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] 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 detergents or cleaning agents and therefore do not contribute to the product's effectiveness. Reducing the packaging content relative to the total weight of the detergent portions 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 rate using water-soluble film-wrapped detergent dosing units remains a crucial 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 manufacture.

[0009] WO 2018 / 229037 A1 discloses a method for producing a viscoelastic molded body for textile treatment

[0010] 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 / or feel. The detergent portion units should offer high product performance and be easy and safe for consumers to handle.

[0011] 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) 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 mixture; v) continuously passing the surfactant-containing and gel-forming mixture through a forming device, solidifying the surfactant-containing and gel-forming mixture in the forming device to form a dimensionally stable gel body strand;(vi) Continuous discharge of the dimensionally stable gel strand from the forming device, wherein the forming device is an outlet opening or the forming device is designed as a tube, one end of which serves as an inlet opening for the surfactant- and gel-forming mixture and the other end of which serves as an outlet opening for the gel strand, the outlet opening defining the cross-sectional area of ​​the exiting gel strand.

[0012] 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.

[0013] 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.

[0014] 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.

[0015] 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.

[0016] 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.%.

[0017] Preferred gel bodies still contain dye.

[0018] Preferred gel bodies are transparent. A gel body is considered "transparent" if, in the wavelength range of 410 to 800 nm, it exhibits a transmission above 50%, preferably above 60%, and particularly above 80% at at least one wavelength, preferably 600 nm. The transmission is determined by 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 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.

[0020] 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.

[0021] 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.

[0022] 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.

[0023] 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.

[0024] 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.

[0025] n according to the benzylidenealditol compound of the formula (GB-I) preferably stands for 1.

[0026] m according to the benzylidenealditol compound formula (GB-I) preferably stands for 1.

[0027] 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.

[0028] 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.

[0029] Preferred gel bodies contain at least one 2,5-diketopiperazine compound of formula (GB-II) as a gelling agent. 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 an N, N-Di(aryl-(C 1 -C 4 )alkyl)aminocarbonyl-(C 1 -C 4 )alkyl group. ,

[0030] 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).

[0031] 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-Ilb) 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.

[0032] 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-IIb). 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.

[0033] 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.

[0034] 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.

[0035] 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.

[0036] 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.

[0037] 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.

[0038] 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.

[0039] Compounds of formula (GB-IV1) are therefore particularly preferred. where R 2< has the meanings given for formula (GB-IV).

[0040] 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.

[0041] 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 and second flowable compositions are fed to the mold in the same line. This method is characterized by a simplified apparatus design. 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.

[0042] For the aforementioned reasons, it is preferred to supply the first flowable composition and the second flowable composition to the mixing device in separate lines.

[0043] 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, preferably from 35:1 to 8:1.

[0044] For mixing as well as for transferring to 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.

[0045] The mixing device is preferably selected from the group of rotor-stator mixers. Static-dynamic mixers are particularly preferred.

[0046] Upon exiting 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 of 23°C to 60°C.

[0047] The surfactant- and gelling agent-containing mixture is preferably introduced into the forming device at a filling rate of 20 ml / s to 800 ml / s.

[0048] Suitable forming devices include those known to those skilled in the art for forming strands. A process in which the mixture is continuously forced out of a forming opening under pressure is particularly preferred.

[0049] The mixing device and forming device can be structurally integrated or designed as separate devices.

[0050] In its simplest embodiment, a sufficiently stable exit opening is used as the forming device. The opening area of ​​this exit opening determines the cross-sectional area of ​​the exiting extruded strand.

[0051] In a further developed embodiment, the forming device is designed as a tube, one end of which serves as an inlet opening for the surfactant- and gelling agent-containing mixture, and the other end as an outlet opening for the extruded strand. Again, the opening area of ​​the outlet determines the cross-sectional area of ​​the exiting extruded strand. Preferably, the opening area of ​​the tube and its cross-sectional area are identical.

[0052] In a further development, the forming device comprises a tube and an outlet nozzle connected to this tube in an interchangeable manner.

[0053] If the forming device and the mixing device are designed as separate devices, the surfactant-containing and gelling agent-containing mixture is preferably guided through a supply line after exiting the mixing device and before entering the forming device.

[0054] If the surfactant- and gelling agent-containing mixture is guided 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 forming device's outlet opening. If the cross-sectional area of ​​the feed line is smaller than the cross-sectional area of ​​the forming device's outlet opening, the flow velocity of the surfactant- and gelling agent-containing mixture upon exiting the feed line into the forming device will be lower than upon 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 rates in the feed line and forming device, the curing behavior of the surfactant-containing and gelling agent-containing mixture can be influenced appropriately.

[0055] The time interval between the exit of the surfactant- and gel-forming mixture from the mixing device and its entry into the forming device is preferably 1 to 20 seconds, particularly preferably 5 to 40 seconds. This applies especially to process configurations in which the mixing device and forming device are designed separately.

[0056] If the mixing device and forming device are structurally integrated, for example in the form of a mixer with an attached outlet opening, a device for calibrating the extrusion 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.

[0057] To accelerate solidification or facilitate further processing, the dimensionally stable gel strand is preferably cooled. Cooling preferably takes place under defined climatic conditions, where, in addition to temperature, the humidity in the process chamber is also monitored and controlled.

[0058] The extruded strand exiting the forming device is preferably cut to length in a suitable manner following step vi) to form individual shaped bodies. Ultrasonic cutting is particularly advantageous for this cutting.

[0059] 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.

[0060] 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.

[0061] 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. 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.

[0062] 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.

[0063] 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.

[0064] 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 include 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.

[0065] 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.

[0066] 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.

[0067] 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.

[0068] In a preferred method embodiment, the gel strand is covered with a molded body. Alternatively, or in combination with covering by means of a molded body, the dimensionally stable gel strand is drawn onto a pre-molded molded body. If the gel strand is drawn onto a first pre-molded molded body and the side opposite the side covered by the first pre-molded molded body is covered with a second pre-molded molded body, a sandwich-like detergent portion unit is obtained that is particularly advantageous in terms of handling and appearance.

[0069] 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) 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 discharge the dimensionally stable gel body strand from the forming device onto at least one first pre-formed molded body;vii) Covering the side of the gel body strand opposite the side covered by the first pre-formed shape with a second pre-formed shape; viii) Cutting the gel body strand to length to form a detergent portion unit comprising a gel body as well as the first and the second pre-formed shape; wherein the forming device is an outlet opening or the The forming device is designed as a tube, one end of which serves as an inlet opening for the surfactant-containing and gelling agent-containing mixture and the other end of which serves as an outlet opening for the gel body strand, wherein the outlet opening determines the cross-sectional area of ​​the exiting gel body strand.

[0070] The molded part can be manufactured in various ways. The use of cast parts has proven to be technically simple. 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.

[0071] Due to their ease of large-scale production, pressed bodies, especially tablets, are particularly preferred as molded bodies.

[0072] Regardless of the manufacturing process used, the molded body preferably has a breaking strength of 50 N to 300 N, in particular of 50 N to 150 N.

[0073] This fracture toughness ensures, firstly, sufficient stability of the molded tablet during production, transport, and handling by the consumer, and secondly, satisfactory dissolution behavior of the tablet in an aqueous solution. The hardness of the tablet is measured by deformation until fracture, whereby the force is applied to the tablet's lateral surfaces and the maximum force they can withstand is determined. A tablet testing device from Sotax, for example, is suitable for determining the tablet hardness.

[0074] Preferred molded bodies have a printed design.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] 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 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.

[0079] 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.%.

[0080] 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 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

[0081] In summary, this registration provides, among other things, the following items: 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.wherein the forming device is an outlet opening or the forming device is designed as a tube, one end of which serves as an inlet opening for the surfactant- and gelling agent-containing mixture and the other end of which serves as an outlet opening for the gel body strand, the outlet opening defining the cross-sectional area of ​​the exiting gel body strand. 2. Method according to point 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 any 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.%, an aqueous-organic solvent. 4. Method according to any of the preceding points, wherein the second free-flowing gelling agent-containing composition contains a low molecular weight gelling agent with a molar mass of up to 2000 g / mol.wherein its weight fraction in the total weight of the composition is preferably less than 5 wt.%, more preferably 0.1 to 5 wt.%, and particularly preferably 0.1 to 2.5 wt.%. 5. A process according to any one of the preceding points, wherein the second flowable gel-forming composition contains a low molecular weight gel-forming agent selected from the group consisting of cyclic dipeptides, cyclic dipeptide derivatives, and dibenzylidene sorbitols. 6. A process according to any one of the preceding points, wherein the second flowable gel-forming composition contains dibenzylidene sorbitol as a low molecular weight gel-forming agent. 7. A process according to any one of the preceding points, wherein the second flowable gel-forming composition further contains an organic solvent. 8. A process according to any one of the preceding points, wherein the second flowable gel-forming composition contains a gel-forming agent and an organic solvent in a total weight fraction above 50 wt.%.preferably above 70 wt% and particularly above 90 wt%. 9. A method according to any one of the preceding points, wherein the first flowable composition and the second flowable composition are supplied to the mixing device in separate lines. 10. A method according to any 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 35:1 to 8:1. 11. A method according to any one of the preceding points, wherein the flowable compositions in the mixing device are subjected to a shear rate of 50 to 5000 s⁻¹, preferably 80 to 2000 s⁻¹, and particularly 100 to 1200 s⁻¹. 12. A method according to any one of the preceding points, wherein the mixing device is selected from the group of rotor-stator mixers. 13. A method according to any one of the preceding points,wherein the mixing device is selected from the group of static-dynamic mixers. 14. Method according to any of the preceding points, wherein the surfactant- and gelling agent-containing mixture has a temperature above 23°C, preferably in the range of 23°C to 60°C, upon exiting the mixing device. 15. Method according to any of the preceding points, wherein the mixing device and the forming device are designed as separate devices. 16. Method according to any of the preceding points, wherein the time interval between the exit of the surfactant- 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. 17. Method according to any of the preceding points, wherein the surfactant- and gelling agent-containing mixture is introduced into the forming device at a filling rate of 20 ml / s to 800 ml / s. 18. Method according to any of the preceding points,19. Method according to any of the preceding points, wherein the surfactant- and gelling agent-containing mixture is guided through a feed line after exiting the mixing device and before entering the forming device. 20. Method according to any of the preceding points, wherein the surfactant- and gelling agent-containing mixture is guided through a feed line after exiting 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. 21. Method according to any of the preceding points, wherein the surfactant- and gelling agent-containing mixture is guided through a feed line after exiting 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.wherein the surfactant- and gelling agent-containing mixture is guided through a feed line after exiting 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. 22. Method according to any of the preceding points, wherein the dimensionally stable gel body strand is cooled. 23. Method according to any of the preceding points, wherein the dimensionally stable gel body is cut to length following step vi). 24. Method according to any of the preceding points, wherein the dimensionally stable gel body is cut to length by ultrasonic cutting following step vi). 25. Method according to any of the preceding points, wherein the gel body has a weight of 10 g to 28 g, preferably 12 g to 23 g, and particularly 15 g to 19 g. 26. Method according to any of the preceding points, wherein the gel body has a flat underside.whose largest diagonal is greater than the height of the gel body. 27. 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. 28. Method according to any of the preceding points, wherein the gel body has an oval bottom surface. 29. Method according to any of the preceding points, wherein the gel body has an ellipsoidal or round, preferably a round, bottom surface. 30. Method according to any of the preceding points, wherein the gel body has an angular bottom surface, preferably an angular bottom surface with rounded corners. 31. Method according to any of the preceding points, wherein the gel body has a triangular, square, or hexagonal bottom surface. 32. Method according to any of the preceding points, wherein the gel body has a top surface that is plane parallel to the bottom surface. 33. Method according to any of the preceding points,wherein the gel body has a bottom and a top having the same geometric shape and wherein the bottom and the top have the same area. 34. Method according to any one of the preceding points, wherein the gel body has a bottom and a top having the same geometric shape and wherein the bottom and the top have different area sizes. 35. Method according to any one of the preceding points, wherein the gel body has a bottom and a top connected to each other by a cylindrical lateral surface. 36. Method according to any one of the preceding points, wherein the gel body has a bottom and a top and the area of ​​the top is 80 to 100%, preferably 90 to 100% and particularly 98 to 100% of the bottom. 37. Method according to any one of the preceding points,wherein the dimensionally stable gel strand is covered with a pre-formed molded body. 38. Method according to any of the preceding points, wherein the dimensionally stable gel strand is discharged onto a pre-formed molded body. 39. Method according to any of points 37 or 38, wherein the molded body is a cast body. 40. Method according to any of points 37 or 38, wherein the molded body is a pressed body, preferably a tablet. 41. Method according to any of points 37 to 40, wherein the molded body has a tensile strength of 50 N to 300 N, in particular of 50 N to 150 N. 42. Method according to any of points 37 to 41, wherein the molded body has a printed design. 43. A method according to any one of points 37 to 42, 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. 44. A method according to any one of points 37 to 43,wherein the molded body contains a washing or cleaning active ingredient from the group of fragrances. 45. Method according to any one of points 37 to 44, 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. 46. Method according to any one of points 37 to 45, wherein the molded 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, or anionic or non-ionic aromatic polyesters.

Claims

1. Method for producing a detergent portion unit, comprising a) a dimensionally stable gel body, comprising the steps: i) providing a first flowable surfactant-containing composition; ii) providing a second flowable gel-forming 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 mixture containing surfactant and gel-forming agent; v) continuously passing the mixture containing surfactant and agent through a forming device, solidifying the mixture containing surfactant and gel-forming agent 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, wherein the forming device comprises an outlet opening and / or the forming device is designed as a pipe, one end of which serves as an inlet opening for the mixture containing surfactant and gel-forming agent and the other end of which serves as an outlet opening for the gel body strand, wherein the outlet opening determines the cross-sectional area of the emerging gel body strand.

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

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

4. Method according to one of the previous claims, wherein the second flowable gel-forming composition contains low-molecular-weight gel-forming agents with a molar mass of up to 2000 g / mol, wherein their weight proportion of the total weight of the composition is preferably less than 5 wt.%, preferably 0.1 to 5 wt.%, and 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 35:1 to 8:1.

6. Method according to one of the previous 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 span between the exit of the mixture containing surfactant and gel-forming agent 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 one 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 body strand is discharged onto a prefabricated moulded body or covered with a prefabricated moulded body.

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