Process for manufacturing a detergent portion unit

Abstract

Disclosed is a process for manufacturing a detergent portion unit comprising a) a dimensionally stable solid gel, the process involving the steps of: i) providing a first free-flowing surfactant-containing composition; ii) providing a second free-flowing composition that contains a gelatinizing agent and is different from the first free-flowing composition; iii) continuously feeding the first and second free-flowing compositions to a mixing device; iv) mixing the first and second free-flowing compositions by means of the mixing device such that a mixture containing surfactant and a gelatinizing agent is formed; v) continuously conveying the mixture containing surfactant and a gelatinizing agent through a shaping device such that the mixture containing surfactant and a gelatinizing agent solidifies in the shaping device and a dimensionally stable solid gel bar is formed; vi) continuously conveying the dimensionally stable solid gel bar out of the shaping device.

Description

[0001] .Method for producing a detergent portion unit'

[0002] The present invention relates to a process for producing a detergent portion unit comprising a gel body.

[0003] The packaging and distribution of detergents and cleaning agents are constantly evolving. For some time now, a key focus has been on convenient dosing of detergents and cleaning agents for consumers and simplifying the steps required to carry out a washing or cleaning process. 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 detergent tablets, which can be designed as single- or multi-phase products.

[0004] To produce the 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 deep-drawing process. In an alternative process, a water-soluble polymer is formed into a receiving container using injection molding.

[0005] The water-soluble packaging material used to package the filled detergent portion units is generally hygroscopic. The water absorption capacity and tendency of the packaging material during production, packaging, storage, and subsequent use by the consumer can lead to portion units adhering to the surfaces of machines or packaging materials and preventing optimal conveyance, or to adjacent portion units sticking together, for example, in shared outer packaging. To prevent this tendency of the water-soluble portion units to adhere, it is possible to modify their surface properties by applying a powder. Powdering the water-soluble detergent portion units, in turn, requires an additional process step.

[0006] The water-soluble packaging materials used generally do not have any washing or cleaning properties, and therefore do not contribute to the product's effectiveness. Reducing the proportion of packaging in the total weight of detergent portion units would therefore not result in any loss of performance and would be welcome for reasons of sustainability and cost-effectiveness.

[0007] Finally, the washing performance achieved by the detergent dosage unit is directly related to its dissolution properties. Especially in view of the increasing use of cold-wash processes, it is preferable to keep the thickness of the water-soluble film material contained in the detergent dosage unit as low as possible in order to accelerate the dissolution process. However, reducing the thickness of the surrounding film material simultaneously results in reduced mechanical stability of the dosage units. Overcoming this apparent dichotomy between mechanical stability and dissolution rate using water-soluble film-packaged detergent dosage units remains a relevant consideration in the development of water-soluble detergent dosage units.

[0008] An alternative to the previously described sachets is offered by detergent tablets, although sufficient mechanical stability and a high dissolution rate are incompatible in a similar way to the case of sachets.

[0009] An alternative to fully compressed detergent tablets is offered by 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 a non-compressed gel phase, and processes for their production.

[0010] Against the background of the previously described prior art, the application was based on the objective of providing efficient processes for the production of rapidly dissolving detergent portion units that exhibit high product and storage stability, are easy to package using minimal packaging materials, and appeal to the consumer through an appealing olfactory, visual, and / or tactile quality. The detergent portion units should exhibit high product performance and be easy and safe to handle for the consumer.

[0011] A first subject matter of the application is a method for producing 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 agent-containing composition different from the first flowable composition; iii) continuously feeding the first and second flowable compositions to a mixing device; iv) mixing the first and second flowable compositions by means of the mixing device to form a surfactant-containing and gel-forming agent-containing mixture; v) continuously passing the surfactant-containing and gel-forming agent-containing mixture through a forming device to solidify the surfactant-containing and gel-forming agent-containing mixture in the forming device to form a dimensionally stable gel body strand;vi) continuously discharging the dimensionally stable gel body strand from the forming device;

[0012] The term "detergent portion unit" describes a packaging containing a measured portion of a detergent or cleaning agent. Detergent portion units therefore refer to packaging for both textile washing and packaging for cleaning hard surfaces such as ceramics, glass, metal, or tiles. The detergent portion unit preferably has a weight of 14 g to 42 g, preferably 18 g to 38 g, and in particular 20 g to 34 g.

[0013] The detergent portion unit comprises a gel body. The detergent portion unit can consist of the gel body. In this case, the gel body preferably has a weight of 14 g to 42 g, preferably 18 g to 38 g, in particular 20 g to 34 g. If the detergent portion unit comprises further components in addition to the gel body, the weight of the gel body is preferably 10 g to 28 g, preferably 12 g to 23 g, and in particular 15 g to 20 g.

[0014] Gel bodies are bodies that exhibit elastic deformation behavior under the application of force. Bodies are considered dimensionally stable if they have an intrinsic shape stability that enables them to assume a non-disintegrating spatial shape under normal conditions of production, storage, transport, and handling by the consumer. This spatial shape does not change under these conditions even over a prolonged period, preferably 4 weeks, more preferably 8 weeks, and especially 32 weeks. This means that under the normal conditions of production, storage, transport, and handling by the consumer, they remain in the spatial-geometric shape determined by production, i.e., they do not melt.

[0015] The process is particularly suitable for the manufacture of gel bodies with a high surfactant content. In preferred embodiments, the first flowable surfactant-containing composition contains, based on its total weight, 30 to 70 wt.%, preferably 40 to 60 wt.%, and in particular 45 to 55 wt.% surfactant.

[0016] For the producibility and subsequent dissolving power of the gel bodies, it has proven advantageous if they 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 flowable compositions. Thus, it is preferred if the second flowable gel-forming agent-containing composition also contains an organic solvent. Particularly preferred flowable gel-forming agent-containing compositions contain gel-forming agent and organic solvent in a total weight proportion above 50 wt.%, preferably above 70 wt.%, and in particular above 90 wt.%.

[0017] Preferred gel bodies also contain dye.

[0018] Preferred gel bodies are transparent. "Transparent" refers to gel bodies that exhibit a transmission of more than 50%, preferably more than 60%, and especially more than 80% in the wavelength range from 410 to 800 nm at at least one wavelength, preferably at 600 nm. Transmission is determined using VIS spectrometry at a sample temperature of 20°C and a cuvette length of 10 mm.

[0019] For the production and subsequent storage and transport properties of the gel bodies, it has proven advantageous to use low-molecular-weight gel formers with a molar mass of up to 2000 g / mol in the gel body, with their weight fraction of the total weight of the gel body preferably being less than 5 wt.%, 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 gel formers with their specific gelling properties.

[0020] In a preferred embodiment, the low-molecular-weight gelling agent has a water solubility of less than 0.1 g / L (20°C). The solubility of the organic gelling agent is determined at 20°C in double-distilled, demineralized water.

[0021] Furthermore, gel formers are preferably suitable which have a structure containing at least one hydrocarbon structural unit having 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.

[0022] Particularly preferred gel bodies are characterized in that said gel bodies contain at least one benzylidene alditol compound of the formula (GB-I) as gelling agent

[0023] wherein

[0024] *- represents a covalent single bond between an oxygen atom of the alditol backbone and the intended radical, n represents 0 or 1, preferably 1, m represents 0 or 1, preferably 1,

[0025] R 1 , R 2 and R 3independently of one another represents 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 radicals together with the residual molecule form a 5- or 6-membered ring,

[0026] R 4 , R 5 and R e independently of one another represent a hydrogen atom, a halogen atom, a Ci-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 Ci-C4 alkoxy group, a Ci-C4 alkoxy-C2-C4 alkyl group, two of the radicals together with the residual molecule form a 5- or 6-membered ring.

[0027] Due to the stereochemistry of the alditols, it should be noted that both the said benzylidene alditols in the L-configuration or in the D-configuration, or a mixture of both, are suitable according to the invention. Due to their natural availability, the benzylidene alditol compounds in the D-configuration are preferably used according to the invention. It has been found to be preferred if the alditol backbone of the benzylidene alditol compound according to formula (GB-I) contained in the shaped body is derived from D-glucitol, D-mannitol, D-arabinitol, D-ribitol, D-xylitol, L-glucitol, L-mannitol, L-arabinitol, L-ribitol, or L-xylitol.

[0028] Particularly preferred are those gel bodies which are characterized in that R 1 , R 2 , R 3 , R 4 , R 5 and R eaccording to the benzylidenealditol compound of the formula (GB-I), independently of one another, represents a hydrogen atom, methyl, ethyl, chlorine, fluorine or methoxy, preferably a hydrogen atom. n according to the benzylidenealditol compound of the formula (GB-I) preferably represents 1. m according to the benzylidenealditol compound of the formula (GB-I) preferably represents 1.

[0029] Most preferably, the gel body contains as benzylidene alditol compound of formula (GB-I) at least one compound of formula (GB-11) where R 1 , R 2 , R 3 , R 4 , R 5 and R e as defined in formula (I). Most preferably, according to formula (GB-11) R 1 , R 2 , R 3 , R 4 , R 5 and R e independently of one another represent a hydrogen atom, methyl, ethyl, chlorine, fluorine or methoxy, preferably a hydrogen atom.

[0030] Most preferably, the benzylidene alditol compound of formula (GB-I) is selected from 1,3:2,4-di-G-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.

[0031] Preferred gel bodies contain as gelling agent at least one 2,5-diketopiperazine compound of the formula (GB-I I) wherein

[0032] R 1 , R 2 , R 3 and R 4independently of one another represent a hydrogen atom, a hydroxy group, a (Ci-Ce)-alkyl group, a (C2-Ce)-alkenyl group, a (C2-C6)-acyl group, a (C2-C6)-acyloxy group, a (Ci-Ce)-alkoxy group, an amino group, a (C2-C6)-acylamino group, a (Ci-C6)-alkylaminocarbonyl group, an aryl group, an aroyl group, an aroyloxy group, an aryloxy group, an aryl-(Ci-C4)-alkyloxy group, an aryl-(Ci-C3)-alkyl group, a heteroaryl group, a heteroaryl-(Ci-C3)-alkyl group, a (C1-C4)-hydroxyalkyl group, a (Ci-C4)-aminoalkyl group, a carboxy-(Ci-C3)-alkyl group, where at least two of the radicals R 1 to R 4 together with the remaining molecule can form a 5 or 6-membered ring,

[0033] R 5represents a hydrogen atom, a linear (Ci to Ce) alkyl group, a branched (C3 to Cw) alkyl group, a (C3 to C6) cycloalkyl group, a (C2-Ce) alkenyl group, a (C2-C6) alkynyl group, a (Ci-C4) hydroxyalkyl group, a (Ci-C4) alkoxy-(Ci-C4) alkyl group, a (C1-C4) acyloxy-(Ci-C4) alkyl group, an aryloxy-(Ci-C4) alkyl group, an O-(aryl-(Ci-C4) alkyl)oxy-(Ci-C4) alkyl group, a (Ci-C4) alkylsulfanyl-(Ci-C4) alkyl group, an aryl group, an aryl-(Ci-C3) alkyl group, a heteroaryl group, a Heteroaryl-(Ci-C3)-alkyl group, a (C1-C4)-hydroxyalkyl group, a (Ci-C4)-aminoalkyl group, an N-(Ci-C4)-alkylamino-(Ci-C4)-alkyl group, an N,N-(Ci-C4)-dialkylamino-(Ci-C4)-alkyl group, an N-(C2-C8)-acylamino-(Ci-C4)-alkyl group, an N-(C2-C8)-acyl-N-(Ci-C4)-alkylamino-(Ci-C4)-alkyl group, an N-(C2-C8)-aroyl-N-(Ci-C4)-alkylamino-(Ci-C4)-alkyl group, an N,N-(C2-C8)-diacylamino-(Ci-C4)-alkyl group,an N-(aryl-(Ci-C4)-alkyl)amino-(Ci-C4)-alkyl group, an N,N-di(aryl-(Ci-C4)-alkyl)amino-(Ci-C4)-alkyl group, a (Ci-C4)-carboxyalkyl group, a (Ci-C4)-alkoxycarbonyl-(Ci-C3)-alkyl group, a (Ci-C4)-acyloxy-(Ci-C3)-alkyl group, a guanidino-(Ci-C3)-alkyl group, an aminocarbonyl-(Ci-C4)-alkyl group, an N-(Ci-C4)-alkylaminocarbonyl-(Ci-C4)-alkyl group, an N,N-di((Ci-C4)-alkyl)aminocarbonyl-(Ci-C4)-alkyl group, an N-(C2-C8)-acylaminocarbonyl-(Ci- C4) alkyl group, an N,N-(C2-C8)-diacylaminocarbonyl-(Ci-C4)-alkyl group, an N-(C2-Cs)-acyl-N-(Ci-C4)-alkylaminocarbonyl-(Ci-C4)-alkyl group, a N-(aryl-(Ci-C4)-alkyl)aminocarbonyl-(Ci-C4)-alkyl group, an N-(aryl-(Ci-C4)-alkyl)-N-(Ci-C6)-alkylaminocarbonyl-(Ci-C4)-alkyl group or one N,N-Di(aryl-(Ci-C4)-alkyl)aminocarbonyl-(Ci-C4)-alkyl group.,

[0034] It is preferred according to the invention if R 3 and R 4according to formula (GB-II) represents a hydrogen atom. It is particularly preferred according to the invention if R 2 , R 3 and R 4 according to formula (GB-II) represents a hydrogen atom. Therefore, very particularly preferred shaped bodies according to the invention contain at least one 2,5-diketopiperazine compound according to formula (GB-IIa) where R 1 and R 5 as defined under formula (GB-II) (vide supra).

[0035] It has been found to be preferable if the residue R 1 according to formula (GB-II) and according to formula (GB-IIa) in the para-position of the phenyl ring. Therefore, for the purposes of the present invention, preferred shaped bodies according to the invention are those which contain at least one 2,5-diketopiperazine compound according to formula (GB-IIb), (GB-Ilb) where R 1 and R 5as previously defined under formula (GB-II) (vide supra). The numbers 3 and 6 positioned on the ring atoms in formula (GB-IIb) merely mark the

[0036] Positions 3 and 6 of the diketopiperazine ring, as they are generally used in the context of the invention for the naming of all 2,5-diketopiperazines according to the invention.

[0037] The 2,5-diketopiperazine compounds of formula (GB-II) have 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 was illustrated by way of example in formula (GB-IIb). The 2,5-diketopiperazine compound of formula (GB-II) of the compositions according to the invention is preferably, based on 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.

[0038] Preferred gel bodies contain at least one 2,5-diketopiperazine compound of the formula (GB-

[0039] 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 preferred for selection.

[0040] It is also possible for the gel bodies according to the invention to contain as gelling agents a) at least one diarylamidocystin compound of the formula (GB-III)

[0041] wherein

[0042] X + independently represents a hydrogen atom or an equivalent of a cation,

[0043] R 1 , R 2 , R 3 and R 4 independently of one another 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 R 1 with R 2 or R 3 with R 4forms a 5- or 6-membered fused ring, which in turn can be substituted by at least one group selected from the group consisting of Ci-C4 alkyl group, Ci-C4 alkoxy group, C2-C4 hydroxyalkyl group, hydroxyl group, amino group, N-(Ci-C4 alkyl)amino group, N,N-di(Ci-C4 alkyl)amino group, N-(C2-C4 hydroxyalkyl)amino group, N,N-di(C2-C4 hydroxyalkyl)amino group.

[0044] 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.

[0045] Said gel bodies may contain at least one compound of formula (GB-III) in which R 1 , R 2 , R 3 and R 4independently of one another 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, or R 1 with R 2 or R 3 with R 4 forms a 5- or 6-membered fused ring, which in turn may be substituted by at least one group selected from the group consisting of Ci-C4 alkyl group, Ci-C4 alkoxy group, C2-C4 hydroxyalkyl group, or hydroxyl group. Shaped bodies which are particularly suitable as diarylamidocystine compounds of the formula (GB-III) N,N'-dibenzoylcystine (R 1 = R 2 = R 3 = R 4 = hydrogen atom; X + = independently of one another represent hydrogen atom or an equivalent of a cation), in particular N,N'-dibenzoyl-L-cystine.

[0046] The N-(C8-C24)-hydrocarbylglyconamide compounds suitable as gel formers a) preferably have the formula (GB-IV) where n is 2 to 4, preferably 3 or 4, especially 4;

[0047] R 1 is selected from hydrogen, C1-C18 alkyl radicals, C1-C3 hydroxy or methoxyalkyl radicals, preferably C1-C3 alkyl, hydroxyalkyl or methoxyalkyl radicals, particularly preferably methyl;

[0048] R 2 is selected from Cs-C24 alkyl radicals, Cs-C24 monoalkenyl radicals, C8-C24 dialkenyl radicals, C8-C24 trialkenyl radicals, Cs-C24 hydroxyalkyl radicals, Cs-C24 hydroxyalkenyl radicals, C1-C3 hydroxyalkyl radicals or methoxy-Ci-Cs alkyl radicals, preferably Cs-Cis alkyl radicals and mixtures thereof, more preferably Cs, C10, C12, C16, C18, C19 and C21 alkyl radicals and mixtures thereof, most preferably C12 and C20 alkyl radicals or a mixture thereof.

[0049] In particularly preferred embodiments, the radical is HO-CH2-(CHOH) n -C- one of a

[0050] II

[0051] O

[0052] Glycuronic acid, in particular the glycuronic acid of a hexose (n=4), derived residue. Glucuronic acid is particularly preferred here. R 1 is preferably H or a short-chain alkyl radical, especially methyl. R 2 is preferably a long-chain alkyl radical, for example a Cs-Cis alkyl radical.

[0053] Compounds of the formula (GB-IV1) are therefore particularly preferred. where R 2 has the meanings given for formula (GB-IV).

[0054] In a particularly preferred embodiment, the at least one low-molecular-weight gelling agent of the second flowable gelling agent-containing composition is selected from the group consisting of cyclic dipeptides, cyclic dipeptide derivatives, and dibenzylidene sorbitols. Due to its technical effect, the at least one gelling agent of the second flowable gelling agent-containing composition is particularly preferred to be dibenzylidene sorbitol (DBS).

[0055] In step iii) of the process, the first and second flowable compositions are fed to the mixing device. In one embodiment of the process, the first flowable composition and the second flowable composition are fed to the mold in the same line. This process is characterized by a reduced apparatus structure. With this process, a partial mixing of the first and second flowable compositions can already take place in the feed line leading to the mold. The disadvantages of this process are reduced control of the gelation process and, in the event of a production interruption, increased cleaning effort before the production apparatus is restarted. For the latter reasons, it is preferable to feed the first flowable composition and the second flowable composition to the mixing device in separate lines.

[0056] The process according to the invention is particularly suitable for processes in which flowable compositions are mixed in widely differing 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, preferably 35:1 to 8:1.

[0057] For the mixing but also for the further transfer into the forming device, it has proven advantageous if the flowable compositions in the mixing device are subjected to a shear rate of 50 to 5000 s-1, preferably of 80 to 2000 s-1 and in particular of 100 to 1200 s-1.

[0058] The mixing device is preferably selected from the group of rotor-stator mixers. Static-dynamic mixers are particularly preferred.

[0059] When leaving the mixing device, the surfactant-containing and gelling agent-containing mixture preferably has a temperature above 23°C, particularly preferably a temperature in the range from 23°C to 60°C.

[0060] The surfactant-containing and gelling agent-containing mixture is preferably introduced into the forming device at a filling rate of 20 ml / s to 800 ml / s.

[0061] Suitable forming devices are those known to those skilled in the art for forming shaped strands. A particularly preferred method involves continuously pressing the mixture out of a forming opening under pressure.

[0062] The mixing device and the forming device can be structurally integrated or designed as a separate device.

[0063] In its simplest form, a sufficiently stable outlet opening is used as the forming device. The opening area of ​​this outlet opening determines the cross-sectional area of ​​the emerging extruded strand.

[0064] In a further developed embodiment, the forming device is designed as a tube, one end of which serves as the inlet opening for the surfactant- and gelling agent-containing mixture, and the other end as the outlet opening for the extruded strand. Again, the opening area of ​​the outlet opening determines the cross-sectional area of ​​the emerging extruded strand. Preferably, the opening area of ​​the tube and its cross-sectional area are identical.

[0065] In a further development, the forming device comprises a tube and an outlet nozzle connected to this tube in an interchangeable manner.

[0066] If the forming device and the mixing device are designed as separate devices, the mixture containing surfactant and gelling agent is preferably guided through a feed line after leaving the mixing device and before entering the forming device.

[0067] If the surfactant- and gel-forming agent-containing mixture is fed through a feed line after exiting the mixing device and before entering the forming device, the cross-sectional area of ​​the feed line may differ from the cross-sectional area of ​​the exit opening of the forming device. If the cross-sectional area of ​​the feed line is smaller than the cross-sectional area of ​​the exit opening of the forming device, the flow velocity of the surfactant- and gel-forming agent-containing mixture is lower when exiting the feed line into the forming device than when exiting the forming device. The opposite is true if the cross-sectional area of ​​the feed line is larger than the cross-sectional area of ​​the forming device.By implementing different flow velocities in the feed line and the forming device, the curing behavior of the surfactant-containing and gelling agent-containing mixture can be influenced in a suitable manner.

[0068] The time interval between the surfactant-containing and gelling agent-containing mixture leaving the mixing device and entering the forming device is preferably 1 to 20 seconds, particularly preferably 5 to 40 seconds. This applies in particular to processes in which the mixing device and forming device are designed separately.

[0069] If the mixing device and the forming device are structurally integrated, for example in the form of a mixer with an attached outlet opening, a device for calibrating the extruded strand is preferably connected to the outlet opening. This calibration device can, for example, be designed in the form of a trough open at the top.

[0070] To accelerate solidification or to facilitate further processing, the dimensionally stable gel body strand is preferably cooled. Cooling preferably takes place under defined climatic conditions, where, in addition to the temperature, the humidity in the process chamber is also monitored and regulated. Following step vi), the extruded strand emerging from the forming device is preferably cut to length in a suitable manner to form individual molded bodies. Cutting is particularly preferably carried out by ultrasonic cutting.

[0071] The spatial shape of the gel body is fundamentally freely selectable; its side surfaces can be convex, concave, or flat, for example. However, certain spatial configurations have proven particularly advantageous in terms of manufacturability, storage, and use of the gel bodies.

[0072] In correspondingly 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 produce, for example, by means of a casting process, they can also be packaged easily and in a space-saving manner and are suitable for dosing via the dosing or dispensing chambers of electronic cleaning appliances. It is preferred if the gel body has a flat underside whose largest diagonal is more than 1.5 times, preferably more than twice, the height of the gel body.

[0073] For manufacturability, for example, with regard to demolding 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. Corresponding gel bodies with a non-square underside are also preferred by many consumers due to their appearance. Therefore, preferred gel bodies are, for example, those that have a bottom and a top side connected by a cylindrical outer surface.

[0074] Advantages in terms of space utilization during production and packaging are realized by angular undersides. If, for example, the gel bodies are cast in the form of sheets, which are subsequently cut into gel bodies, angular undersides are advantageous because such gel bodies can be cut without creating any residue and can be packaged in a space-saving manner. In an alternative embodiment, preferred gel bodies therefore have angular undersides, in particular triangular, square, or hexagonal undersides. For further processing or packaging, it can be advantageous if the gel body has a angular underside with rounded corners.

[0075] With regard to the production, packaging and use of the detergent portion units, it has also proven advantageous if the gel bodies have an upper side that is plane-parallel to the lower side. In a first preferred geometric embodiment, the gel body has a lower side and an upper side which have the same geometric shape, wherein the lower side and the upper side have the same surface area. Corresponding gel bodies can, as already described, be produced in a simple manner, for example by casting sheets and subsequently cutting the sheets into individual gel bodies. These gel bodies can also be spatially aligned more easily in any subsequent process steps, during packaging or use by the user due to the geometric identity of the lower and upper sides than gel bodies with a lower body symmetry.This is especially true for gel bodies that simultaneously have a top surface that is plane-parallel to the bottom surface. Examples of such gel bodies are circular cylinders, elliptical cylinders, parallelepipeds, rhombohedrons, straight or oblique prisms, cuboids, or cubes. The group of circular cylinders and elliptical cylinders includes vertical circular cylinders and elliptical cylinders, as well as oblique circular cylinders and elliptical cylinders. Due to their ease of manufacture by singulating from a single sheet, gel bodies in the form of vertical circular cylinders, vertical elliptical cylinders, straight prisms, straight cuboids, or cubes are preferred.

[0076] In an alternative embodiment, the gel body has a bottom and a top surface that have the same geometric shape, with the bottom and top surfaces having different surface areas. Such gel bodies may be preferred due to their attractive appearance or optimized fit, coupled with comparatively simple manufacturing. Examples of such gel bodies are circular cylinders or elliptical cylinders with a convex or concave bottom surface and a flat top surface. Further examples are truncated cones or truncated pyramids.

[0077] In summary, preferred subject matters of the application can be characterized as detergent portion units comprising a gel body with a bottom side and a top side, wherein the area of ​​the top side is 80 to 100%, preferably 90 to 100% and in particular 98 to 100% of the bottom side.

[0078] For the production of detergent portion units which comprise further components in addition to the gel body, a procedure in which the gel body is combined with a prefabricated molded body is suitable.

[0079] In a preferred process variant, the gel strand is covered with a molded body. Alternatively, or in combination with the covering with a molded body, the dimensionally stable gel strand is directed onto a prefabricated molded body. If the gel strand is directed onto a first prefabricated molded body and the side opposite the side covered with the first prefabricated molded body is covered with a second prefabricated molded body, a sandwich-like detergent portion unit is obtained that is particularly advantageous in terms of handling and appearance.

[0080] A particularly preferred process variant for producing a detergent portion unit, comprising a) a dimensionally stable gel body b) two shaped bodies, comprises the steps: i) providing a first flowable surfactant-containing composition; ii) providing a second flowable gel-forming agent-containing composition different from the first flowable composition; iii) continuously feeding the first and second flowable compositions to a mixing device; iv) mixing the first and second flowable compositions by means of the mixing device to form a surfactant-containing and gel-forming agent-containing mixture; v) continuously passing the surfactant-containing and gel-forming agent-containing mixture through a forming device to solidify the surfactant-containing and gel-forming agent-containing mixture in the forming device to form a dimensionally stable gel body strand;vi) continuously discharging the dimensionally stable gel body strand from the forming device onto at least one first prefabricated molded body; vii) covering the side of the gel body strand opposite the side covered with the first prefabricated molded body with a second prefabricated molded body; viii) cutting the gel body strand to length to form a detergent portion unit comprising a gel body and the first and second prefabricated molded bodies.

[0081] The molded body can be manufactured in a variety of ways. The use of cast bodies has proven to be technically feasible and straightforward. The production of the molded body by casting processes has the advantage of allowing the production of a wide variety of geometries. The cast bodies are preferably solidified melts.

[0082] Due to their ease of large-scale production, compressed bodies, especially tablets, are particularly preferred as shaped bodies.

[0083] Regardless of the process used for its production, the tablet preferably has a breaking strength of 50 N to 300 N, in particular 50 N to 150 N. This breaking strength ensures, on the one hand, sufficient stability of the tablet during production, transport, and handling by the consumer, and, on the other hand, satisfactory dissolution behavior of the tablet in an aqueous solution. The hardness of the tablet is measured by deformation until fracture, whereby the force acts on the side surfaces of the tablet and the maximum force it can withstand is determined. A tablet testing device from Sotax, for example, is suitable for determining tablet hardness.

[0084] Preferred molded bodies have a print.

[0085] If the gel body is combined with a molded body as described above, the dimensionally stable gel body, partially covered by a molded body, is finally removed from the mold. The gel body and the molded body are preferably bonded together.

[0086] In a preferred embodiment of the detergent portion units, the shaped body also contributes to the washing and cleaning action. Corresponding detergent portion units comprise a shaped body that, based on its total weight, contains more than 40% by weight, preferably more than 60% by weight, particularly preferably more than 80% by weight of washing or cleaning active ingredient.

[0087] The first group of active washing or cleaning ingredients integrated into the molded body are fragrances. Their incorporation into the molded body ensures a perceptible fragrance experience for the consumer, which cannot be achieved to the same extent when the fragrances are incorporated into the gel body.

[0088] Another group of washing or cleaning-active ingredients preferably incorporated into the coating substance are the builders, in particular citrates, zeolites, silicates, and carbonates, particularly preferably citrates and zeolites. The weight fraction of these active substances in the total weight of the coating substance is preferably 5 to 60 wt.%, in particular 10 to 50 wt.%. Particularly preferred are coating substances which, based on their total weight, contain 5 to 60 wt.%, in particular 10 to 50 wt.% zeolite. These active substances not only contribute to the intended washing and cleaning action, but also improve the contour sharpness and durability of the printed image when the molded body surface is printed.

[0089] For the sharpness of the contours and durability of the printed image, the use of active ingredients from the group of polymeric detergent or cleaning agents, preferably from the group of celluloses and cellulose derivatives and anionic or non-ionic aromatic polyesters, preferably from the group of celluloses, microcrystalline celluloses and carboxymethylcelluloses, and anionic or non-ionic aromatic polyesters, is also advantageous. The weight proportion of these cellulose-based active ingredients to the total weight of the coating substance is preferably 2 to 50% by weight.

[0090] The composition of some preferred detergent portion units can be found in the following tables (data in wt.% based on the total weight of the gel body or the coating substance unless otherwise stated).

[0091]

[0092] In summary, this application provides, among other things, the following items:

[0093] 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 surfactant-containing composition; ii) providing a second flowable gel-forming agent-containing composition different from the first flowable composition; iii) continuously feeding the first and second flowable compositions to a mixing device; iv) mixing the first and second flowable compositions by means of the mixing device to form a surfactant-containing and gel-forming agent-containing mixture; v) continuously passing the surfactant-containing and gel-forming agent-containing mixture through a forming device to solidify the surfactant-containing and gel-forming agent-containing mixture in the forming device to form a dimensionally stable gel body strand; vi) continuously discharging the dimensionally stable gel body strand from the forming device.

[0094] 2. Process according to point 1, wherein the first flowable surfactant-containing composition contains, based on its total weight, 30 to 70 wt.%, preferably 40 to 60 wt.% and in particular 45 to 55 wt.% surfactant.

[0095] 3. Process according to one of the preceding points, wherein the dimensionally stable gel body contains, based on its total weight, 15 to 35 wt.%, preferably 20 to 30 wt.% of an aqueous-organic solvent.

[0096] 4. Process according to one of the preceding points, wherein the second flowable gelling agent-containing composition contains low molecular weight gelling agent with a molar mass of up to 2000 g / mol, wherein its weight proportion of the total weight of the composition is preferably less than 5 wt.%, preferably 0.1 to 5 wt.%, particularly preferably 0.1 to 2.5 wt.%.

[0097] 5. The method according to any one of the preceding points, wherein the second flowable gelling agent-containing composition contains low molecular weight gelling agent selected from the group of cyclic dipeptides, cyclic dipeptide derivatives and dibenzylidene sorbitols.

[0098] 6. The method according to any one of the preceding points, wherein the second flowable gelling agent-containing composition contains dibenzylidene sorbitol as low molecular weight gelling agent.

[0099] 7. The method according to any one of the preceding points, wherein the second flowable gelling agent-containing composition further contains an organic solvent.

[0100] 8. The process according to any one of the preceding points, wherein the second flowable gelling agent-containing composition contains gelling agent and organic solvent in a total weight proportion above 50 wt.%, preferably above 70 wt.%, and in particular above 90 wt.%. 9. The process according to any one of the preceding points, wherein the first flowable composition and the second flowable composition are fed to the mixing device in separate lines.

[0101] 10. Method according to one of the preceding points, wherein the first flowable composition and the second flowable composition are mixed in the mixing device in a weight ratio of 50:1 to 5:1, preferably of 35:1 to 8:1.

[0102] 11. Process according to one of the preceding points, wherein the flowable compositions are subjected in the mixing device to a shear rate of 50 to 5000 s-1, preferably 80 to 2000 s-1 and in particular 100 to 1200 s-1.

[0103] 12. Method according to one of the preceding points, wherein the mixing device is selected from the group of rotor-stator mixers.

[0104] 13. Method according to one of the preceding points, wherein the mixing device is selected from the group of static-dynamic mixers.

[0105] 14. Process according to one of the preceding points, wherein the surfactant-containing and gelling agent-containing mixture has a temperature above 23°C, preferably in the range from 23°C to 60°C, when leaving the mixing device.

[0106] 15. Method according to one of the preceding points, wherein the mixing device and the forming device are designed as separate devices.

[0107] 16. Method according to one of the preceding points, wherein the time period between the exit of the surfactant-containing and gelling agent-containing mixture from the mixing device and its entry into the forming device is 1 to 60 seconds, preferably 5 to 40 seconds.

[0108] 17. Method according to one of the preceding points, wherein the surfactant-containing and gelling agent-containing mixture is introduced into the forming device at a filling rate of 20 ml / s to 800 ml / s.

[0109] 18. Method according to one of the preceding points, wherein the surfactant-containing and gelling agent-containing mixture is passed through a feed line after leaving the mixing device and before entering the forming device.

[0110] 19. Method according to one of the preceding points, wherein the surfactant-containing and gelling agent-containing mixture is passed through a feed line after leaving the mixing device and before entering the forming device and the cross-sectional area of ​​the feed line differs from the cross-sectional area of ​​the outlet opening of the forming device.

[0111] 20. Method according to one of the preceding points, wherein the surfactant-containing and gelling agent-containing mixture is passed through a feed line after leaving the mixing device and before entering the forming device and the cross-sectional area of ​​the feed line is smaller than the cross-sectional area of ​​the outlet opening of the forming device.

[0112] 21. Method according to one of the preceding points, wherein the surfactant-containing and gelling agent-containing mixture is passed through a feed line after leaving the mixing device and before entering the forming device and the cross-sectional area of ​​the feed line is larger than the cross-sectional area of ​​the outlet opening of the forming device.

[0113] 22. Method according to one of the preceding points, wherein the dimensionally stable gel body strand is cooled.

[0114] 23. Method according to one of the preceding points, wherein the dimensionally stable gel body is cut to length following step vi).

[0115] 24. Method according to one of the preceding points, wherein the dimensionally stable gel body is cut to length by ultrasonic cutting following step vi).

[0116] 25. Method according to one of the preceding points, wherein the gel body has a weight of 10 g to 28 g, preferably of 12 g to 23 g, in particular of 15 g to 19 g.

[0117] 26. A method according to any one of the preceding points, wherein the gel body has a flat bottom whose largest diagonal is greater than the height of the gel body.

[0118] 27. Method according to one of the preceding points, wherein 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.

[0119] 28. Method according to one of the preceding points, wherein the gel body has an oval underside.

[0120] 29. The method according to any one of the preceding points, wherein the gel body has an ellipsoidal or round, preferably a round, bottom. 30. The method according to any one of the preceding points, wherein the gel body has a square bottom, preferably a square bottom with rounded corners.

[0121] 31. Method according to one of the preceding points, wherein the gel body has a triangular, square or hexagonal bottom side.

[0122] 32. Method according to one of the preceding points, wherein the gel body has an upper side that is plane-parallel to the underside.

[0123] 33. Method according to one of the preceding points, wherein the gel body has a bottom side and a top side which have the same geometric shape and wherein the bottom side and the top side have the same surface area.

[0124] 34. Method according to one of the preceding points, wherein the gel body has a bottom side and a top side which have the same geometric shape and wherein the bottom side and the top side have different surface sizes.

[0125] 35. Method according to one of the preceding points, wherein the gel body has a bottom side and a top side which are connected to one another by a cylindrical outer surface.

[0126] 36. Method according to one of the preceding points, wherein the gel body has a bottom side and a top side and the area of ​​the top side is 80 to 100%, preferably 90 to 100% and in particular 98 to 100% of the bottom side.

[0127] 37. Method according to one of the preceding points, wherein the dimensionally stable gel body strand is covered with a prefabricated shaped body.

[0128] 38. Method according to one of the preceding points, wherein the dimensionally stable gel body strand is directed onto a prefabricated molded body.

[0129] 39. Method according to one of items 37 or 38, wherein the shaped body is in the form of a cast body.

[0130] 40. Process according to one of items 37 or 38, wherein the shaped body is in the form of a pressed body, preferably a tablet.

[0131] 41. Method according to one of items 37 to 40, wherein the shaped body has a breaking strength of 50 N to 300 N, in particular of 50 N to 150 N.

[0132] 42. The process according to any one of items 37 to 41, wherein the shaped body has a print. 43. The process according to any one of items 37 to 42, wherein the shaped body contains, based on its total weight, more than 40% by weight, preferably more than 60% by weight, particularly preferably more than 80% by weight, of washing or cleaning-active ingredient.

[0133] 44. Process according to any one of items 37 to 43, wherein the shaped body contains a washing or cleaning active ingredient from the group of fragrances.

[0134] 45. Process according to one of items 37 to 44, wherein the shaped body contains a washing or cleaning active ingredient from the group of builders, in particular at least one active ingredient from the group of citrates, zeolites, silicates and carbonates, preferably from the group of citrates and zeolites.

[0135] 46. ​​Process according to one of items 37 to 45, wherein the shaped body contains a polymeric washing or cleaning-active ingredient, preferably a polymeric washing or cleaning-active ingredient from the group of celluloses and cellulose derivatives, anionic or non-ionic aromatic polyesters, preferably from the group of celluloses, microcrystalline celluloses, carboxymethylcelluloses, anionic or non-ionic aromatic polyesters.

Claims

Patent 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 free-flowing surfactant-containing composition; ii) providing a second free-flowing gelling agent-containing composition different from the first free-flowing composition; iii) continuously feeding the first and second free-flowing compositions to a mixing device; iv) mixing the first and second free-flowing compositions by means of the mixing device to form a surfactant-containing and gelling agent-containing mixture; v) continuously passing the surfactant-containing and gelling agent-containing mixture through a forming device, solidifying the surfactant-containing and gelling agent-containing mixture in the forming device to form a dimensionally stable gel body strand; vi) continuously drawing the dimensionally stable gel body strand out of the forming device.

2. The method of claim 1, 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.

3. Method according to one of the preceding claims, wherein the dimensionally stable gel body contains, based on its total weight, 15 to 35 wt.%, preferably 20 to 30 wt.% of an aqueous-organic solvent.

4. A method according to any of the preceding claims, 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 composition is preferably less than 5 wt.%, preferably 0.1 to 5 wt.%, particularly preferably 0.1 to 2.5 wt.%.

5. Method according to one of the preceding claims, wherein the first flowable composition and the second flowable composition are mixed in the mixing device in a weight ratio of 50:1 to 5:1, preferably from 35:1 to 8:

1.

6. Method according to one of the preceding claims, wherein the mixing device and the forming device are designed as separate devices.

7. Method according to one of the preceding claims, wherein the time interval between the exit of the surfactant-containing and gelling agent-containing mixture from the mixing device and its entry into the forming device is 1 to 60 seconds, preferably 5 to 40 seconds.

8. Method according to one of the preceding claims, wherein the dimensionally stable gel body is cut to length following step vi).

9. Method according to any of the preceding claims, wherein the gel body has a weight of 10 g to 28 g, preferably 12 g to 23 g, in particular 15 g to 19 g.

10. Method according to one of the preceding claims, wherein the dimensionally stable gel strand is directed onto a pre-made molded body or covered with a pre-made molded body.

Images