METHOD FOR PRODUCING A DETERGENT PORTION UNIT

Description

[0001] The present invention relates to a method for producing a detergent portion unit comprising a gel body.

[0002] The packaging and presentation of detergents and cleaning agents are subject to constantly changing requirements. For some time now, a major focus has been on convenient dosing by the consumer and simplifying the steps required for washing or cleaning. One technical solution is pre-portioned detergents or cleaning agents, for example, water-soluble containers with one or more compartments for powdered or liquid detergents or cleaning agents. Another technical solution is offered by detergent tablets, which can be single-phase or multi-phase.

[0003] To manufacture water-soluble containers, water-soluble polymers are typically formed into receiving chambers, which are then filled with a detergent or cleaning agent and finally sealed. The receiving chambers can be produced, for example, from water-soluble polymer films using a thermoforming process. Alternatively, a water-soluble polymer is injection-molded into a receiving container.

[0004] The water-soluble packaging material used for the filled detergent portion units is generally hygroscopic. The water absorption tendency and capacity of the packaging material can lead to portion units adhering to machine or packaging surfaces during manufacturing, packaging, storage, and subsequent use by the consumer. This can result in portion units not being optimally conveyed, or adjacent portion units, for example, within a shared outer package, sticking together. To prevent this adhesion of the water-soluble portion units, their surface properties can be modified by applying a powder. However, powdering the water-soluble detergent portion units requires an additional process step.

[0005] The water-soluble packaging materials used are generally not detergent- or cleaning-active and therefore do not contribute to the product's effectiveness. Reducing the packaging content relative to the total weight of the detergent portion units would thus not result in any loss of performance and would be welcome from both a sustainability and economic perspective.

[0006] Ultimately, the washing performance achieved by the detergent portion unit is directly related to its dissolution properties. Especially with the increasing use of cold washing processes, it is advantageous to minimize the thickness of the water-soluble film material contained within the detergent portion unit to accelerate the dissolution process. However, reducing the thickness of the surrounding film material simultaneously reduces the mechanical stability of the portion units. Overcoming this apparent dichotomy between mechanical stability and dissolution speed by means of detergent dosing units packaged in water-soluble films remains a relevant consideration in the development of water-soluble detergent portion units.

[0007] An alternative to the portion packs described above are detergent tablets, but in this case, sufficient mechanical stability and high dissolution rate are similarly incompatible, just as in the case of the portion packs.

[0008] An alternative to fully compressed detergent tablets are multiphase detergent portion units, for example in the form of core tablets, which, in addition to a tableted body, also contain wax or gel phases. For example, European patent EP 1 032 642 B1 describes detergent tablets comprising a compressed phase and an uncompressed gel phase, and methods for their production. DE 10 2017 210143 A1 discloses solid surfactant compositions, wherein the formulation comprises surfactant and gelling agent. DE 10 2019 210893 A1 and US 6 413 928 B1 relate to multiphase detergent / cleaning agent molded bodies.

[0009] Against the background of the previously described prior art, the application aimed to provide efficient processes for the production of rapidly dissolving detergent portion units that exhibit high product and storage stability, can be easily packaged using minimal amounts of packaging material, and appeal to consumers through their attractive odor, appearance, and feel. The detergent portion units should offer high product performance and be easy and safe for consumers to handle.

[0010] A first subject matter of the application is a process for manufacturing a detergent portion unit, comprising a) a dimensionally stable gel body comprising the steps of: i) providing a first flowable surfactant-containing composition; ii) providing a second flowable gel-forming composition different from the first flowable composition; iii) feeding the first and second flowable compositions to a mold; iv) introducing the first and second flowable compositions into the mold; v) mixing the first and second flowable compositions in the mold by means of a dynamic mixing device to form a surfactant-containing and gel-forming mixture; vi) allowing the surfactant-containing and gel-forming mixture to solidify in the mold to form a dimensionally stable gel body, wherein the first flowable composition and the second flowable composition are introduced into the mold by means of separate injectors.

[0011] The term "detergent portion unit" describes a form of packaging in which a measured portion of a detergent or cleaning agent is present. Detergent portion units therefore refer to packaging for both textiles and hard surfaces such as ceramics, glass, metal, or tiles. A detergent portion unit preferably weighs between 14 g and 42 g, more preferably between 18 g and 38 g, and particularly between 20 g and 34 g.

[0012] The detergent portion unit comprises a gel body. The detergent portion unit can consist solely of the gel body. In this case, the gel body preferably weighs between 14 g and 42 g, more preferably between 18 g and 38 g, and particularly between 20 g and 34 g. If the detergent portion unit comprises other components besides the gel body, the weight of the gel body is preferably between 10 g and 28 g, more preferably between 12 g and 23 g, and particularly between 15 g and 20 g.

[0013] Gel bodies are defined as bodies that exhibit elastic deformation behavior under the influence of force. Dimensionally stable bodies are those that possess intrinsic dimensional stability, enabling them to maintain a non-disintegrating spatial shape under normal manufacturing, storage, transport, and consumer handling conditions. This spatial shape must remain unchanged under these conditions for extended periods, preferably 4 weeks, particularly preferably 8 weeks, and especially 32 weeks. In other words, under normal manufacturing, storage, transport, and consumer handling conditions, the body must retain the spatial-geometric shape determined by the manufacturing process, i.e., it must not degrade.

[0014] The shape of the gel body is generally freely selectable; its side surfaces can, for example, be convex, concave, or flat. However, certain spatial configurations have proven particularly advantageous with regard to the manufacturability, storage, and use of the gel bodies.

[0015] In suitably advantageous detergent portion units, the gel body has a flat underside whose largest diagonal is greater than the height of the gel body. These bodies are not only easy to manufacture, for example by casting, but they can also be packaged simply and compactly and are suitable for dosing via the dosing or dispenser chambers of electronic cleaning devices. Preferably, the gel body has a flat underside whose largest diagonal is more than 1.5 times, preferably more than 2 times, the height of the gel body.

[0016] For manufacturability, for example, regarding the demolding of the gel body from a mold, it has proven advantageous if the underside of the gel body has no corners. Preferred gel bodies are therefore characterized by oval undersides or, alternatively, by ellipsoidal or round, preferably round, undersides. Such gel bodies with a non-angular underside are also preferred by many consumers due to their appearance. Therefore, gel bodies with a bottom and a top surface connected by a cylindrical outer surface are particularly preferred.

[0017] Advantages regarding space utilization during manufacturing and packaging are achieved through square bottom surfaces. For example, if the gel bodies are cast in the form of sheets which are subsequently cut into gel bodies, square bottom surfaces are advantageous because such gel bodies can be cut without producing any waste and can be packaged in a space-saving manner. In an alternative embodiment, preferred gel bodies therefore have square bottom surfaces, in particular triangular, square, or hexagonal bottom surfaces. For further processing or packaging, it can be advantageous if the gel body has a square bottom surface with rounded corners.

[0018] In terms of the manufacture, packaging and use of the detergent portion units, it has also proven advantageous if the gel bodies have a top surface that is parallel to the bottom surface.

[0019] In a first preferred geometric embodiment, the gel body has a bottom and a top surface with the same geometric shape and the same surface area. As previously described, such gel bodies can be easily produced, for example, by casting sheets and subsequently cutting the sheets into individual gel bodies. Furthermore, due to the geometric identity of the bottom and top surfaces, these gel bodies can be more easily oriented in subsequent process steps, during packaging, or during use by the user than gel bodies with lower symmetry. This is particularly true for gel bodies that also have a top surface that is plane-parallel to the bottom surface.Examples of such gel bodies are circular cylinders, elliptical cylinders, parallelepipeds, rhombohedrons, right or oblique prisms, cuboids, or cubes. The group of circular and elliptical cylinders further includes perpendicular circular and elliptical cylinders as well as oblique circular and elliptical cylinders. Due to their ease of production by singulation from a plate, gel bodies in the form of perpendicular circular cylinders, perpendicular elliptical cylinders, right prisms, right cuboids, or cubes are preferred.

[0020] In an alternative embodiment, the gel body has a bottom and a top surface with the same geometric shape, but with different surface areas. Such gel bodies may be preferred due to their attractive appearance or optimized fit, combined with relatively simple manufacturing. Examples of such gel bodies are circular or elliptical cylinders with a convex or concave bottom surface and a flat top surface. Other examples include truncated cones or truncated pyramids.

[0021] In summary, preferred subject matter of the application can be characterized as detergent portion units comprising a gel body with a bottom and a top, wherein the area of ​​the top is 80 to 100%, preferably 90 to 100% and particularly 98 to 100% of the bottom.

[0022] The process is particularly suitable for the formulation of gel bodies with a high surfactant content. In preferred embodiments, the first free-flowing surfactant-containing composition contains, based on its total weight, 30 to 70 wt.%, preferably 40 to 60 wt.%, and particularly 45 to 55 wt.% surfactant.

[0023] For the manufacturability and subsequent dissolution of the gel bodies, it has proven advantageous for them to contain 15 to 35 wt.%, preferably 20 to 30 wt.%, of an aqueous-organic solvent. The aqueous-organic solvent of the gel body is preferably introduced via the first and second free-flowing compositions. It is therefore preferred if the second free-flowing composition containing the gelling agent also contains an organic solvent. Particularly preferred free-flowing compositions containing the gelling agent and organic solvent contain a total weight fraction above 50 wt.%, preferably above 70 wt.%, and particularly above 90 wt.%.

[0024] Preferred gel bodies still contain dye.

[0025] Preferred gel bodies are transparent. Gel bodies are described as "transparent" if, in the wavelength range of 410 to 800 nm, at least one wavelength, preferably 600 nm, exhibits a transmission above 50%, preferably above 60%, and particularly above 80%. The transmission is determined by VIS spectrometry at a sample temperature of 20°C and a cuvette length of 10 mm.

[0026] For the production and subsequent storage and transport properties of the gel bodies, it has proven advantageous to use low-molecular-weight gelling agents with a molar mass of up to 2000 g / mol in the gel body, wherein their weight fraction to the total weight of the gel body is preferably less than 5 wt.%, more preferably 0.1 to 5 wt.%, and particularly preferably 0.1 to 2.5 wt.%. Furthermore, the advantages of the process according to the invention are particularly evident in the processing of these low-molecular-weight gelling agents with their specific gelling properties.

[0027] In a preferred embodiment, the low-molecular-weight gelling agent has a solubility in water of less than 0.1 g / L (20°C). The solubility of the organic gelling compound is determined at 20°C in double-distilled, demineralized water.

[0028] Furthermore, gelling agents are preferably suitable which have a structure containing at least one hydrocarbon structural unit with 6 to 20 carbon atoms (preferably at least one carbocyclic, aromatic structural unit) and additionally an organic structural unit covalently bonded to the aforementioned hydrocarbon unit, which has at least two groups selected from -OH, -NH-, or mixtures thereof.

[0029] Particularly preferred gel bodies are characterized in that said gel bodies contain at least one benzylidenealditol compound of formula (GB-I) as a gelling agent. wherein *- for a covalent single bond between an oxygen atom of the alditol backbone and the intended residue, n for 0 or 1, preferably 1, m for 0 or 1, preferably 1, R 1< , R 2< and R 3< independently of each other represent a hydrogen atom, a halogen atom, a C 1-C 4 alkyl group, a cyano group, a nitro group, an amino group, a carboxyl group, a hydroxy group, a -C(=O)-NH-NH 2 group, a -NH-C(=O)-(C 2-C 4 alkyl) group, a C 1-C 4 alkoxy group, a C 1-C 4 alkoxy-C 2-C 4 alkyl group, two of the residues together with the residue molecule form a 5- or 6-membered ring, R 4< , R 5< and R 6< independently of each other represent a hydrogen atom, a halogen atom, a C1-C4 alkyl group, a cyano group, a nitro group, an amino group, a carboxyl group, a hydroxy group, a -C(=O)-NH-NH2 group, a -NH-C(=O)-(C2-C4 alkyl) group, a C1-C4 alkoxy group,a C1-C4 alkoxy-C2-C4 alkyl group, two of the residues together with the rest molecule forming a 5- or 6-membered ring.

[0030] Due to the stereochemistry of the alditols, it should be noted that, according to the invention, both the aforementioned benzylidenealditols in the L-configuration or in the D-configuration, or a mixture of both, are suitable. Due to their natural availability, the benzylidenealditol compounds in the D-configuration are preferably used according to the invention. It has proven preferable if the alditol backbone of the benzylidenealditol compound contained in the molded body according to formula (GB-I) is derived from D-glucitol, D-mannitol, D-arabinitol, D-ribitol, D-xylitol, L-glucitol, L-mannitol, L-arabinitol, L-ribitol, or L-xylitol.

[0031] Particularly preferred are such gel bodies which are characterized in that R 1< , R 2< , R 3< , R 4< , R 5< and R 6< according to benzylidenealditol compound of formula (GB-I) independently represent a hydrogen atom, methyl, ethyl, chlorine, fluorine or methoxy, preferably a hydrogen atom.

[0032] n according to the benzylidenealditol compound of the formula (GB-I) preferably stands for 1.

[0033] m according to the benzylidenealditol compound formula (GB-I) preferably stands for 1.

[0034] The gel body most preferably contains at least one compound of formula (GB-I1) as a benzylidenealditol compound of formula (GB-I). wherein R< 1< , R< 2< , R< 3< , R< 4< , R< 5< and R< 6< are defined as in formula (I). Most preferably, according to formula (GB-I1), R< 1< , R< 2< , R< 3< , R< 4< , R< 5< and R< 6< represent independently a hydrogen atom, methyl, ethyl, chlorine, fluorine or methoxy, preferably a hydrogen atom.

[0035] The benzylidenealditol compound of formula (GB-I) is most preferably selected from 1,3:2,4-Di-O-benzylidene-D-sorbitol; 1,3:2,4-Di-O-(p-methylbenzylidene)-D-sorbitol; 1,3:2,4-Di-O-(p-chlorobenzylidene)-D-sorbitol; 1,3:2,4-Di-O-(2,4-dimethylbenzylidene)-D-sorbitol; 1,3:2,4-Di-O-(p-ethylbenzylidene)-D-sorbitol; 1,3:2,4-Di-O-(3,4-dimethylbenzylidene)-D-sorbitol or mixtures thereof.

[0036] Preferred gel bodies contain as a gelling agent at least one 2,5-diketopiperazine compound of formula (GB-II) wherein R1<, R2<, R3< and R4< independently represent a hydrogen atom, a hydroxyl group, a (C1-C6) alkyl group, a (C2-C6) alkenyl group, a (C2-C6) acyl group, a (C2-C6) acyloxy group, a (C1-C6) alkoxy group, an amino group, a (C2-C6) acylamino group, a (C1-C6) alkylaminocarbonyl group, an aryl group, an aroyl group, an aroyloxy group, an aryloxy group, an aryl-(C1-C4) alkyloxy group, an aryl-(C1-C3) alkyl group, a heteroaryl group, a heteroaryl-(C1-C3) alkyl group, a (C 1-C4)-hydroxyalkyl group, a (C1-C4)-aminoalkyl group, a carboxy-(C1-C3)-alkyl group, wherein at least two of the residues R1< to R4< can form a 5- or 6-membered ring together with the remaining molecule, R5< represents a hydrogen atom, a linear (C1 to C6)-alkyl group, a branched (C3 to C10)-alkyl group, a (C3 to C6)-cycloalkyl group, a (C2-C6)-alkenyl group,a (C2-C6)-alkynyl group, a (C1-C4)-hydroxyalkyl group, a (C1-C4)-alkoxy-(C1-C4)-alkyl group, a (C1-C4)-acyloxy-(C1-C4)-alkyl group, an aryloxy-(C1-C4)-alkyl group, an O-(aryl-(C1-C4)-alkyl)oxy-(C1-C4)-alkyl group, a (C1-C4)-alkylsulfanyl-(C1-C4)-alkyl group, an aryl group, an aryl-(C1-C3)-alkyl group, a heteroaryl group, a heteroaryl-(C1-C3)-alkyl group, a (C1-C4)-hydroxyalkyl group, a (C1-C4)-aminoalkyl group, an N-(C1-C4)-alkylamino-(C1-C4)-alkyl group, an N,N-(C1-C4)-dialkylamino-(C1-C4)-alkyl group, an N-(C2-C8)-acylamino-(C1-C4)-alkyl group, an N-(C2-C8)-acyl-N-(C1-C4)-alkylamino-(C1-C4)-alkyl group, an N-(C2-C8)-aroyl-N-(C1-C4)-alkylamino-(C1-C4)-alkyl group, an N,N-(C2-C8)-diacylamino-(C1-C4)-alkyl group, a N-(aryl-(C1-C4)-alkyl)amino-(C1-C4)-alkyl group, an N,N-Di(aryl-(C1-C4)-alkyl)amino-(C1-C4)-alkyl group, a (C1-C4)-carboxyalkyl group, a (C1-C4)-alkoxycarbonyl-(C1-C3)-alkyl group, a (C1-C4)-acyloxy-(C1-C3)-alkyl group, a guanidino-(C1-C3)-alkyl group, an aminocarbonyl-(C1-C4)-alkyl group, an N-(C1-C4)-alkylaminocarbonyl-(C1-C4)-alkyl group, an N,N-Di((C1-C4)-alkyl)aminocarbonyl-(C1-C4)-alkyl group, an N-(C2-C8 )-Acylaminocarbonyl-(C 1 -C 4 )-alkyl group, an N,N-(C 2 -C 8 )-diacylaminocarbonyl-(C 1 -C 4 )-alkyl group, an N-(C 2 -C 8 )-acyl-N-(C 1 -C 4 )-alkylaminocarbonyl-(C 1 -C 4 )-alkyl group, an N-(aryl-(C 1 -C 4 )-alkyl)aminocarbonyl-(C 1 -C 4 )-alkyl group, an N-(aryl-(C 1 -C 4 )-alkyl)-N-(C 1 -C 6 )-alkylaminocarbonyl-(C 1 -C 4 )-alkyl group or one N,N-Di(aryl-(C 1 -C 4 )alkyl)aminocarbonyl-(C 1 -C 4 )alkyl group. ,

[0037] According to the invention, it is preferred if R3< and R4< represent a hydrogen atom according to formula (GB-II). It is particularly preferred if R2<, R3<, and R4< represent a hydrogen atom according to formula (GB-II). Therefore, particularly preferred molded bodies according to the invention contain at least one 2,5-diketopiperazine compound according to formula (GB-IIa). wherein R 1< and R 5< are defined as under formula (GB-II) (vide supra).

[0038] It has proven preferable if the residue R 1< according to formula (GB-II) and according to formula (GB-IIa) binds in the para position of the phenyl ring. Therefore, for the purposes of the present invention, those shaped bodies according to the invention are preferred which contain at least one 2,5-diketopiperazine compound according to formula (GB-IIb). wherein R1< and R5< are defined as above under formula (GB-II) (see above). The numbers 3 and 6 positioned at the ring atoms in formula (GB-IIb) merely mark, for illustrative purposes, positions 3 and 6 of the diketopiperazine ring, as they are generally used within the scope of the invention for naming all 2,5-diketopiperazines according to the invention.

[0039] The 2,5-diketopiperazine compounds of formula (GB-II) exhibit chiral centers at least at the carbon atoms of positions 3 and 6 of the 2,5-diketopiperazine ring. The numbering of ring positions 3 and 6 is illustrated by way of example in formula (GB-Ilb). The 2,5-diketopiperazine compound of formula (GB-II) of the compositions according to the invention is preferably, with respect to the stereochemistry of the carbon atoms at positions 3 and 6 of the 2,5-diketopiperazine ring, the configurational isomer 3S,6S, 3R,6S, 3S,6R, 3R,6R or mixtures thereof, particularly preferably 3S,6S.

[0040] Preferred gel bodies contain at least one 2,5-diketopiperazine compound of formula (GB-II) as a gelling agent, selected from 3-benzyl-6-carboxyethyl-2,5-diketopiperazine, 3-benzyl-6-carboxymethyl-2,5-diketopiperazine, 3-benzyl-6-(p-hydroxybenzyl)-2,5-diketopiperazine, 3-benzyl-6-iso-propyl-2,5-diketopiperazine, 3-benzyl-6-(4-aminobutyl)-2,5-diketopiperazine, 3,6-di(benzyl)-2,5-diketopiperazine, 3,6-di(p-hydroxybenzyl)-2,5-diketopiperazine, 3,6-di(p-(benzyloxy)benzyl)-2,5-diketopiperazine, 3-Benzyl-6-(4-imidazolyl)methyl-2,5-diketopiperazine, 3-Benzyl-6-methyl-2,5-diketopiperazine, 3-Benzyl-6-(2-(benzyloxycarbonyl)ethyl)-2,5-diketopiperazine, or mixtures thereof. Compounds with the aforementioned configurational isomers are particularly suitable for selection.

[0041] It is also possible that the gel bodies according to the invention contain, as gelling agents, a) at least one diarylamidocystin compound of formula (GB-III). wherein X+< independently represents a hydrogen atom or an equivalent of a cation, R1<, R2<, R3< and R4< independently represent a hydrogen atom, a halogen atom, a C1-C4 alkyl group, a C1-C4 alkoxy group, a C2-C4 hydroxyalkyl group, a hydroxyl group, an amino group, an N-(C1-C4 alkyl)amino group, an N,N-di(C1-C4 alkyl)amino group, an N-(C2-C4 hydroxyalkyl)amino group, an N,N-di(C2-C4 hydroxyalkyl)amino group, or R1< with R2< or R3< with R4< forms a 5- or 6-membered annealed ring, which in turn is linked with at least one group consisting of a C1-C4 alkyl group, a C1-C4 alkoxy group, C 2-C4-hydroxyalkyl group, hydroxyl group, amino group, N-(C1-C4-alkyl)amino group, N,N-Di(C1-C4-alkyl)amino group, N-(C2-C4-hydroxyalkyl)amino group, N,N-Di(C2-C4-hydroxyalkyl)amino group.

[0042] Each of the stereocenters contained in the compound of formula (GB-III) can independently represent the L- or D-stereoisomer. According to the invention, it is preferred if said cystine compound of formula (GB-III) is derived from the L-stereoisomer of cysteine.

[0043] The gel bodies in question may contain at least one compound of the formula (GB-III) in which R 1< , R 2< , R 3< and R 4< independently represent a hydrogen atom, a halogen atom, a C 1 -C 4 alkyl group, a C 1 -C 4 alkoxy group, a C 2 -C 4 hydroxyalkyl group, a hydroxyl group, or R 1< with R 2< or R 3< with R 4< forms a 5- or 6-membered annealed ring, which in turn may each be substituted with at least one group consisting of a C 1 -C 4 alkyl group, a C 1 -C 4 alkoxy group, a C 2 -C 4 hydroxyalkyl group, or a hydroxyl group. In particular, such shaped bodies are especially suitable which contain as diarylamidocystine compound of the formula (GB-III) N,N'-dibenzoylcystine (R 1< = R 2< = R 3< = R 4< = hydrogen atom; X +< = independently of each other for hydrogen atom or an equivalent of a cation), in particular N,N'-dibenzoyl-L-cystine.

[0044] The N-(C 8 -C 24 )-hydrocarbylglyconamide compounds suitable as gelling agents a) preferably have the formula (GB-IV) where n 2 to 4, preferably 3 or 4, in particular 4, is; R 1< is selected from hydrogen, C 1 - C 16 alkyl groups, C 1 - C 3 hydroxy or methoxyalkyl groups, preferably C 1 - C 3 alkyl, hydroxyalkyl or methoxyalkyl groups, particularly preferably methyl; R 2< is selected from C 8 -C 24 alkyl groups, C 8 -C 24 monoalkenyl groups, C 8 -C 24 dialkenyl groups, C 8 -C 24 trialkenyl groups, C 8 -C 24 hydroxyalkyl groups, C 8 -C 24 hydroxyalkenyl groups, C 1 -C 3 hydroxyalkyl groups or methoxy-C 1 -C 3 alkyl groups, preferably C 8 -C 18 alkyl groups and mixtures thereof, more preferably C 8 , C 10 , C 12 , C 14 , C 16 and C 18 alkyl groups and mixtures thereof, most preferably C 12 and C 14 alkyl groups or a mixture thereof.

[0045] In particularly preferred embodiments, the remainder A residue derived from a glycuronic acid, in particular the glycuronic acid of a hexose (n=4). Glucuronic acid is a particularly preferred residue. R1< is preferably H or a short-chain alkyl residue, in particular methyl. R2< is preferably a long-chain alkyl residue, for example a C8-C18 alkyl residue.

[0046] Compounds of formula (GB-IV1) are therefore particularly preferred. where R 2< has the meanings given for formula (GB-IV).

[0047] In a particularly preferred embodiment, the at least one low-molecular-weight gelling agent of the second free-flowing gelling agent-containing composition is selected from the group consisting of cyclic dipeptides, cyclic dipeptide derivatives, and dibenzylidene sorbitols. Due to its technical properties, the at least one gelling agent of the second free-flowing gelling agent-containing composition, dibenzylidene sorbitol (DBS), is particularly preferred.

[0048] In step iii) of the process, the first and second flowable compositions are fed to the mold. In a non-inventive embodiment of the process, the first and second flowable compositions are fed to the mold in the same line. This method is characterized by a reduced apparatus setup. Partial mixing of the first and second flowable compositions can occur in the feed line leading to the mold. The disadvantages of this method are reduced control over the gelation process and, in the event of a production interruption, increased cleaning effort before restarting the production apparatus.

[0049] For the latter reasons, according to the invention, the first flowable composition and the second flowable composition are supplied to the mold in separate lines.

[0050] Materials suitable for manufacturing the mold include those known to experts for the production of casting molds, such as materials from the groups of metals, polymers, or rubbers. With regard to forming the gel body from the mold, materials from the silicone group have proven particularly suitable.

[0051] In step iv) of the process, the first and second flowable compositions are introduced into the mold. In a non-inventive embodiment of the process, the first and second flowable compositions are introduced into the mold using a common injector. This method, as with the previously described common feed, is characterized by a reduced apparatus setup. Additionally, in this case as well, partial mixing of the first and second flowable compositions can occur directly in the common injector. However, the disadvantages of this method, albeit to a lesser extent than with the common feed, are reduced control over the gelation process and, in the event of a production interruption, increased cleaning effort before restarting the production apparatus.

[0052] For the latter reasons, according to the invention, the first flowable composition and the second flowable composition are introduced into the mold by means of separate injectors.

[0053] An injector is a device suitable for introducing a flowable composition into a mold. Examples of injectors include filling nozzles and nozzles.

[0054] In a preferred method variant, the first flowable composition and the second flowable composition are introduced into the mold simultaneously in step iv). This procedure improves the desired mixing of the two compositions due to turbulent flow.

[0055] The process according to the invention is particularly suitable for processes in which flowable compositions are mixed in significantly different weight proportions. Thus, in the process according to the invention, the first flowable composition and the second flowable composition are preferably mixed in a weight ratio of 50:1 to 5:1, more preferably from 35:1 to 8:1.

[0056] The introduction of the first flowable composition and the second flowable composition into the mold preferably takes place at a filling rate of 1 ml / s to 25 ml / s.

[0057] For process efficiency, it has also proven advantageous to lower the dynamic mixing device before introducing the first and second flowable compositions into the mold. It is particularly preferred to introduce the first and second flowable compositions into the effective area of ​​the mixing element of the dynamic mixing device.

[0058] For example, impeller mixers can be used as mixers. Preferred mixing devices have a gear as the mixing element. The use of a dynamic mixing device comprising two meshing gears as the mixing element is particularly preferred. A corresponding arrangement of the mixing elements not only enables the homogeneous mixing of the two flowable compositions but also ensures continuous cleaning of the two gears used as mixing elements.

[0059] The mixing element preferably fills only 1 to 10 vol.%, more preferably 2 to 8 vol.% of the internal volume of the mold. It is preferably positioned at the center of the mold. Positioning the mixing element near the bottom of the mold is also preferred, as this allows its effect on the two compositions to begin early.

[0060] To aid the mixing process, the mixing element and the mold in step v) can be moved relative to each other. Such relative movement can be achieved by moving the mixing element, the mold, or both the mixing element and the mold. This relative movement improves the mixing of the two compositions within the mold.

[0061] A technically simple preferred method variant involves moving the mixing element within the mold in step v). This movement can occur horizontally, vertically, or both horizontally and vertically. In a horizontal movement, the mixing element moves parallel to the mold's opening surface; in a vertical movement, the movement is perpendicular to this surface.

[0062] Alternatively, or in conjunction with the movement of the mixing element, the mold can be moved in step v). Such relative movement can result, for example, from transporting the mold on a conveyor belt or from a vibration of the mold. The mold can also move horizontally, vertically, or both horizontally and vertically. In a horizontal movement, the mold's direction of movement is parallel to its opening surface; in a vertical movement, the direction of movement is perpendicular to this surface.

[0063] The mixing of the first flowable composition and the second flowable composition in step v) preferably takes place over a period of 1 to 20 seconds, preferably from 2 to 10 seconds.

[0064] In step vi) of the process, the surfactant- and gelling agent-containing mixture solidifies in the mold, forming a dimensionally stable gel. To accelerate the solidification process, the surfactant- and gelling agent-containing mixture can be cooled in step vi). Cooling preferably takes place under defined climatic conditions, in which, in addition to the temperature, the humidity in the process chamber is also monitored and controlled.

[0065] Finally, the dimensionally stable gel body can be removed from the mold.

[0066] For the production of detergent portion units, which include other components besides the gel body, a suitable procedure is to combine the gel body with a pre-made molded body.

[0067] In a first preferred method, the mold into which the first and second flowable preparations are introduced in step iv) is partially filled with a pre-made mold body. The pre-made mold body preferably covers at least part, and more preferably completely, the bottom surface of the mold into which the first and second flowable preparations are introduced in step iv).

[0068] In an alternative or, in combination with, the second preferred method described above, the surfactant- and gelling agent-containing mixture is covered with a pre-formed mold body before, during, or after solidification in step vi). It is preferred that the entire surface of the surfactant- and gelling agent-containing mixture visible in the mold is covered with a pre-formed mold body.

[0069] If the surfactant- and gelling agent-containing mixture is introduced into the mold onto a first pre-made molded body and the side opposite the side covered by the first pre-made molded body is covered with a second pre-made molded body, a sandwich-like detergent portion unit is obtained that is particularly advantageous in terms of handling and appearance.

[0070] A particularly preferred method variant for the production of a detergent portion unit, comprising a) a dimensionally stable gel body b) two molded bodies The steps include: i) Providing a first free-flowing surfactant-containing composition; ii) Providing a second free-flowing composition containing a gelling agent, different from the first free-flowing composition; iii) Feeding the first and second free-flowing compositions into a mold; iv) Introducing the first and second free-flowing compositions into the mold, the bottom of which is at least partially covered by a first pre-formed mold body; v) Mixing the first and second free-flowing compositions in the mold by means of a dynamic mixing device to form a surfactant-containing and gelling agent-containing mixture; vi) Covering the side of the dimensionally stable gel body opposite the side covered by the first pre-formed mold body with a second pre-formed mold body; vii) Allowing the surfactant-containing and gelling agent-containing mixture to solidify in the mold to form a dimensionally stable gel body;viii) Molding the gel body to form a detergent portion unit comprising a gel body and the first and second pre-formed molded bodies; wherein the first flowable composition and the second flowable composition are introduced into the mold by means of separate injectors.

[0071] Preferred molded parts fill 5 to 45 vol.%, preferably 10 to 25 vol.% of the mold.

[0072] The molded part can be manufactured in various ways. The use of cast parts has proven to be a technically simple method. Manufacturing the molded part through casting processes has the advantage that a wide variety of geometries can be produced. Ideally, the cast parts are solidified molten metal.

[0073] Due to their ease of large-scale production, pressed bodies, especially tablets, are particularly preferred as molded bodies.

[0074] Regardless of the manufacturing process used, the molded tablet preferably has a breaking strength of 50 N to 300 N, particularly 50 N to 150 N. This breaking strength ensures, firstly, sufficient stability of the molded tablet during production, transport, and handling by the consumer, and secondly, satisfactory dissolution behavior of the molded tablet in an aqueous solution. The hardness of the molded tablet is measured by deformation until fracture, whereby the force acts on the side surfaces of the molded tablet and the maximum force with which they can withstand is determined. A tablet testing device from Sotax, for example, is suitable for determining the molded tablet hardness.

[0075] Preferred molded bodies have a printed design.

[0076] If the gel body is combined with a molded body as described above, the dimensionally stable gel body, partially covered by the molded body, is then removed from the mold. The gel body and the molded body are preferably bonded together.

[0077] In a preferred embodiment of the detergent portion units, the molded body also contributes to the washing and cleaning effect. Such detergent portion units comprise a molded body which, based on its total weight, contains more than 40% by weight, preferably more than 60% by weight, and particularly preferably more than 80% by weight, of washing or cleaning active ingredient.

[0078] The first group of washing or cleaning active ingredients integrated into the molded body consists of fragrances. Their incorporation into the molded body ensures a perceptible fragrance experience for the consumer, which cannot be guaranteed to the same extent if the fragrances are incorporated into the gel body.

[0079] Another group of washing- or cleaning-active ingredients preferably incorporated into the coating material consists of the base materials, in particular citrates, zeolites, silicates, and carbonates, especially citrates and zeolites. The weight fraction of these active ingredients in the total weight of the coating material is preferably 5 to 60 wt.%, in particular 10 to 50 wt.%. Coating materials containing 5 to 60 wt.%, in particular 10 to 50 wt.%, of citrate and / or zeolite, based on their total weight, are particularly preferred. These active ingredients not only contribute to the intended washing and cleaning effect but also improve the contour sharpness and durability of the printed image if the surface of the molded part is printed.

[0080] For improved contour sharpness and durability of the printed image, the use of an active ingredient from the group of polymeric washing or cleaning agents, preferably from the group of celluloses and cellulose derivatives and anionic or non-ionic aromatic polyesters, more preferably from the group of celluloses, microcrystalline celluloses and carboxymethylcelluloses, and anionic or non-ionic aromatic polyesters, is also advantageous. The weight fraction of these cellulose-based active ingredients in the total weight of the coating material is preferably 2 to 50 wt.%.

[0081] The composition of some preferred detergent portion units can be found in the following tables (values ​​in wt% based on the total weight of the gel body or the coating substance unless otherwise stated). formula 1 Formula 2 Formula 3 Formula 4 Gel body Total surfactant 30 to 70 40 to 60 40 to 60 45 to 55 Anionic surfactant 20 to 40 20 to 40 25 to 35 25 to 35 Alkylethoxylate 15 to 30 15 to 30 20 to 30 20 to 30 Enzyme preparation 0.2 to 8 0.3 to 6 0.3 to 6 0.3 to 6 organic solvent 5 to 30 5 to 30 10 to 28 10 to 28 Water < 20 1 to 15 2 to 14 3 to 13 Gelling agent 0.1 to 5 0.1 to 5 0.1 to 2.5 0.1 to 2.5 Misc ad 100 ad 100 ad 100 ad 100 Molded body Framework material from the group of citrates, zeolites, silicates and carbonates 5 to 90 50 to 90 50 to 80 50 to 80 Formula 6 Formula 7 Formula 8 Formula 9 Gel body Total surfactant 30 to 70 40 to 60 40 to 60 45 to 55 Anionic surfactant 20 to 40 20 to 40 25 to 35 25 to 35 Alkylethoxylate 15 to 30 15 to 30 20 to 30 20 to 30 Enzyme preparation 0.2 to 8 0.3 to 6 0.3 to 6 0.3 to 6 organic solvent 5 to 30 5 to 30 10 to 28 10 to 28 Water < 20 1 to 15 2 to 14 3 to 13 Gelling agent 0.1 to 5 0.1 to 5 0.1 to 2.5 0.1 to 2.5 Misc ad 100 ad 100 ad 100 ad 100 coating substance Framework material from the group of citrates, zeolites, silicates and carbonates 5 to 90 50 to 90 50 to 80 50 to 80 Cellulose and cellulose derivatives 0.5 to 10 1.0 to 8.0 1.0 to 5.0 1.0 to 5.0 Formula 11 Formula 12 Formula 13 Formula 14 Gel body Total surfactant 30 to 70 40 to 60 40 to 60 45 to 55 Anionic surfactant 20 to 40 20 to 40 25 to 35 25 to 35 Alkylethoxylate 15 to 30 15 to 30 20 to 30 20 to 30 Enzyme preparation 0.2 to 8 0.3 to 6 0.3 to 6 0.3 to 6 organic solvent 5 to 30 5 to 30 10 to 28 10 to 28 Water < 20 1 to 15 2 to 14 3 to 13 Gelling agent 0.1 to 5 0.1 to 5 0.1 to 2.5 0.1 to 2.5 Misc ad 100 ad 100 ad 100 ad 100 coating substance Framework material from the group of citrates and zeolites 10 to 70 20 to 60 20 to 60 30 to 50 Formula 15 Formula 16 Formula 17 Formula 18 Gel body Total surfactant 30 to 70 40 to 60 40 to 60 45 to 55 Anionic surfactant 20 to 40 20 to 40 25 to 35 25 to 35 Alkylethoxylate 15 to 30 15 to 30 20 to 30 20 to 30 Enzyme preparation 0.2 to 8 0.3 to 6 0.3 to 6 0.3 to 6 organic solvent 5 to 30 5 to 30 10 to 28 10 to 28 Water < 20 1 to 15 2 to 14 3 to 13 Gelling agent 0.1 to 5 0.1 to 5 0.1 to 2.5 0.1 to 2.5 Misc ad 100 ad 100 ad 100 ad 100 coating substance Framework material from the group of citrates and zeolites 10 to 70 20 to 60 20 to 60 30 to 50 Cellulose and cellulose derivatives 0.5 to 10 1.0 to 8.0 1.0 to 5.0 1.0 to 5.0

[0082] In summary, this registration provides, among other things, the following items: 1. A method for producing a detergent portion unit, comprising: a) a shape-stable gel body, comprising the steps of: i) providing a first free-flowing surfactant-containing composition; ii) providing a second free-flowing gel-forming composition different from the first free-flowing composition; iii) feeding the first and second free-flowing compositions to a mold; iv) introducing the first and second free-flowing compositions into the mold; v) mixing the first and second free-flowing compositions in the mold by means of a dynamic mixing device to form a surfactant-containing and gel-forming mixture; vi) allowing the surfactant-containing and gel-forming mixture to solidify in the mold to form a shape-stable gel body, wherein the first free-flowing composition and the second free-flowing composition are introduced into the mold by means of separate injectors. 2.1. Method according to point 1, wherein the gel body has a weight of 14 g to 42 g, preferably 18 g to 38 g, and particularly 20 g to 34 g. 3. Method according to any of the preceding points, wherein the gel body has a flat bottom surface, the largest diagonal of which is greater than the height of the gel body. 4. Method according to any of the preceding points, wherein the gel body has a flat bottom surface, the largest diagonal of which is more than 1.5 times, preferably more than 2 times, the height of the gel body. 5. Method according to any of the preceding points, wherein the gel body has an oval bottom surface. 6. Method according to any of the preceding points, wherein the gel body has an ellipsoidal or round, preferably round, bottom surface. 7. Method according to any of the preceding points, wherein the gel body has an angular bottom surface. 8. Method according to any of the preceding points, wherein the gel body has a triangular, square, or hexagonal bottom surface. 9.10. Method according to any of the preceding points, wherein the gel body has a square bottom surface with rounded corners. 11. Method according to any of the preceding points, wherein the gel body has a top surface that is plane parallel to the bottom surface. 12. Method according to any of the preceding points, wherein the gel body has a bottom surface and a top surface that have the same geometric shape and wherein the bottom surface and the top surface have the same area. 13. Method according to any of the preceding points, wherein the gel body has a bottom surface and a top surface that have the same geometric shape and wherein the bottom surface and the top surface have different area sizes. 14. Method according to any of the preceding points, wherein the gel body has a bottom surface and a top surface that are connected to each other by a cylindrical lateral surface.A method according to any one of the preceding points, wherein the gel body has a bottom and a top surface, and the area of ​​the bottom surface comprises 80 to 100%, preferably 90 to 100%, and particularly 98 to 100%, of the top surface. 15. A method according to any one of the preceding points, wherein the mold is made of a material from the group consisting of metals, polymers, or rubbers. 16. A method according to any one of the preceding points, wherein the mold is made of a material from the group consisting of silicones. 17. A method according to any one of the preceding points, wherein the first flowable composition and the second flowable composition are introduced into the mold simultaneously. 18. A method according to any one of the preceding points, wherein the first flowable composition and the second flowable composition are mixed in the mold in a weight ratio of 50:1 to 5:1, preferably 35:1 to 8:1. 19.20. Method according to any of the preceding points, wherein the first flowable composition and the second flowable composition are introduced into the mold at a filling rate of 1 ml / s to 25 ml / s. 21. Method according to any of the preceding points, wherein the mixing element of the dynamic mixing device is lowered before the first flowable composition and the second flowable composition are introduced into the mold. 22. Method according to any of the preceding points, wherein the first flowable composition and the second flowable composition are introduced into the effective area of ​​the mixing element of the dynamic mixing device. 23. Method according to any of the preceding points, wherein the dynamic mixing device comprises a gear as the mixing element. 24.25. Method according to any of the preceding points, wherein the mixing element fills 1 to 10 vol.%, preferably 2 to 8 vol.%, of the internal volume of the mold. 26. Method according to any of the preceding points, wherein the mixing element of the dynamic mixing device is located at the center of volume of the mold. 27. Method according to any of the preceding points, wherein in step v) the mixing element and the mold are moved relative to each other. 28. Method according to any of the preceding points, wherein in step v) the mixing element is moved in the mold. 29. Method according to any of the preceding points, wherein in step v) the mixing element is moved in the mold in a horizontal and / or vertical direction. 30. Method according to any of the preceding points, wherein in step v) the mold is moved in a horizontal and / or vertical direction. 31.32. A method according to any of the preceding points, wherein the mixing of the first flowable composition and the second flowable composition in step v) takes place over a period of 1 to 20 seconds, preferably 2 to 10 seconds. 33. A method according to any of the preceding points, wherein the surfactant- and gel-forming-containing mixture is cooled in step vi). 34. A method according to any of the preceding points, wherein the dimensionally stable gel body is subsequently formed from the mold following step vi). 35. A method according to any of the preceding points, wherein the mold into which the first and second flowable preparations are introduced in step iv) is partially filled with a pre-formed mold body. 36. A method according to point 34, wherein the bottom surface of the mold into which the first and second flowable preparations are introduced in step iv) is at least partially, preferably completely, covered with a pre-formed mold body. 37.A method according to any of the preceding points, wherein the surfactant- and gelling agent-containing mixture is covered with a pre-molded body before, during, or after solidification in step vi). 37. A method according to point 36, wherein the surface of the surfactant- and gelling agent-containing mixture is completely covered with a pre-molded body. 38. A method according to any of points 34 to 37, wherein the pre-molded body fills 5 to 45 vol.%, preferably 10 to 25 vol.%, of the mold. 39. A method according to any of points 34 to 38, wherein the molded body is a cast body. 40. A method according to any of points 34 to 39, wherein the molded body is a compressed body, preferably a tablet. 41. A method according to any of points 34 to 40, wherein the molded body has a tensile strength of 30 N to 300 N, preferably 50 N to 150 N. 42. A method according to any of points 34 to 41, wherein the molded body has a print. 43.A method according to any one of points 34 to 42, wherein the shape-stable gel body, partially covered by a mold, is formed from the mold following step vi). 44. A method according to any one of the preceding points, wherein the first free-flowing surfactant-containing composition contains, based on its total weight, 30 to 70 wt.%, preferably 40 to 60 wt.%, and particularly 45 to 55 wt.% surfactant. 45. A method according to any one of the preceding points, wherein the shape-stable gel body contains, based on its total weight, 15 to 35 wt.%, preferably 20 to 30 wt.%, an aqueous-organic solvent. 46. ​​A method according to any of the preceding points, wherein the second flowable gelling agent-containing composition contains a low molecular weight gelling agent with a molar mass of up to 2000 g / mol, wherein the weight fraction of the gelling agent in relation to the total weight of the gel is preferably less than 5 wt.%, more preferably 0.1 to 5 wt.%, and particularly preferably 0.1 to 2.5 wt.%. 47.A method according to any of the preceding points, wherein the second flowable gelling agent-containing composition contains a low molecular weight gelling agent selected from the group consisting of cyclic dipeptides, cyclic dipeptide derivatives, and dibenzylidene sorbitols. 48. A method according to any of the preceding points, wherein the second flowable gelling agent-containing composition contains dibenzylidene sorbitol as a low molecular weight gelling agent. 49. A method according to any of the preceding points, wherein the second flowable gelling agent-containing composition further contains an organic solvent. 50. A method according to any of the preceding points, wherein the second flowable gelling agent-containing composition contains gelling agents and organic solvents in a total weight fraction above 50 wt%, preferably above 70 wt%, and particularly above 90 wt%. 51. A method according to any of points 34 to 50, wherein the molded body contains, based on its total weight, more than 40 wt%.-%, preferably more than 60 wt.%, particularly preferably more than 80 wt.% washing or cleaning active ingredient. 52. Method according to any one of points 34 to 51, wherein the molded body contains a washing or cleaning active ingredient from the group of fragrances. 53. Method according to any one of points 34 to 54, wherein the molded body contains a washing or cleaning active ingredient from the group of framework materials, in particular at least one active ingredient from the group of citrates, zeolites, silicates and carbonates, preferably from the group of citrates and zeolites. 54.A method according to any one of points 34 to 53, wherein the molded body contains a polymeric washing or cleaning active ingredient, preferably a polymeric washing or cleaning active ingredient from the group consisting of celluloses and cellulose derivatives and anionic or non-ionic aromatic polyesters, preferably from the group consisting of celluloses, microcrystalline celluloses and carboxymethylcelluloses, and anionic or non-ionic aromatic polyesters. 55. A method according to any one of points 34 to 54, wherein the gel body and the molded body are bonded together.

Claims

1. A method for producing a detergent portion unit, comprising a) a dimensionally stable gel body, comprising the steps of: i) providing a first flowable composition containing surfactants; ii) providing a second flowable composition containing a gelling agent, which is different from the first flowable composition; iii) feeding the first and second flowable compositions into a mould; iv) introducing the first and second flowable compositions into the mould; v) mixing the first and second flowable compositions in the mould by means of a dynamic mixing device to form a mixture containing a surfactant and a gelling agent; vi) allowing the mixture containing surfactant and gelling agent to set in the mould to form a dimensionally stable gel body, wherein the first flowable composition and the second flowable composition are introduced into the mould by means of separate injectors.

2. A method according to any of the preceding claims, wherein the first flowable composition and the second flowable composition are mixed in the mould in a weight ratio of 50:1 to 5:1, preferably of 35:1 to 8:1.

3. A method according to any of the preceding claims, wherein the dynamic mixing device comprises two intermeshing gears as the mixing element.

4. A method according to any of the preceding claims, wherein, in step v), the mixing element and the mould are moved relative to one another.

5. A method according to any of the preceding claims, wherein the mixing of the first flowable composition and the second flowable composition in step v) takes place over a period of 1 to 20 seconds, preferably 2 to 10 seconds.

6. A method according to any of the preceding claims, wherein the mould into which the first and second flowable compositions are introduced in step iv) is partially filled with a preformed moulded body.

7. A method according to any of the preceding claims, wherein the first flowable surfactant-containing composition contains, based on its total weight, 30 to 70% by weight, preferably 40 to 60% by weight and in particular 45 to 55% by weight of surfactant.

8. A method according to any of the preceding claims, wherein the second flowable gel-forming agent-containing composition contains a low-molecular-weight gel-forming agent with a molar mass of up to 2000 g / mol, wherein its weight fraction of the total weight of the gel body is preferably less than 5 wt.%, more preferably 0.1 to 5 wt.%, and, more particularly, 0.1 to 2.5 wt%.