersible materials (such as polymers or copolymers containing PVA), a temperature of 90 to 130 ℃, particularly 105 to 115 ℃ is preferred. The duration of the thermal treatment (particularly the contact time when using a hot plate) is preferably 0.1 to 7 seconds, particularly preferably 0.2 to 6 seconds, particularly 0.3 to 4 seconds. It has been shown that a contact time lower than 1 second, particularly within the range of 400 to 900 milliseconds, preferably 500 to 800 milliseconds is particularly advantageous for the material made of polyvinyl alcohol.

[0033] For reasons of process efficiency, the method according to the invention is designed so that during the process operation, not just a single detergent dispensing unit, but a plurality of detergent dispensing units are produced in parallel. A two-dimensional structure comprising at least 14, preferably at least 20, receiving containers is preferably formed from the first water-soluble film in step iii).

[0034] In this two-dimensional structure, the formed receiving chambers are preferably arranged in rows. For subsequent filling, the receiving chambers formed in step iii) are preferably arranged in rows, the rows being arranged orthogonal to the conveying direction of the water-soluble film.

[0035] In an alternative embodiment, a two-dimensional structure is formed in step iii) in which the receiving chambers are arranged in rows extending orthogonally to the transport direction of the water-soluble film and are each offset from one another by one third, preferably half, of the receiving container width.

[0036] In a two-dimensional structure, the receiving chambers are preferably arranged in such a way that each receiving container is adjacent to at least one intermediate region which is in turn surrounded by three receiving chambers.

[0037] In the step iv) of this method, the receiving chamber is at least partially filled with a detergent-activated composition or a cleaning-activated composition. In principle, detergent-activated compositions or cleaning-activated compositions well known to those skilled in the art are suitable for filling, wherein flowable compositions (such as powders or liquids) are preferred because they can be easily subpackaged. In order to ensure that the bottom area of ​​the receiving chamber is fully filled and in order to further improve the appearance and feel of the detergent dosing unit, the receiving chamber is preferably filled with a hardening liquid in step iv). Suitable hardening liquids include, for example, melts or gels, which harden by cooling and / or owing to progressive gelation.

[0038] The flowable composition that is introduced into the receiving chamber, preferably harden the flowable composition, particularly harden the quantity of flowable gel phase can change.For example, in the step iv) of this method, can only single flowable composition be introduced into the receiving chamber.Perhaps, and because the increase of formula freedom and the product appearance of improvement, can in step iv) two flowable compositions or three flowable compositions or four kinds of flowable compositions be introduced into the receiving chamber.Two, three, four kinds or more kinds of flowable compositions are preferably different on its composition, and comprise for example different active substances, have different active substance contents or different colors.

[0039] If more than one flowable composition (e.g., two, three, or four flowable compositions) is introduced into the receiving chamber in step iv), the two, three, or four flowable compositions are preferably introduced into the receiving chamber so that they are not in direct contact with each other. This procedure prevents undesirable reactions between the active ingredients contained in the different flowable compositions and improves the product appearance.

[0040] Alternatively or in combination with hardening the flowable composition, the receiving chamber can be filled with powder in step iv).

[0041] For efficient filling of the receiving chamber with powder, it has proven advantageous if the powder has a free-flow capacity of more than 40%, preferably more than 50%, in particular more than 60%, based on a standard.

[0042] The free-flowing capacity of a powder relates to its ability to flow freely under its own weight. The free-flowing capacity is determined by the time it takes for 1000 ml of detergent powder to flow out of a standardized flow test funnel (which is initially closed in its discharge direction and has an outlet with a diameter of 16.5 mm). This time is measured by measuring the time it takes for the entire granular mixture (in particular the powder phase, preferably powder and / or granules, e.g., powder) to flow out after the outlet is opened and compared with the outflow rate (in seconds) of a standard test sand, the outflow rate of which is defined as 100%. The limiting sand mixture used for calibrating the flow device is dry sea sand. In this case, sea sand with a particle size of 0.4 to 0.8 mm, such as available from Carl Roth, Germany under CAS No. [14808-60-7], is used. For drying, the sea sand is dried in a drying cabinet at 60°C for 24 hours on a plate with a maximum layer height of 2 cm before measurement.

[0043] Preferred embodiments of the powder according to the invention have an angle of repose / tilt of 26 to 35, 27 to 34, 28 to 33, measured according to the method mentioned below after 24 hours of preparation of the granular mixture of the solid composition, in particular the powdered solid phase, preferably the powder and / or granules, and storage at 20° C. Such an angle of repose has the advantage that the cavity can be filled relatively quickly and precisely with the at least one solid phase.

[0044] To determine the angle of repose (also known as the tilt angle) of a powder, a powder funnel with a capacity of 400 ml and an outlet diameter of 25 mm is simply suspended on a tripod. The funnel is moved upward at a speed of 80 mm / min using a manually operated knurled wheel, causing the granular mixture, particularly the powdery phase, preferably powder and / or granular material, such as powder, to flow out. This forms a so-called conical pile. The conical pile height and conical pile diameter of each particle phase are determined. The tilt angle is calculated as the quotient of the conical pile height and the conical pile diameter multiplied by 100.

[0045] Particularly suitable are powders having a free-flowing capacity in % of more than 40%, preferably more than 50%, in particular more than 55%, particularly preferably more than 60%, more particularly preferably from 63% to 80%, for example from 65% to 75%, compared to the above-mentioned standard test substances. Particularly suitable are granular mixtures of solid compositions, in particular powders and / or granules, having a free-flowing capacity in % of more than 40%, preferably more than 45%, in particular more than 50%, particularly preferably more than 55%, more particularly preferably more than 60%, compared to the above-mentioned standard test substances, the free-flowing capacity being measured 24 hours after preparation of the powder and storage at 20° C.

[0046] Lower values ​​for the free-flow capacity are less suitable because, from a procedural perspective, precise metering of the powder is essential. In particular, values ​​greater than 50%, particularly greater than 55%, and preferably greater than 60% (wherein the free-flow capacity is measured 24 hours after powder preparation and storage at 20°C) have proven advantageous because good metering of the granular mixture, particularly the powdered phase, preferably a powder and / or granules, such as a powder, results in only minor fluctuations in the metered quantity or composition. More precise metering leads to consistent product properties and thus avoids economic losses due to over-metering. It is further advantageous if the granular mixture, particularly the powdered phase, preferably a powder and / or granules, such as a powder, can be metered well, thereby enabling faster metering process sequences. Furthermore, such good free-flow capacity makes it easier to avoid situations where the powder reaches the portion of the water-soluble coating required to create a sealing seam.

[0047] In a particularly preferred method variant, the receiving chamber is preferably filled sequentially with the hardening liquid and the powder in step iv). If one or more hardening flowable compositions are introduced into the receiving chamber, the powder is preferably poured into the receiving chamber in step iv) such that the surface of the one or more hardening flowable compositions facing the opening of the receiving chamber is completely covered with powder.

[0048] The degree of filling of the at least partially filled receiving space in step iv) is preferably higher than 20% by volume, more preferably higher than 50% by volume, in particular higher than 80% by volume.

[0049] With regard to the subsequent visual and tactile properties of the detergent or cleaning agent dispensing unit, it is particularly preferred that the receiving chamber at least partially filled in step iv) has a filling level of 60 to 120% by volume, preferably 80 to 110% by volume, in particular 90 to 100% by volume.

[0050] This method is particularly suitable for producing detergent or cleaning agent dispensing units in which the receiving chamber is at least partially filled with two different detergent-active or cleaning-active compositions in step iv) in such a way that these different detergent-active or cleaning-active compositions do not mix. Therefore, corresponding method variants are preferred.

[0051] In step v) of the method, a second water-soluble film is supplied. As in step ii), in a preferred embodiment, the film supplied in step v) is also a thermoplastic water-soluble film.

[0052] The water-soluble film can be supplied continuously or discontinuously. A continuous process is preferred to improve the efficiency of the process. In a particularly preferred embodiment of the process, the first water-soluble film is continuously conveyed in step ii). For the sake of cost-effectiveness and safety of the process, in step v), the first water-soluble film is preferably supplied at a speed of 0.04 m / s, preferably greater than 0.08 m / s.

[0053] The water-soluble film may comprise one or more structurally different water-soluble polymers. Suitable water-soluble polymer(s) for the second water-soluble film are in particular polymers from the group of (optionally acetalized) polyvinyl alcohol (PVAL) and copolymers thereof.

[0054] The water-soluble film used to produce the packaging unit is preferably based on polyvinyl alcohol or a polyvinyl alcohol copolymer, the molecular weight of which is preferably between 10,000 and 1,000,000 gmol. -1 , preferably 20,000 to 500,000 gmol -1 , particularly preferably 30,000 to 100,000 gmol -1 , especially 40,000 to 80,000 gmol -1 Preferred water-soluble films comprise at least 30% by weight, preferably at least 50% by weight, in particular at least 70% by weight of polyvinyl alcohol or a polyvinyl alcohol copolymer.

[0055] The production of polyvinyl alcohol and polyvinyl alcohol copolymers generally involves the hydrolysis of the intermediate polyvinyl acetate. Preferred polyvinyl alcohol and polyvinyl alcohol copolymers have a degree of hydrolysis of 70 to 100 mol %, preferably 80 to 90 mol %, particularly preferably 81 to 89 mol %, in particular 82 to 88 mol %.

[0056] In addition to vinyl alcohol, preferred polyvinyl alcohol copolymers also contain ethylenically unsaturated carboxylic acids, or salts or esters thereof. In addition to vinyl alcohol, such polyvinyl alcohol copolymers particularly preferably contain sulfonic acids (such as 2-acrylamido-2-methyl-1-propanesulfonic acid (AMPS)), acrylic acid, methacrylic acid, acrylic acid esters, methacrylic acid esters, or mixtures thereof; among these esters, C 1-4 Alkyl esters or hydroxyalkyl esters. Ethylenically unsaturated dicarboxylic acids (for example, itaconic acid, maleic acid, fumaric acid, and mixtures thereof) are possible as additional monomers.

[0057] Suitable water-soluble membranes for use in the dispensing units according to the invention are those sold by MonoSol LLC, for example under the names M8630, M8720, M8310, C8400 or M8900. Other suitable membranes include those sold by Aicello Chemical Europe GmbH under the name PT, GA, KC or membranes from KL; or VF-HP membranes from Kuraray; and the Hi-Selon series from Mitsubishi Chemical Corporation.

[0058] The second water-soluble film supplied in step v) preferably has a thickness of 80 μm or less, in particular 65 μm or less, most preferably 55 μm or less.

[0059] In terms of mechanical stability of the disposable detergent package, while using minimal packaging means, the ratio of the thickness of the first water-soluble film to the thickness of the second water-soluble film is preferably 3:1 to 1:1, preferably 2.5:1 to 1.1:1, and particularly 2:1 to 1.2:1. Preferably, the second water-soluble film supplied in step v) is thinner than the first water-soluble film supplied in step ii).

[0060] In step vi) of the method, the at least partially filled receiving chamber is sealed. Sealing is preferably performed under the influence of a solvent or heat.

[0061] After sealing, in step vii) of the method, the water-soluble film of the detergent or cleaning agent dispensing unit is shrunk. The water-soluble film is shrunk in a device designed for this purpose, known as a shrink tunnel. The shrink tunnel allows for targeted heating of the water-soluble film encapsulating the detergent or cleaning agent dispensing unit.

[0062] The shrink tunnel has a conveying system that helps convey the detergent or cleaning agent packaging units through the shrink tunnel. For example, the conveying system can be an endless conveyor belt.

[0063] For example, the heat may be transferred in the shrink tunnel by thermal radiation or hot air.In the method according to the invention, the water-soluble film in step vii) is preferably shrunk by exposure to hot air.

[0064] For reasons of process economy, it is preferred that the detergent or cleaning agent dispensing unit rests on the conveying device in step vii) with a first water-soluble film.

[0065] In the first shrink tunnel, the hot air preferably has a temperature of 120 to 290° C., preferably 140 to 260° C., in particular 175 to 230° C. In step vii), the residence time of the detergent or cleaning agent packaging unit in the shrink tunnel is preferably 1 to 10 seconds, more preferably 2 to 6 seconds.

[0066] After leaving the shrink tunnel, the pre-shrinked detergent or cleaning agent portioning unit is cooled in step viii). Cooling is preferably carried out by means of cold air, which preferably has a temperature of 5 to 35°C, particularly preferably 10 to 30°C, in particular 15 to 25°C.

[0067] Cooling serves to stabilize the shrinkage results, allowing further rapid processing of the detergent or cleaning agent portioned units and thus preparing them for subsequent method steps.

[0068] In step viii), the residence time of the pre-shrinked detergent or cleaning agent dispensing unit on the cooling path is 1 to 60 seconds, preferably 5 to 30 seconds.

[0069] To achieve more consistent shrinking results and a particularly favorable feel and appearance, it has proven helpful to turn the pre-shrinked detergent or cleaning agent dispensing unit over before it enters the shrinking tunnel in step ix). The detergent or cleaning agent dispensing unit can be turned over manually or mechanically. Mechanical turning of the detergent or cleaning agent dispensing unit is preferred.

[0070] In a preferred method variant, the detergent or cleaning agent dispensing unit is turned over in such a way that its side pointing in the conveying direction during the previous contraction in step vii) faces away from the conveying direction in the further step ix).

[0071] In a further preferred method variant, the detergent or cleaning agent dispensing unit is turned over in such a way that its lower side resting on the conveying device during the previous shrinking in step vii) forms the upper side of the detergent or cleaning agent dispensing unit facing away from the conveying device in the further step ix).

[0072] In a particularly preferred method variant, the detergent or cleaning agent dispensing unit is turned over in such a way that:

[0073] - the side thereof pointing in the conveying direction during the previous contraction in step vii) faces away from the conveying direction in the further step ix), and

[0074] The lower side thereof, which rested on the conveying device during the previous shrinking in step vii), forms the upper side of the detergent or cleaning agent dispensing unit facing away from the conveying device in the further step ix).

[0075] Preferably, in step ix), the detergent or cleaning agent dispensing unit is placed on the conveying device with the second water-soluble film.

[0076] It is particularly preferred that the detergent or cleaning agent dispensing unit described above is placed on the conveying device in step vii) with a first water-soluble film and in step ix) with a second water-soluble film.

[0077] As in step vii), heat may be transferred in step ix) by, for example, thermal radiation or hot air.According to the present invention, preferably, the water-soluble film is shrunk in step ix) by exposure to hot air.

[0078] In the second shrink tunnel, the hot air preferably has a temperature of 120 to 290° C., preferably 140 to 260° C., in particular 175 to 230° C. In step ix), the residence time of the detergent or cleaning agent packaging unit in the shrink tunnel is preferably 1 to 10 seconds, more preferably 2 to 6 seconds.

[0079] In principle, shrink tunnels known to the person skilled in the art are suitable for carrying out the shrinking in step vii) and step ix). Preferred forms of shrink tunnels are recirculating air shrink tunnels and convection shrink tunnels.

[0080] Shrink tunnels based on the recirculating air principle are characterized by high thermal efficiency. In these shrink tunnels, heated air is blown from below and / or from both sides of the tunnel entrance area onto the detergent or cleaning agent dispensing units. The resulting airflow moves in the conveying direction to the tunnel exit area, where the heated air can be extracted according to the recirculating air principle and fed back into the circuit.

[0081] Shrink tunnels based on the convection principle are characterized by their shrinking properties. In these tunnels, the hot air is evenly distributed in the shrink tunnel by means of circulation.

[0082] The shrink tunnels used in step vii) and step ix) can be the same or different. In other words, the detergent or cleaning agent dispensing unit can be conveyed through the same shrink tunnel in step vii) and step ix), but the shrink tunnels in step vii) and step ix) can also be different shrink tunnels.

[0083] If different shrink tunnels are used for step vii) and step ix), these shrink tunnels can differ, for example, in their design principle and their mode of operation. Such a method variant can be achieved, for example, by combining a recirculating air shrink tunnel in one method step with a convection shrink tunnel in another method step.

[0084] Alternatively, different shrink tunnels can have the same design principle and the same mode of operation, but differ from each other in their process parameters. This process variant can be implemented, for example, by using two recirculating air shrink tunnels maintaining different hot air temperatures or residence times.

[0085] Therefore, a preferred method variant is characterized in that:

[0086] - the residence time of the detergent or cleaning agent packaging unit in the first shrink tunnel in step vii) and step ix)

[0087] The residence time in the second shrink tunnel is different, and / or

[0088] The temperature of the hot air in the first shrink tunnel in step vii) is different from the temperature of the hot air in the second shrink tunnel in step ix).

[0089] The use of different shrinkage conditions has proven to be particularly useful in the production of multi-phase detergent or cleaning agent dosing units. In other words, such a method is particularly advantageous if the receiving chamber is at least partially filled with two different detergent-active or cleaning-active compositions in step iv) in such a way that these different detergent-active or cleaning-active compositions do not mix.

[0090] As already described after step vii), the shrunken detergent or cleaning agent portioning unit is cooled after step ix), preferably by means of cold air.

[0091] The final product of the process is preferably packaged in a sales container after optional conditioning at controlled storage temperature and / or humidity.

[0092] This application provides, inter alia, the following topics:

[0093] 1. A method for producing a detergent or cleaning agent dispensing unit, comprising the steps of:

[0094] i) providing a mold having at least one mold cavity;

[0095] ii) supplying a first water-soluble film to the mold cavity;

[0096] iii) molding the first water-soluble film into the mold cavity to form a receiving chamber;

[0097] iv) filling the receiving compartment with at least one detergent-active composition or cleaning-active composition to form an at least partially filled receiving compartment;

[0098] v) supplying a second water-soluble film;

[0099] vi) sealing the at least partially filled receiving chamber with the second water-soluble film to form a detergent or cleaning agent dispensing unit containing a water-soluble wrapper;

[0100] vii) conveying the detergent or cleaning agent dispensing unit through a shrinking tunnel by means of a conveying device, and shrinking the water-soluble film of the detergent or cleaning agent dispensing unit in the shrinking tunnel to form a pre-shrinked detergent or cleaning agent dispensing unit;

[0101] viii) cooling the pre-shrunk detergent or cleaning agent dispensing unit in a cooling section outside the first shrink tunnel;

[0102] ix) conveying the pre-shrinked detergent or cleaning agent dispensing unit through a shrinking tunnel by means of a conveying device, and shrinking the water-soluble film of the pre-shrinked detergent or cleaning agent dispensing unit in the shrinking tunnel to form a shrunken detergent or cleaning agent dispensing unit.

[0103] 2. The method according to clause 1, wherein in step i) a deep drawing die having at least one cavity is provided.

[0104] 3. The method according to clause 2, wherein the deep drawing die has a horizontal carousel having at least one cavity.

[0105] 4. The method according to one of the preceding clauses, wherein a thermoplastic water-soluble film is supplied in step ii).

[0106] 5. The process according to one of the preceding clauses, wherein the water-soluble film in step ii) is selected from films of optionally acetalized polyvinyl alcohol or copolymers thereof.

[0107] 6. The method according to one of the preceding clauses, wherein the first water-soluble film supplied in step ii) preferably has a thickness of 60 to 2000 μm, preferably 60 to 800 μm, in particular 60 to 200 μm.

[0108] 7. The method according to one of the preceding clauses, wherein in step iii) the first water-soluble film is molded under exposure to heat.

[0109] 8. The method according to one of the preceding clauses, wherein in step iv) the receiving chamber is filled with a hardening liquid.

[0110] 9. The method according to one of the preceding clauses, wherein in step iv) the receiving chamber is filled with powder.

[0111] 10. Method according to one of the preceding clauses, wherein the receiving chamber is preferably filled successively with hardening liquid and powder in step iv).

[0112] 11. The method according to one of the preceding clauses, wherein the receiving chamber is at least partially filled in step iv) with two different washing-active or cleaning-active compositions in such a way that these different washing-active or cleaning-active compositions do not mix.

[0113] 12. Method according to one of the preceding clauses, wherein, in step iv), the at least partially filled receiving chamber has a filling level higher than 20% by volume, preferably higher than 50% by volume, in particular higher than 80% by volume.

[0114] 13. Method according to one of the preceding clauses, wherein, in step iv), the at least partially filled receiving chamber has a filling level of 60 to 120% by volume, preferably 80 to 110% by volume, in particular 90 to 100% by volume.

[0115] 14. The method according to one of the preceding clauses, wherein a thermoplastic water-soluble film is supplied in step v).

[0116] 15. The method according to one of the preceding clauses, wherein the second water-soluble film supplied in step v) is selected from films of optionally acetalized polyvinyl alcohol or copolymers thereof.

[0117] 16. The method according to one of the preceding clauses, wherein the second water-soluble film supplied in step v) has a thickness of 80 μm or less, in particular 65 μm or less, most preferably 55 μm or less.

[0118] 17. The method according to one of the preceding clauses, wherein the ratio of the thickness of the first water-soluble film supplied in step ii) to the thickness of the second water-soluble film supplied in step v) is 3:1 to 1:1, preferably 2.5:1 to 1.1:1, in particular 2:1 to 1.2:1.

[0119] 18. The method according to one of the preceding clauses, wherein the second water-soluble film supplied in step v) is thinner than the first water-soluble film supplied in step ii).

[0120] 19. The method according to one of the preceding clauses, wherein the sealing in step vi) is performed under the influence of a solvent.

[0121] 20. The method according to one of the preceding clauses, wherein the sealing in step vi) is performed under the influence of heat.

[0122] 21. The method according to one of the preceding clauses, wherein the water-soluble film is shrunk in step vii) by exposure to hot air.

[0123] 22. The method according to clause 21, wherein the hot air has a temperature of 120 to 290°C, preferably 140 to 260°C, in particular 175 to 230°C.

[0124] 23. The method according to one of the preceding clauses, wherein, in step vii), the residence time of the detergent or cleaning agent dispensing unit in the shrink tunnel is 1 to 10 seconds, preferably 2 to 6 seconds.

[0125] 24. The method according to one of the preceding clauses, wherein the detergent or cleaning agent dispensing unit is placed on the conveying device in step vii) with the first water-soluble film.

[0126] 25. The method according to one of the preceding clauses, wherein in step viii) the pre-shrinked detergent or cleaning agent dispensing unit is cooled by means of cold air.

[0127] 26. The method according to clause 25, wherein the cold air has a temperature of 5 to 35°C, preferably 10 to 30°C, in particular 15 to 25°C.

[0128] 27. The method according to one of the preceding clauses, wherein, in step viii), the residence time of the pre-shrinked detergent or cleaning agent portioning units on the cooling section is 1 to 60 seconds, preferably 5 to 30 seconds.

[0129] 28. The method according to one of the preceding clauses, wherein the pre-shrinked detergent or cleaning agent dispensing unit is turned over before entering the shrinking tunnel in step ix).

[0130] 29. The method according to one of the preceding clauses, wherein the lower side of the detergent or cleaning agent dispensing unit resting on the conveying device in step vii) forms the upper side of the detergent or cleaning agent dispensing unit facing away from the conveying device in step ix).

[0131] 30. The method according to one of the preceding clauses, wherein the water-soluble film is shrunk in step ix) by exposure to hot air.

[0132] 31. Method according to clause 30, wherein the hot air has a temperature of 120 to 290°C, preferably 140 to 260°C, in particular 175 to 230°C.

[0133] 32. The method according to one of the preceding clauses, wherein, in step ix), the residence time of the detergent or cleaning agent dispensing unit in the shrink tunnel is 1 to 10 seconds, preferably 2 to 6 seconds.

[0134] 33. The method according to one of the preceding clauses, wherein the detergent or cleaning agent dispensing unit is placed on the conveying device in step ix) with the second water-soluble film.

[0135] 34. The method according to one of the preceding clauses, wherein the shrink tunnel in step vii) and the shrink tunnel in step ix) are identical.

[0136] 35. The method according to one of the preceding clauses, wherein the shrink tunnel in step vii) and the shrink tunnel in step ix) are different.

[0137] 36. The method according to one of the preceding clauses, wherein the shrinking in step vii) and / or step ix) is performed by means of a recirculating air shrink tunnel.

[0138] 37. The method according to one of clauses 1 to 35, wherein the shrinking in step vii) and / or step ix) is performed by means of a convection shrink tunnel.

[0139] 38. The method according to one of the preceding clauses, wherein the residence time of the detergent or cleaning agent dispensing unit in step vii) in the first shrink tunnel is different from the residence time in step ix) in the second shrink tunnel.

[0140] 39. The method according to one of the preceding clauses, wherein the temperature of the hot air in the first shrink tunnel in step vii) is different from the temperature of the hot air in the second shrink tunnel in step ix).

[0141] 40. The method according to one of the preceding clauses, wherein the shrunken detergent or cleaning agent dispensing unit is cooled after step ix), preferably by means of cold air. Example

[0142] By means of the method according to the invention, a detergent or cleaning agent dispensing unit is produced having a first phase and a second phase.

[0143] To this end, a water-soluble receiving chamber is produced by deep-drawing a PVOH-containing film. A flowable composition is poured into the receiving chamber and hardens after a short time. The hardened phase is completely covered with a free-flowing powder. The partially filled receiving chamber is then closed by placing a second PVOH-containing film on top and sealing it with heat.

[0144] The compositions of some exemplary hardened flowable compositions may be found in Table 1 below:

[0145] Table 1

[0146] A B C D E PEG 400 17.9 23.1 23.1 13.9 27.8 30% PVOH in glycerol 35.7 30.8 30.8 55.6 55.6 1,3-Propanediol - - - 27.8 13.9 glycerin - 15.4 - - - Sulfonic acid-containing acrylate copolymer - 30.8 30.8 - - Xylitol 26.8 - - - water 10.7 - 15.4 - - Nonionic surfactant 1 8.9 - - - - Nonionic surfactant 2 - - - 2.8 2.8

[0147] A basic formulation for a free-flowing powder may be found in Table 2.

[0148] Table 2

[0149]

[0150] Sealed detergent or cleaning agent dispensing units are characterized by low strength and deform in a clearly visible manner under the influence of their own weight. These sealed detergent or cleaning agent dispensing units are then subjected to different shrinkage methods 1-5:

[0151] Method 1

[0152] The detergent or cleaning agent dispensing units are treated with hot air at a temperature of 190° C. for a period of 5 seconds in a shrink tunnel.

[0153] The resulting shrunken detergent or cleaning agent dispensing unit exhibits improved strength compared to untreated detergent or cleaning agent dispensing units. However, the strength is still insufficient.

[0154] Method 2

[0155] The detergent or cleaning agent dispensing units are treated with hot air at a temperature of 230° C. for a period of 5 seconds in a shrink tunnel.

[0156] The resulting shrunken detergent or cleaning agent dispensing unit exhibits improved strength compared to untreated detergent or cleaning agent dispensing units. However, the strength is still insufficient.

[0157] Method 3

[0158] In the first shrink tunnel, the detergent or cleaning agent dispensing unit is treated with hot air at a temperature of 190° C. for a period of 5 seconds. After passing through a cooling section outside the first shrink tunnel, the pre-shrunk detergent or cleaning agent dispensing unit is again treated with hot air at a temperature of 190° C. for a period of 5 seconds in a second shrink tunnel. The detergent or cleaning agent dispensing unit is oriented in both shrink tunnels with the hardened flowable composition facing downward.

[0159] The resulting shrunken detergent or cleaning agent dispensing units exhibit improved and sufficient strength compared to untreated detergent or cleaning agent dispensing units and detergent or cleaning agent dispensing units treated according to methods 1 and 2.

[0160] Method 4

[0161] The method is carried out as in method 3, but the detergent or cleaning agent dispensing units are oriented in two shrink tunnels with the hardened flowable composition facing upwards.

[0162] The resulting shrunken detergent or cleaning agent dispensing units exhibit improved and sufficient strength compared to untreated detergent or cleaning agent dispensing units and detergent or cleaning agent dispensing units treated according to methods 1, 2 and 3.

[0163] Method 5

[0164] The method is carried out as in method 3, but the detergent or cleaner dispensing units are oriented with the hardened flowable composition facing downwards in the first shrink tunnel and with the hardened flowable composition facing upwards in the second shrink tunnel.

[0165] The resulting shrunken detergent or cleaning agent dispensing units exhibit improved and sufficient strength compared to untreated detergent or cleaning agent dispensing units and detergent or cleaning agent dispensing units treated according to methods 1, 2, 3 and 4.

[0166] Force-displacement measurements of detergent or cleaning agent dispensing units produced according to methods 3, 4 and 5 yield the following values:

[0167]

Claims

1. A method for producing a detergent or cleaning agent dispensing unit, comprising the steps of: i) providing a mold having at least one mold cavity; ii) supplying a first water-soluble film to the mold cavity; iii) molding the first water-soluble film into the mold cavity to form a receiving chamber; iv) filling the receiving compartment with at least one detergent-active composition or cleaning-active composition to form an at least partially filled receiving compartment; v) supplying a second water-soluble film; vi) sealing the at least partially filled receiving chamber with the second water-soluble film to form a detergent or cleaning agent dispensing unit containing a water-soluble wrapper; vii) conveying the detergent or cleaning agent dispensing unit through a shrinking tunnel by means of a conveying device, and shrinking the water-soluble film of the detergent or cleaning agent dispensing unit in the shrinking tunnel to form a pre-shrinked detergent or cleaning agent dispensing unit; viii) cooling the pre-shrunk detergent or cleaning agent dispensing unit in a cooling section outside the first shrink tunnel; ix) conveying the pre-shrinked detergent or cleaning agent dispensing unit through a shrinking tunnel by means of a conveying device, and shrinking the water-soluble film of the pre-shrinked detergent or cleaning agent dispensing unit in the shrinking tunnel to form a shrunken detergent or cleaning agent dispensing unit.

2. The method according to claim 1, wherein in step vii) the water-soluble film is shrunk by exposure to hot air.

3. The method according to claim 2, wherein the hot air has a temperature of 120 to 290°C, preferably 140 to 260°C, in particular 175 to 230°C.

4. The method according to claim 1, wherein: In step vii), the residence time of the detergent or cleaning agent dispensing unit in the shrink tunnel is 1 to 10 seconds, preferably 2 to 6 seconds. 5 . The method according to claim 1 , wherein the detergent or cleaning agent dispensing unit is placed on the conveying device in step vii) with the first water-soluble film. 6 . The method according to claim 1 , wherein the pre-shrinked detergent or cleaning agent dispensing unit is cooled in step viii) by means of cold air.

7. The method according to claim 6, wherein the cold air has a temperature of 5 to 35°C, preferably 10 to 30°C, in particular 15 to 25°C.

8. The method according to claim 1, wherein: In step viii), the residence time of the pre-shrinked detergent or cleaning agent dispensing unit on the cooling section is 1 to 60 seconds, preferably 5 to 30 seconds.

9. The method according to claim 1, wherein: Before entering the shrinking tunnel in step ix), the pre-shrinking detergent or cleaning agent dispensing unit is turned over.

10. The method according to one of the preceding claims, wherein the water-soluble film is deformed in step ix) by exposure to hot air.

11. The method according to claim 10, wherein the hot air has a temperature of 120 to 290°C, preferably 140 to 260°C, in particular 175 to 230°C.

12. The method according to claim 1, wherein: In step ix), the residence time of the detergent or cleaning agent dispensing unit in the shrink tunnel is 1 to 10 seconds, preferably 2 to 6 seconds. 13 . The method according to claim 1 , wherein the detergent or cleaning agent dispensing unit is placed on the conveying device in step ix) with the second water-soluble film.

14. The method according to one of the preceding claims, wherein the shrinking in step vii) and / or step ix) is performed by means of a recirculating air shrink tunnel.

15. The method according to one of claims 1 to 13, wherein the shrinking in step vii) and / or step ix) is performed by means of a convection shrink tunnel.

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