Solid benzyl oxide compositions, methods of making, and uses in cleaning

Abstract

An object of the present disclosure is to provide a solid composition that does not require PPE for handling. [Solution] Solid alkali metal benzyl oxide compositions that provide flowable solids, i.e., flowable powders and flowable granules, as well as solid compositions containing the alkali metal benzyl oxide compositions in combination with additional components are disclosed. Methods of making the solid compositions and methods of using the solid compositions are also provided. The solid compositions are particularly useful for making solid cleaning compositions, including degreasing compositions, that are advantageously PPE-free, offering improved safety over liquid formulations.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims priority under 35 U.S.C. § 119 to U.S. Provisional Application No. 63 / 491,981, filed March 24, 2023, which is incorporated herein by reference in its entirety.

[0002] FIELD OF THE INVENTION The present disclosure generally relates to solid alkali metal benzyl oxide compositions and solid compositions containing the alkali metal benzyl oxide compositions in combination with additional components, including solid acids, that advantageously do not require PPE for handling. Methods for making the solid compositions and the solid compositions are also provided. The solid compositions are particularly useful for making solid cleaning compositions, including degreasing compositions, that advantageously do not include PPE and offer improved safety over liquid formulations. [Background technology]

[0003] Removing complex and persistent soils, such as polymerized soils, is a challenge in various industries, including the food processing industry. Traditionally, highly alkaline cleaning compositions have been required. However, in some industries, the time and effort required to shut down operations to effectively clean soiled surfaces presents a significant barrier. For example, operations may require that tanks, lines, pumps, and other processing equipment be cleaned periodically. However, some operations may experience significant time between cleanings (as may be required by certain production processes). Other equipment, particularly high, out-of-place piping, ductwork (exterior and interior), roofs and ceilings, heating, cooling, and air conditioning (HVAC) surfaces, product freezers and coolers, and many other surfaces in food manufacturing environments, may sometimes be left for long periods without thorough cleaning, posing even greater challenges to removing complex and persistent soils, such as polymerized soils. In some cases, these soils are so difficult to remove that it is less expensive to replace equipment than to pay for the intensive labor required to properly clean the surfaces.

[0004] Thus, there is a continuing need for improved cleaning compositions and methods of use that do not require major changes to the design of equipment and food processing facilities. Cleaning compositions and methods of use that extend food production times and maintain a safe and clean food processing environment are desirable.

[0005] Traditionally, highly alkaline and caustic cleaning compositions are required to effectively remove complex and persistent soils, such as polymerized soils. For example, commercially available degreaser products rely on the cleaning power of caustic alkali or sodium hydroxide to attack polymerized greasy soils (see, e.g., Easy Off™, Greasestrip Plus™). The pH of these cleaners is often at least 12-13 or higher. Additionally, the alkalinity of these cleaners comes from alkali or alkaline earth metal hydroxides, such as sodium hydroxide (NaOH) or caustic alkali. These products are limited to liquid compositions, resulting in a variety of undesirable attributes. Many consumers are unwilling to transport and / or handle highly alkaline and caustic compositions because this poses various safety concerns and hazards. This is the result of various requirements for employee use of personal protective equipment (PPE) to reduce employee exposure to hazardous or corrosive materials. PPE can include, for example, goggles, eyewash stations, masks, and other protective gear.

[0006] Therefore, a need exists to provide a solid caustic-based composition that does not require PPE for handling. Summary of the Invention [Problem to be solved by the invention]

[0007] It is therefore an object of the present disclosure to provide a solid composition that does not require PPE for handling.

[0008] It is a further object of the present disclosure to provide methods of making and using such solid compositions.

[0009] Other objects, embodiments, and advantages of the present disclosure will be apparent to those skilled in the art in view of the following disclosure, drawings, and appended claims. [Means for solving the problem]

[0010] The following objects, features, advantages, aspects, and / or embodiments are not exhaustive and do not limit the overall disclosure. No single embodiment is required to provide each and every object, feature, or advantage. Any of the objects, features, advantages, aspects, and / or embodiments disclosed herein may be integrated with one another either fully or partially.

[0011] According to one aspect of the present disclosure, a solid composition includes an alkali metal benzyl oxide, a sulfonate carrier, and a solid acid, wherein the solid does not require PPE for handling.

[0012] According to a further aspect of the present disclosure, a solid composition comprises an alkali metal benzyl oxide, a sulfonate carrier, and a non-hygroscopic solid acid, wherein the solid is a tablet, block, powder, or granule, wherein the solid is a dimensionally stable solid or a flowable solid, and wherein the solid does not require personal protective equipment (PPE) for handling.

[0013] According to an additional aspect of the present disclosure, a method of making a solid composition includes combining either (i) an alkali metal hydroxide, benzyl alcohol, and a sulfonate carrier to form the solid composition in situ, or (ii) a premix comprising an alkali metal benzyl oxide and a sulfonate carrier with a solid acid, and adding the solid acid to form the solid composition.

[0014] According to an additional aspect of the present disclosure, a method of using the solid cleaning composition includes forming a use solution of the cleaning composition, contacting a surface in need of cleaning, degreasing, and / or stripping with the use solution, and removing soil from the surface, wherein the pH of the use solution is from about 8 to less than about 11, or from about 8 to about 10.5 for non-PPE applications.

[0015] According to yet a further aspect of the present disclosure, a solid composition comprises an alkali metal benzyl oxide and a sulfonate carrier, wherein the solid is a flowable solid or a compacted solid, including a flowable powder and / or flowable granules.

[0016] According to an additional aspect of the present disclosure, a method of making a solid composition includes combining an alkali metal hydroxide, a benzyl oxide, and a sulfonate carrier to form the solid composition in situ.

[0017] According to an additional aspect of the present disclosure, a method of using the solid cleaning composition includes forming a use solution of the cleaning composition, contacting a surface in need of cleaning, degreasing, and / or stripping with the use solution, and removing soil from the surface.

[0018] These and / or other objects, features, advantages, aspects, and / or embodiments will become apparent to those skilled in the art after reviewing the following Brief Description of the Drawings and Detailed Description. Moreover, the present disclosure encompasses aspects and / or embodiments not expressly disclosed but that can be understood by reading the present disclosure, including at least (a) combinations of the disclosed aspects and / or embodiments, and / or (b) reasonable variations not shown or described.

[0019] While multiple embodiments are disclosed, still other embodiments will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive. [Brief explanation of the drawings]

[0020] [Figure 1] 1 shows a graph evaluating polymerized soil removal as described in Example 3 of sodium benzyl oxide-containing solid cleaning compositions compared to a commercial control degreaser formulation at comparable and reduced pH.

[0021] Various embodiments of the present disclosure will now be described in detail with reference to the drawings, wherein like reference numerals represent like parts throughout the several views. Reference to various embodiments does not limit the scope of the present disclosure. The figures presented herein are presented for exemplary illustration of the invention, not as a limitation to the various embodiments according to the present disclosure. To facilitate understanding of the present invention, those skilled in the art will not need to consider the nearly infinite number of different permutations of the features described in the following detailed description within the separate drawings. DETAILED DESCRIPTION OF THE INVENTION

[0022] The present disclosure should not be limited to what is set forth herein, as variations can be made and will be understood by those skilled in the art. Unless otherwise specified, features shown or described are not essential to enable the basic operation of the present disclosure. It is further understood that all terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting in any manner or scope. For example, as used in this specification and the appended claims, the singular forms "a," "an," and "the" can include plural referents unless the content clearly dictates otherwise. Furthermore, all units, prefixes, and symbols may be denoted in their SI-recognized form.

[0023] Numerical ranges recited herein are inclusive of the numbers defining the range and include each integer within the defined range. Throughout this disclosure, various aspects of the disclosure are presented in a range format. The description in range format should be understood merely for convenience and brevity and should not be construed as an indefinite limitation on the scope of the disclosure. Accordingly, the description of a range should be considered to have specifically disclosed all possible subranges, fractions, and individual numbers within that range. For example, description of a range such as 1 to 6 should be considered to have specifically disclosed subranges such as 1 to 3, 1 to 4, 1 to 5, 2 to 4, 2 to 6, 3 to 6, etc., as well as individual numbers within that range (e.g., 1, 2, 3, 4, 5, 6), and decimals and fractions (e.g., 1.2, 3.8, 1 1 / 2, 4 3 / 4). This applies regardless of the breadth of the range.

[0024] As used herein, the term "and / or," e.g., "X and / or Y," should be understood to mean either "X and Y" or "X or Y," and should be interpreted as giving explicit support for both meanings or either meaning; e.g., A and / or B includes the alternatives i) A, ii) B, or iii) A and B.

[0025] It should be understood that certain features that are, for clarity, described herein in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any subcombination.

[0026] The methods and compositions of the present disclosure may comprise, consist essentially of, or consist of the components and ingredients of the present disclosure, as well as other components described herein. As used herein, "consisting essentially of" means that the methods, systems, devices, and compositions may include additional steps, components, or ingredients, but only if the additional steps, components, or ingredients do not materially alter the basic and novel characteristics of the claimed methods, systems, devices, and compositions.

[0027] Unless otherwise defined, all technical and scientific terms used above have the same meaning as commonly understood by one of ordinary skill in the art related to embodiments of the present disclosure.

[0028] The term "invention" or "present invention" is not intended to refer to any single embodiment of a particular invention, but rather is intended to encompass all possible embodiments described in the specification and claims.

[0029] As used herein, the term "about" refers to the variation in numerical quantity that may occur, for example, through typical measurement techniques and equipment, with respect to any quantifiable variable, including, but not limited to, concentration, mass, volume, time, molecular weight, temperature, pH, humidity, molar ratio, and logarithmic number of bacteria or viruses. Furthermore, given the solid and liquid handling procedures used in the real world, there are certain inadvertent errors and variations that are likely due to differences in the manufacture, source, or purity of ingredients used to make a composition or carry out a method, etc. The term "about" also encompasses these variations. Whether modified by the term "about," the claims include equivalents to the quantity.

[0030] The terms "actives" or "percent actives" or "percent by weight actives" or "actives concentration" are used interchangeably herein and refer to the concentration expressed as a percentage of the ingredients involved in cleaning, minus inactive ingredients such as water or salt. Sometimes they are given as a percentage in parentheses, e.g., "chemical (10%)."

[0031] As used herein, the term "alkyl" or "alkyl group" refers to a saturated hydrocarbon having one or more carbon atoms, including straight-chain alkyl groups (e.g., methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, etc.), cyclic alkyl groups (or "cycloalkyl" or "alicyclic" or "carbocyclic" groups) (e.g., cyclopropyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, etc.), branched-chain alkyl groups (e.g., isopropyl, tert-butyl, sec-butyl, isobutyl, etc.), and alkyl-substituted alkyl groups (e.g., alkyl-substituted cycloalkyl groups and cycloalkyl-substituted alkyl groups).

[0032] Unless otherwise specified, the term "alkyl" includes both "unsubstituted alkyls" and "substituted alkyls." As used herein, the term "substituted alkyl" refers to alkyl groups having substituents replacing one or more hydrogens on one or more carbons of the hydrocarbon backbone. Such substituents may include, for example, alkenyl, alkynyl, halogeno, hydroxyl, alkylcarbonyloxy, arylcarbonyloxy, alkoxycarbonyloxy, aryloxy, aryloxycarbonyloxy, carboxylate, alkylcarbonyl, arylcarbonyl, alkoxycarbonyl, aminocarbonyl, alkylaminocarbonyl, dialkylaminocarbonyl, alkylthiocarbonyl, alkoxyl, phosphate, phosphonato, phosphinato, cyano, amino (including alkylamino, dialkylamino, arylamino, diarylamino, and alkylarylamino), acylamino (including alkylcarbonylamino, arylcarbonylamino, carbamoyl, and ureido), imino, sulfhydryl, alkylthio, arylthio, thiocarboxylate, sulfate, alkylsulfinyl, sulfonate, sulfamoyl, sulfonamido, nitro, trifluoromethyl, cyano, azido, heterocyclic, alkylaryl, or aromatic (including heteroaromatic) groups.

[0033] In some embodiments, the substituted alkyl can include a heterocyclic group. As used herein, the term "heterocyclic group" includes closed ring structures similar to carbocyclic groups in which one or more of the carbon atoms in the ring is an element other than carbon, such as nitrogen, sulfur, or oxygen. Heterocyclic groups can be saturated or unsaturated. Exemplary heterocyclic groups include, but are not limited to, aziridine, ethylene oxide (epoxide, oxirane), thiirane (episulfide), dioxirane, azetidine, oxetane, thietane, dioxetane, dithietane, dithiete, azolidine, pyrrolidine, pyrroline, oxolane, dihydrofuran, and furan.

[0034] As used herein, the term "antimicrobial agent" refers to a compound or composition that reduces or inactivates microbial populations, including but not limited to bacteria, viruses, fungi, and algae, within about 10 minutes, about 8 minutes, about 5 minutes, about 3 minutes, about 2 minutes, about 1 minute, or about 30 seconds. Preferably, the term antimicrobial agent refers to a composition that provides at least about a 3 log, 3.5 log, 4 log, 4.5 log, or 5 log reduction in microbial populations within about 10 minutes, about 8 minutes, about 5 minutes, about 3 minutes, about 2 minutes, about 1 minute, or about 30 seconds.

[0035] As used herein, the term "cleaning" refers to methods used to promote or assist in stain removal, bleaching, microbial population reduction, and any combination thereof. As used herein, the term "microorganism" refers to any non-cellular or unicellular (including colonial) organism. Microorganisms include all prokaryotes. Microorganisms include bacteria (including cyanobacteria), spores, lichens, fungi, protozoa, virinos, viroids, viruses, phages, and some algae. As used herein, the term "microbe" is synonymous with microorganism.

[0036] The term "configured" describes a structure capable of performing a task or adopting a particular configuration. The term "configured" can be used interchangeably with other similar terms such as constructed, arranged, adapted, manufactured, etc.

[0037] As used herein, the term "corrosive" refers to a cleaning composition in a use solution having a pH greater than about 11.5, absent additional evidence of non-corrosive effects. However, as will be appreciated by those skilled in the art, a composition having a pH less than 11.5 can be considered corrosive based on tests (e.g., animal tests to confirm the toxicology of the composition). Similarly, some compositions can be considered non-corrosive at a pH greater than 11.5 as a result of test data or considering buffering capacity (i.e., acid / alkali storage). The classification and testing of "corrosive" formulations are based on the corrosive or irritating effects of the substance and / or formulation. Further explanation of the test requirements (including either animal or human data) is available from various regulatory authorities at the time of this disclosure, including, for example, European Commission, Enterprise and Industry Directorate-General, Position Paper of DG ENTR / G2 on the Classification and Labeling of Preparations with Extreme pH Values (11.5 < pH < 2) (2007).

[0038] According to an embodiment, the solid composition is non-corrosive as a solid composition combining an alkali metal benzyloxide, a sulfonate carrier, and a solid acid. Advantageously, the solid composition is non-corrosive and does not require personal protective equipment (PPE) for handling, while the fluid solid containing the alkali metal benzyloxide and the sulfonate carrier has a pH, for example, a pH of about 13 - 14, which requires the use of PPE.

[0039] As used herein, the term "exemplary" refers to an example, instance, or illustration and does not indicate the most preferred embodiment unless otherwise specified.

[0040] As used herein, the phrase "free-flowing solid" refers to powders or granules that do not stick together when moved or transported, facilitating movement and pouring. Free-flowing solids can include particles generally having a size of less than about 100 μm, as well as granules that are larger in size, often up to 1000 μm or larger.

[0041] As used herein, the phrase "food processing surface" refers to the surfaces of utensils, machines, equipment, structures, buildings, and the like used as part of food processing, cooking, or storage activities. Examples of food processing surfaces include surfaces of food processing or cooking equipment (e.g., slicing equipment, canning equipment, or transport equipment, including flumes), food processing ware (e.g., utensils, dishes, washware, and bar glasses), and floors, walls, or fixtures of structures in which food processing occurs. Food processing surfaces are found and used in food spoilage prevention air circulation systems, aseptic packaging sanitizers, food refrigeration and cooler cleaners and sanitizers, ware washing sanitizers, bleach cleaning and sanitizing, food packaging materials, cutting board additives, third-sink sanitizers, beverage coolers and warmers, meat cooling or scalding waters, automatic dish sanitizers, sanitizing gels, cooling towers, antimicrobial garment sprays for food processing, and non-aqueous to low-aqueous food preparation lubricants, oils, and rinse additives.

[0042] The term "generally" encompasses both "about" and "substantially."

[0043] The term "hard surface" refers to solid, substantially inflexible surfaces such as countertops, tiles, floors, walls, panels, windows, plumbing fixtures, kitchen and bathroom furniture, appliances, engines, circuit boards, dishes, mirrors, windows, monitors, touchscreens, and thermostats. Hard surfaces are not limited by material; for example, hard surfaces can be glass, metal, tile, vinyl, linoleum, composites, wood, plastic, etc. Hard surfaces can include, for example, healthcare surfaces and food processing surfaces.

[0044] As used herein, the term "microorganism" refers to any non-cellular or unicellular (including colonial) organism. Microorganisms include all prokaryotes. Microorganisms include bacteria (including cyanobacteria), spores, lichens, fungi, protozoa, virinos, viroids, viruses, phages, and some algae. As used herein, the term "microbe" is synonymous with microorganism.

[0045] As used herein, the term "polymer" refers to a molecular complex composed of more than 10 monomeric units and generally includes, but is not limited to, homopolymers, copolymers, such as block, graft, random, and alternating copolymers, terpolymers, and higher "x"-mers, as well as analogs, derivatives, combinations, and blends thereof. Furthermore, unless otherwise specifically limited, the term "polymer" is intended to include all possible isomeric configurations of the molecule, including, but not limited to, isotactic, syndiotactic, and random symmetries, and combinations thereof. Furthermore, unless otherwise specifically limited, the term "polymer" is intended to include all possible geometric configurations of the molecule.

[0046] As used herein, the term "soil" or "stain" refers to any soil including, but not limited to, non-polar, oily and / or hydrophobic materials that may or may not contain particulate matter such as industrial soils, mineral clays, sand, natural mineral matter, carbon black, graphite, kaolin, environmental dust, and / or food-based soils such as blood, proteinaceous soils, starchy soils, greasy soils, cellulosic soils, etc.

[0047] The "scope" of the present disclosure is defined by the appended claims, along with the full scope of equivalents to which such claims are entitled. The scope of the present disclosure is further deemed to include any possible modifications to any of the aspects and / or embodiments disclosed herein that result in other embodiments, combinations, subcombinations, etc., that are apparent to those skilled in the art.

[0048] The term "substantially" refers to a large or significant degree. Thus, given the appropriate context, "substantially" can refer to a plurality, a majority, and / or a vast majority of the quantifiable variable in question.

[0049] As used herein, the term "substantially free" refers to a composition that is completely devoid of the component or has such a small amount of the component that the component does not affect the performance of the composition. The component may be present as an impurity or contaminant and is less than 0.5% by weight. In another embodiment, the amount of the component is less than 0.1% by weight, and in yet another embodiment, the amount of the component is less than 0.01% by weight.

[0050] The term "substantially similar cleaning performance" generally refers to generally achieving the same degree (or at least not significantly less) of cleanliness with the alternative cleaning product or system, or generally with the same effort (or at least not significantly less effort), or both, when using an alternative cleaning product or system rather than a more aggressive, higher pH cleaning composition to address typical soil conditions on typical substrates. This degree of cleanliness may correspond to a general absence of visible soiling or to some lesser degree of cleanliness, depending on the particular cleaning product and the particular substrate.

[0051] The term "surfactant" or "surface active agent" refers to an organic chemical that, when added to a liquid, changes the properties of the liquid at the surface.

[0052] As used herein, the term "ware" refers to items such as eating and cooking utensils, dishware, and other hard surfaces such as showers, sinks, toilets, bathtubs, countertops, windows, mirrors, transportation vehicles, and floors. As used herein, the term "ware washing" refers to washing, cleaning, or rinsing ware. ware also refers to items made of plastic. Types of plastics that can be cleaned with the present compositions include, but are not limited to, those containing polypropylene polymer (PP), polycarbonate polymer (PC), melamine formaldehyde resin or melamine resin (melamine), acrylonitrile-butadiene-styrene polymer (ABS), and polysulfone polymer (PS). Other exemplary plastics that can be cleaned using the compounds and compositions of the present disclosure include polyethylene terephthalate (PET), polystyrene polyamide.

[0053] The terms "weight percent," "wt-%," "percent by weight," "% by weight," and variations thereof, as used herein, refer to the concentration of a substance as the weight of the substance divided by the total weight of the composition multiplied by 100. As used herein, it is understood that "percent," "%," and the like are intended to be synonymous with "weight percent," "wt%," and the like.

[0054] solid composition According to embodiments, solid compositions provide a beneficial alternative to liquid formulations while also providing a non-PPE formulation. The solid composition includes an alkali metal benzyl oxide and a sulfonate carrier. The solid composition may also include an alkali metal benzyl oxide, a sulfonate carrier, and a solid acid. The solid composition may further include additional functional ingredients. Exemplary solid compositions are shown in Tables 1-3 by weight percent. Note that while a component may have a percent actives of 100%, Tables 1-3 do not list the percent actives of the component, but rather list the total weight percentage of the raw materials (i.e., actives concentration + inactive ingredients). [Table 1] [Table 2] [Table 3]

[0055] Alkali Metal Benzyl Oxide The solid compositions and solid cleaning compositions include an alkali metal benzyl oxide. The alkali metal benzyl oxide is a solid, preferably sodium benzyl oxide. In embodiments, the alkali metal benzyl oxide is substantially free of water. In further embodiments, the alkali metal benzyl oxide is free of water.

[0056] In some embodiments, the alkali metal benzyl oxide is present in the solid composition in an amount of at least about 40% to about 80%, about 50% to about 70%, or about 55% to about 65% by weight. Additionally, without being limited by this disclosure, all recited ranges are inclusive of the numbers defining the range and include each integer within the defined range.

[0057] In additional embodiments, the alkali metal benzyl oxide is present in the solid cleaning composition in an amount of at least about 10% to about 80%, about 25% to about 70%, about 30% to about 70%, about 30% to about 60%, or about 30% to about 50% by weight. In additional embodiments, the alkali metal benzyl oxide is present in the solid cleaning composition in an amount of at least about 10% to about 60%, or about 20% to about 50% by weight. Additionally, although not limited by the present disclosure, all recited ranges are inclusive of the numbers defining the range and include each integer within the defined range.

[0058] In additional embodiments, the alkali metal benzyl oxide and sulfonate carrier can be combined in a premix composition in a total amount of at least about 30% to about 80% by weight, about 40% to about 80% by weight, or about 50% to about 70% by weight. Additionally, without being limited by the present disclosure, all recited ranges are inclusive of the numbers defining the range and include each integer within the defined range.

[0059] sulfonates The solid compositions and solid cleaning compositions include a sulfonate carrier comprising a C1-C18 sulfonate or short-chain alkylbenzene or alkylnaphthalene hydrotrope. The class of C1-C18 sulfonate and short-chain alkylbenzene or alkylnaphthalene hydrotropes is anionic hydrotropes, including alkylbenzene sulfonates and alkylnaphthalene sulfonates based on toluene, xylene, and cumene. In embodiments, the hydrotrope is a short-chain alkylbenzene or alkylnaphthalene hydrotrope, which is a C1-C12, C1-C8, or C1-C4 alkylbenzene or alkylnaphthalene hydrotrope.

[0060] In embodiments, the hydrotrope is an alkyl sulfonate, including linear and branched primary and secondary alkyl sulfonates, aromatic sulfonates with or without substituents, or sulfonated carboxylic acid esters. In embodiments, alkyl sulfonates C1-C18 sulfonates include, for example, alpha-olefin sulfonates (AOS).

[0061] Exemplary sulfonate carriers include, for example, sodium xylene sulfonate, sodium toluene sulfonate, sodium cumene sulfonate, potassium toluene sulfonate, ammonium xylene sulfonate, calcium xylene sulfonate, sodium alkyl naphthalene sulfonate, and / or sodium butyl naphthalene sulfonate. In a preferred embodiment, the carrier is sodium xylene sulfonate.

[0062] Advantageously, the sulfonate carrier aids in the solidification of the solid compositions and solid cleaning compositions, and further hydrotropes the benzyl alcohol in solution at the point of use once the solid compositions or solid cleaning compositions are dissolved. Advantageously, in still further embodiments, the sulfonate carrier aids in the solidification of the solid compositions and solid cleaning compositions, and further acts as a hydrotrope in solution at the point of use to solubilize hydrophobic compounds such as soils.

[0063] In some embodiments, the sulfonate carrier is present in the composition in an amount of at least about 20% to about 60%, about 30% to about 50%, or about 35% to about 45% by weight. Additionally, without being limited by this disclosure, all recited ranges are inclusive of the numbers defining the range and include each integer within the defined range.

[0064] In additional embodiments, the sulfonate carrier is present in the solid cleaning composition in an amount of at least about 5% to about 40%, about 10% to about 40%, about 20% to about 40%, or about 20% to about 35% by weight. Additionally, without being limited by the present disclosure, all recited ranges are inclusive of the numbers defining the range and include each integer within the defined range.

[0065] In additional embodiments, the sulfonate carrier and alkali metal benzyl oxide can be combined in a premix composition in a total amount of at least about 30% to about 80% by weight, about 40% to about 80% by weight, or about 50% to about 70% by weight. Additionally, without being limited by this disclosure, all recited ranges are inclusive of the numbers defining the range and include each integer within the defined range.

[0066] solid acid The solid composition includes a solid acid to provide a solid composition that provides a desired PPE-free use solution pH. In embodiments, the solid acid is a non-hygroscopic acid. Preferred solid acids include ethylenediaminetetraacetic acid (EDTA) and / or glutamic acid. These preferred solid non-hygroscopic acids offer advantages over other non-hygroscopic acids, including sulfamic acid, citric acid, bisulfate, adipic acid, succinic acid, and tartaric acid.

[0067] In some embodiments, a combination of solid non-hygroscopic acids is used in the solid composition, including at least one of the acids ethylenediaminetetraacetic acid (EDTA) and / or glutamic acid, and an additional solid non-hygroscopic acid, such as one selected from the group consisting of sulfamic acid, citric acid, bisulfate, adipic acid, succinic acid, and tartaric acid. In further embodiments, a combination of solid acids is used in the solid composition, including at least one of the acids ethylenediaminetetraacetic acid (EDTA) and / or glutamic acid and an additional solid acid.

[0068] In additional embodiments, the solid acid is present in the solid cleaning composition in an amount of at least about 20% to about 60%, about 30% to about 60%, about 30% to about 50%, or about 35% to about 45% by weight. Additionally, without being limited by the present disclosure, all recited ranges are inclusive of the numbers defining the range and include each integer within the defined range.

[0069] Additional Functional Ingredients The components of the solid cleaning composition can be further combined with various functional components suitable for use as disclosed herein. In some embodiments, the solid cleaning composition comprising the alkali metal benzyl oxide, the sulfonate carrier, and the solid acid can comprise a majority, or even substantially all, of the total weight of the solid cleaning composition. For example, in some embodiments, the composition contains few or no additional functional components.

[0070] In other embodiments, additional functional ingredients may be included in the solid cleaning composition. The functional ingredient provides the composition with desired properties and functionality. For purposes of this application, the term "functional ingredient" includes materials that, when dispersed or dissolved in a use solution, such as an aqueous solution, and / or concentrate solution, provide beneficial properties in a particular use. Some specific examples of functional materials are discussed in more detail below, although the specific materials discussed are provided merely as examples, and a wide variety of other functional ingredients may be used. For example, many of the functional materials discussed below relate to materials used in cleaning. However, other embodiments may include functional ingredients for use in other applications.

[0071] In some embodiments, the solid cleaning composition may include optical brighteners, defoamers, anti-redeposition agents, bleaching agents, solubility modifiers, dispersants, metal protecting agents, corrosion inhibitors, soil anti-redeposition agents, stabilizers, corrosion inhibitors, chelating enzymes, aesthetic enhancers including fragrances and / or dyes, rheology and / or solubility modifiers, hydrotropes or couplers, buffers, additional solvents, additional cleaning agents, and the like.

[0072] According to embodiments of the present disclosure, various additional functional ingredients may be provided in the solid cleaning composition in amounts of about 0% to about 50% by weight, about 0% to about 40% by weight, about 0% to about 30% by weight, about 0.01% to about 20% by weight, about 0.1% to about 20% by weight, or about 1% to about 20% by weight. Additionally, although not limited by the present disclosure, all recited ranges are inclusive of the numbers defining the range and include each integer within the defined range.

[0073] According to embodiments of the present disclosure, various additional functional ingredients, such as processing aids, may be provided in the solid composition in amounts of about 0% to about 20% by weight, about 0% to about 15% by weight, about 0% to about 10% by weight, about 0.01% to about 10% by weight, about 0.1% to about 10% by weight, or about 1% to about 10% by weight. Additionally, although not limited by the present disclosure, all recited ranges are inclusive of the numbers defining the range and include each integer within the defined range.

[0074] Production method The solid composition is made by combining an alkali metal hydroxide, benzyl alcohol, and a sulfonate carrier to form a solid composition in situ. The solid cleaning composition is made by combining an alkali metal hydroxide, benzyl alcohol, and a sulfonate carrier to form a solid composition in situ, and then adding a solid acid to form the solid composition. In some embodiments, a pre-formed premix of alkali metal benzyl oxide and a sulfonate carrier can be combined with the solid acid to provide the solid composition. In further embodiments, one or more additional functional ingredients can be combined with the solid composition or included in the reagents for in situ reaction to form the solid composition.

[0075] The solid composition provides a stable, flowable powder or granules by combining an alkali metal hydroxide, benzyl alcohol, and a sulfonate carrier. A solid acid is further included to bring the pH of the solid composition to a non-PPE level. Because the powder and / or granules are stable as described herein, a solid acid is not required to create a stable solid.

[0076] The combining step can be the addition of materials and mixing thereof. For example, a solid composition or solid cleaning composition is formed by mixing reagents to form a continuous, one-phase homogeneous solid.

[0077] The composition can be formed using a batch or continuous mixing system. In an exemplary embodiment, a single or twin screw extruder is used to combine and mix one or more agents at high shear to form a homogeneous mixture.

[0078] Specifically, in the forming process, liquid and / or solid components are introduced into a mixing system and continuously mixed until the components form a continuous solid. In exemplary embodiments, the components are mixed in the mixing system for at least approximately 5 seconds, 15 seconds, 30 seconds, 60 seconds, 5 minutes, 10 minutes, 30 minutes, or 60 minutes. The mixture can then be discharged from the mixing system and subjected to further processing, such as powdering.

[0079] In exemplary embodiments, the formed composition begins to harden into a solid form almost instantly during the drying process, providing a solid powder or granules. During the drying process, the particle size of the powder or granules increases over the course of processing, from one minute to several hours, e.g., about two hours. The increased powder size provides a free-flowing powder. The increased granule size provides a free-flowing granule.

[0080] In embodiments, the molar ratio of alkali metal hydroxide to benzyl alcohol reacted with the sulfonate carrier is at least about 1:1 to produce a solid composition, wherein the solid is a flowable solid. In embodiments, the ratio of alkali metal hydroxide to benzyl alcohol is at least about 1:1, at least about 2:1, at least about 1:1 to about 5:1, at least about 2:1 to about 5:1, at least about 2:1 to about 4:1, or about 14:1. As described herein, the ratio of alkali metal hydroxide to benzyl alcohol can be as low as about 1:1, including the sulfonate carrier and / or other stabilizing or solidifying components included in the composition.

[0081] In embodiments, the alkali metal hydroxide is added in an amount of about 10% to about 50% by weight, the benzyl alcohol is added in an amount of about 1% to about 30% by weight, and the sulfonate carrier is added in an amount of about 30% to about 60% by weight, followed by addition of an acid, or in an alternative embodiment, addition of the acid together with the initial reagents to form a solid composition.

[0082] In a further embodiment, the premix of alkali metal benzyl oxide and sulfonate is added in an amount of about 40% to about 80% by weight, and the acid is added in an amount of about 20% to about 60% by weight.

[0083] In embodiments, the molar ratio of alkali metal hydroxide to benzyl alcohol to produce the solid composition is at least about 1:1, at least about 2:1, or preferably from about 2:1 to about 5:1, or from about 2:1 to about 4:1, and in the first step, the alkali metal hydroxide is added in an amount of from about 10% to about 50% by weight, the benzyl alcohol is added in an amount of from about 1% to about 30% by weight, and the sulfonate carrier is added in an amount of from about 30% to about 60% by weight.

[0084] The reagents are combined to provide a solid composition. The solid may comprise a tablet, a block, or a powder. In embodiments, the solid is dimensionally stable. In embodiments, the powder is a free-flowing powder. In embodiments, the granules are free-flowing granules.

[0085] In embodiments, the solid composition comprising an alkali metal benzyl oxide, in some embodiments residual hydrogen peroxide, and a sulfonate carrier is substantially free of water or free of water.In embodiments, the solid composition comprising an alkali metal benzyl oxide, in some embodiments residual hydrogen peroxide, a sulfonate carrier, and a solid acid is substantially free of water or free of water.

[0086] The method may further comprise a spray drying step, including, for example, fluidized bed drying, and / or a granulation step. Spray drying is typically a one-step process in which a liquid is dried with a hot gas; the resulting particles are often finer and do not have an opportunity to agglomerate or grow in size before reaching the product outlet.

[0087] In some embodiments where larger particles are desired, a fluidized bed can be incorporated into the process. In fluidized bed drying, a liquid is dried with hot gas and the resulting particles have the opportunity to be recycled through an atomization zone, allowing for agglomeration or layered growth of the particles to a desired size. Particles of these sizes are often referred to as granules. Granulation is a broader term where finer powders are grown into granules through various methods or pieces of equipment. Fluidized bed granulation is a type of granulation.

[0088] In one embodiment, the dry material is in solid powder or granular form. This advantageously provides a soil-free, free-flowing granule or powder. In one embodiment, the solid composition or solid cleaning composition can be completed in an aqueous solution and then dried (e.g., through spray drying, a fluidized bed dryer, or granulation) to further concentrate the benzyl oxide solid in powder or granular form.

[0089] Alkali metal hydroxide source Alkali metal hydroxides are reagents for forming solid compositions and solid cleaning compositions. Exemplary alkali metal hydroxides include sodium hydroxide, potassium hydroxide, and lithium hydroxide, or mixtures thereof, with sodium hydroxide being most preferred. The alkali metal hydroxide can include one or more of liquid alkali metal hydroxide and solid alkali metal (e.g., caustic beads). The alkali metal hydroxide is preferably liquid and can comprise about 20-74% (active matter basis) alkali metal hydroxide liquid.

[0090] In some embodiments, the solid compositions and solid cleaning compositions contain residual or excess alkali metal hydroxide that is unreacted, depending on the molar ratio of benzyl alcohol to hydroxide used. In preferred embodiments, the residual or excess alkali metal hydroxide promotes the formation of alkali metal benzyl oxide.

[0091] In some embodiments, to form a solid composition, a calculated molar ratio of benzyl oxide to residual sodium hydroxide can be calculated (assuming 100% conversion of benzyl alcohol to benzyl oxide) based on a ratio of alkali metal hydroxide to benzyl alcohol that is at least about 1:1, at least about 2:1, or preferably about 2:1 to about 5:1, or about 2:1 to about 4:1. The calculated amount of residual sodium hydroxide is the preferred route because analytical methods cannot confirm the solid form due to benzyl oxide reverting to benzyl alcohol in solution.

[0092] In some embodiments, the alkali metal hydroxide is combined with benzyl alcohol and the sulfonate carrier in an amount of about 5% to about 60%, about 10% to about 50%, or about 20% to about 40% by weight to form the solid composition in situ. Additionally, without being limited by this disclosure, all recited ranges are inclusive of the numbers defining the range and include each integer within the defined range.

[0093] benzyl alcohol Benzyl alcohol is a reagent for forming solid compositions and solid cleaning compositions. Benzyl alcohol is an aromatic alcohol, and in some embodiments, alternative solvents can be used. Exemplary solvents and solvent systems can include one or more different solvents, including aromatic alcohols such as methylbenzyl alcohol, benzyloxyethanol, or other phenolic alcohols. Benzyl alcohol is preferably combined with an alkali metal hydroxide to form benzyl oxide.

[0094] In some embodiments, benzyl alcohol is combined with an alkali metal hydroxide and sulfonate carrier in an amount of about 1% to about 30%, about 10% to about 30%, or about 20% to about 30% by weight to form a solid composition in situ. Additionally, without being limited by this disclosure, all recited ranges are inclusive of the numbers defining the range and include each integer within the defined range.

[0095] Sulfonate Supports The sulfonate carrier is combined with the alkali metal hydroxide and benzyl alcohol in an amount of about 20% to about 80%, about 30% to about 60%, or about 40% to about 60% by weight to form the solid composition in situ. Additionally, although not limited by this disclosure, all recited ranges are inclusive of the numbers defining the range and include each integer within the defined range.

[0096] How to use Methods using the solid cleaning compositions are suitable for cleaning, degreasing, and / or stripping many soiled surfaces and / or items. In certain embodiments, environmental cleaning methods are provided in which surfaces and / or items are cleaned, degreased, and / or stripped. In other embodiments, any cleaning application requiring a non-corrosive composition and / or a composition that does not require the use of PPE by the user is provided.

[0097] Exemplary industries in which the present method can be used include, but are not limited to, the restaurant industry, the food and beverage industry, consumer degreasing applications, petroleum processing, agricultural and ethanol processing, and pharmaceutical manufacturing. Suitable uses of the compositions and methods described herein can include, for example, cleaning various environmental surfaces. Suitable uses of the compositions and methods described herein can include cleaning hard surfaces.

[0098] The hard surfaces can include various metal surfaces. Advantageously, in some embodiments, the lower pH of the use compositions is non-corrosive and can be used on a variety of surfaces. In one embodiment, the compositions can be used as non-corrosive degreaser compositions (concentrates and use solutions) that are non-aluminum corrosive compositions (i.e., not corrosive to aluminum on more sensitive metal surfaces). Such advantages can be demonstrated, for example, by not etching or otherwise damaging the surface, including reduced or no aluminum mass loss (compared to a control) upon application.

[0099] The compositions and methods can be used as oven cleaners, including microwave ovens, general degreasers, fryer degreasers, smokehouse cleaners, floor cleaners, exhaust hood cleaners, drain cleaners, floor finish removers, floor cleaners, wall cleaners, fryer cleaners, pot and pan cleaners (and other dishes, flatware, etc.), carpet spotters, medical and cosmetic cleaners, equipment cleaners, tar removers, and the like.

[0100] In one embodiment, the method is particularly suitable for cleaning and degreasing difficult soils, such as polymerized fatty soils. The method can also be used to remove soils other than polymerized soils, including, for example, starch, cellulose fibers, proteins, simple carbohydrates, and combinations of any of these soil types with mineral complexes. Examples of specific food soils that can be effectively removed using the method include, but are not limited to, soils resulting from the manufacturing and processing of meat, poultry, vegetables, and fruits, bakery products, soft drinks, brewing and fermentation residues, sugar beet and sugar cane processing, and processed foods containing these ingredients and related ingredients, such as juices, sauces, and condiments. These soils can occur on environmental surfaces, such as walls and floors, freezers and refrigeration systems, heat exchanger surfaces, conveyor surfaces, and other surfaces during manufacturing and packaging processes.

[0101] Methods of using the solid cleaning composition include first forming a use solution. In embodiments, the dilution range for forming the use solution from the solid cleaning composition is from about 1% to about 20%, from about 5% to about 20%, or from about 10% to about 15%.

[0102] The solid cleaning composition can be applied in a use solution or concentrate having a pH of about 8 to about 11.5, or about 8 to about 11, or preferably about 8 to about 10.5. Without being limited by the dilution ratio of the solid cleaning composition, the formation of a use solution of the solid cleaning composition beneficially provides a use solution pH for non-PPE applications.

[0103] According to preferred embodiments, compositions having a pH less than about 11.5 do not require PPE, yet unexpectedly provide the same or substantially similar cleaning, degreasing, and / or stripping benefits as compositions having a pH greater than about 11.5 and / or compositions containing caustic agents. In other aspects, the compositions provide superior cleaning, degreasing, and / or stripping benefits. In other aspects, the compositions provide effective cleaning, degreasing, and / or stripping benefits without damaging treated surfaces, including sensitive metals such as aluminum.

[0104] A use solution is then formed, and the use solution is contacted with a surface or article for a time suitable for treating the surface and / or article. In some embodiments, the use solution of the solid cleaning composition is contacted with the surface or article for a time sufficient to clean the surface or article. In one aspect, the surface or article is contacted with the use solution of the cleaning composition for at least about 1 second, at least about 1 minute, at least about 10 minutes, or at least about 1 hour. In some embodiments, the surface or article is contacted for from about 1 second to about 24 hours, or from about 1 minute to about 2 hours. The soil is then removed from the surface.

[0105] Use solutions of the cleaning compositions can be applied to surfaces or items in need of cleaning at the time of use or as concentrated solutions. In one aspect, the use concentration of the solid cleaning composition comprises from about 100 ppm to about 150,000 ppm, from about 500 ppm to about 100,000 ppm, from about 1,000 ppm to about 100,000 ppm, or from about 5,000 ppm to about 10,000 ppm, including all ranges therebetween.

[0106] Advantageously, methods using the solid cleaning composition do not require the use of PPE as a result of a pH below about 11.5.

[0107] In one embodiment, application of a use solution of the solid cleaning composition does not require substantial mechanical action or excessive temperature. In some embodiments, no additional mechanical force is used to remove soils. In embodiments, the use methods described herein provide cleaning results at least substantially similar to those obtained with the use of prior art caustic, highly alkaline compositions. In additional embodiments, the use methods described herein provide superior soil removal compared to conventional caustic compositions having a pH greater than about 11.5.

[0108] Embodiment The present disclosure is further defined by the following numbered paragraphs:

[0109] [Paragraph 1] An alkali metal benzyl oxide, A solid composition comprising a sulfonate carrier and a non-hygroscopic solid acid, wherein the solid does not require personal protective equipment (PPE) for handling.

[0110] The solid composition of paragraph 1, wherein the alkali metal benzyl oxide comprises sodium benzyl oxide.

[0111] The solid composition of paragraph 1 or 2, wherein the sulfonate carrier is a short chain alkylbenzene or alkylnaphthalene hydrotrope.

[0112] 4. The solid composition of any one of paragraphs 1-3, wherein the sulfonate carrier comprises one or more of sodium xylene sulfonate, sodium toluene sulfonate, sodium cumene sulfonate, potassium toluene sulfonate, ammonium xylene sulfonate, calcium xylene sulfonate, sodium alkyl naphthalene sulfonate, and sodium butyl naphthalene sulfonate.

[0113] 5. The solid composition of any one of paragraphs 1-4, wherein the non-hygroscopic solid acid is the acid EDTA and / or glutamic acid.

[0114] The solid composition of paragraph 5, wherein the non-hygroscopic solid acid is an acid further combined with an additional solid acid, preferably an additional non-hygroscopic solid acid.

[0115] 7. The solid composition of any one of paragraphs 1 through 6, wherein: (a) the alkali metal benzyl oxide comprises about 10-60% by weight of the composition, the sulfonate carrier comprises about 5-40% by weight of the composition, and the non-hygroscopic solid acid comprises about 20-60% by weight of the composition; (b) the alkali metal benzyl oxide comprises about 20-50% by weight of the composition, the sulfonate carrier comprises about 10-30% by weight of the composition, and the non-hygroscopic solid acid comprises about 25-50% by weight of the composition; (c) the alkali metal benzyl oxide and sulfonate carrier are provided in a premix comprising about 40-80% by weight of the composition, and the non-hygroscopic solid acid comprises about 20-60% by weight of the composition; or (d) the alkali metal benzyl oxide and sulfonate carrier are provided in a premix comprising about 50-70% by weight of the composition, and the non-hygroscopic solid acid comprises about 30-50% by weight of the composition.

[0116] 8. The solid composition of any one of paragraphs 1 through 7, wherein the solid is a tablet, a block, or a powder, and wherein the solid is a dimensionally stable solid or a flowable solid.

[0117] 9. The solid composition of any one of paragraphs 1 through 8, wherein the solid consists of an alkali metal benzyl oxide, optionally an alkali metal hydroxide, a sulfonate carrier, and a non-hygroscopic solid acid, and is substantially free of water or free of water.

[0118] 10. The solid composition of any one of paragraphs 1 to 9, further comprising at least one additional functional ingredient suitable for solid cleaning and / or degreasing compositions.

[0119] [Paragraph 11] A method for making a solid composition, comprising: 1. A method comprising: (i) combining an alkali metal hydroxide, benzyl alcohol, and a sulfonate carrier with a non-hygroscopic solid acid to form a solid composition in situ; or (ii) combining a premix comprising an alkali metal benzyl oxide and a sulfonate carrier with a non-hygroscopic solid acid, wherein the molar ratio of alkali metal hydroxide to benzyl alcohol is at least about 2:1 to about 5:1, or preferably about 2:1 to about 4:1; and adding the non-hygroscopic solid acid to form a solid composition.

[0120] 12. The method of paragraph 11, wherein in the first step, the alkali metal hydroxide is added in an amount of about 10% to about 50% by weight, the benzyl alcohol is added in an amount of about 1% to about 30% by weight, and the sulfonate carrier is added in an amount of about 30% to about 60% by weight.

[0121] 13. The method of paragraph 12, wherein the alkali metal hydroxide comprises one or more of a liquid alkali metal hydroxide and a solid alkali metal (e.g., caustic beads), and optionally the alkali metal hydroxide comprises 20 to 74% (active matter basis) alkali metal hydroxide liquid.

[0122] 14. The method of any one of paragraphs 11-13, wherein the solid is a tablet, a block, a powder, or a granule, and wherein the solid is a dimensionally stable solid or a flowable solid.

[0123] 15. The process of any one of paragraphs 11 to 14, further comprising a spray drying step and / or a granulation step.

[0124] [Paragraph 16] A method of using a solid cleaning composition, comprising: forming a use solution of the cleaning composition of any one of Paragraphs 1 through 10 or a composition made by the method of any one of Paragraphs 11 through 15; contacting a surface or article in need of cleaning, degreasing, and / or stripping with the use solution; and removing soil from the surface, wherein the pH of the use solution is from about 8 to less than about 11, or preferably from about 8 to about 10.5, for non-personal protective equipment (PPE) applications.

[0125] 17. The method of paragraph 16, wherein the surface is a hard surface or an article.

[0126] 18. The method of paragraph 16 or 17, wherein the dilution range of the use solution is about 5-20%, or about 10-15%.

[0127] 19. The method of any one of paragraphs 16-18, wherein the surface or article is soiled with polymerized fatty soils.

[0128] 20. The method of any one of paragraphs 16-19, wherein the contacting of the surfaces is for an amount of time between about 1 second and about 24 hours.

[0129] 20. The method of any one of paragraphs 16-19, wherein the contacting of the surfaces is for an amount of time between about 1 minute and about 2 hours.

[0130] The method of any one of paragraphs 16 to 21, wherein removal of the stain does not require additional mechanical force.

[0131] [Paragraph 23] A solid composition comprising an alkali metal benzyl oxide and a sulfonate carrier, wherein the solid is a free-flowing powder or free-flowing granules.

[0132] 24. The solid composition of paragraph 23, comprising about 40% to about 80% by weight of an alkali metal benzyl oxide, comprising sodium benzyl oxide.

[0133] 25. The solid composition of paragraph 23 or 24, comprising about 20% to about 60% by weight of the sulfonate carrier, which is a short chain alkylbenzene or alkylnaphthalene hydrotrope.

[0134] 26. The solid composition of any one of paragraphs 23-25, wherein the sulfonate carrier comprises one or more of sodium xylene sulfonate, sodium toluene sulfonate, sodium cumene sulfonate, potassium toluene sulfonate, ammonium xylene sulfonate, calcium xylene sulfonate, sodium alkyl naphthalene sulfonate, and sodium butyl naphthalene sulfonate.

[0135] 27. The solid composition of any one of paragraphs 23 through 26, wherein the solid composition is substantially free of water or free of water, and optionally further comprises an alkali metal hydroxide.

[0136] [Paragraph 28] A method for making a solid composition, comprising combining an alkali metal hydroxide, benzyl alcohol, and a sulfonate carrier to form a solid composition in situ, wherein the molar ratio of alkali metal hydroxide to benzyl alcohol is at least about 2:1 to about 5:1, or preferably about 2:1 to about 4:1.

[0137] 29. The method of paragraph 28, wherein the alkali metal hydroxide comprises one or more of a liquid alkali metal hydroxide and a solid alkali metal (e.g., caustic beads), and optionally the alkali metal hydroxide comprises 20 to 74% (active matter basis) alkali metal hydroxide liquid.

[0138] 30. The process of paragraph 28 or 29, wherein the solid is a free-flowing powder or free-flowing granules.

[0139] 31. The method of any one of paragraphs 28-30, further comprising adding a solid acid to provide a pH at a non-PPE level.

[0140] 32. The process of any one of paragraphs 29 to 31, further comprising a spray drying step and / or a granulation step.

[0141] 33. The method of any one of paragraphs 28 through 32, further comprising compressing the free-flowing powder or free-flowing granules into a solid.

[0142] [Paragraph 34] A method of using a solid cleaning composition, the method comprising: forming a use solution of the cleaning composition of any one of Paragraphs 23 to 27 or a composition made by the method of any one of Paragraphs 28 to 33; contacting a surface or item in need of cleaning, degreasing, and / or stripping with the use solution; and removing soil from the surface.

[0143] 35. The method of paragraph 34, wherein the surface is a hard surface or article soiled with polymerized greasy soil.

[0144] The method of paragraph 34 or 35, wherein the dilution range of the use solution is about 5-20%, or about 10-15%.

[0145] 37. The method of any one of paragraphs 34-36, wherein the contacting of the surfaces is for an amount of time from about 1 second to about 24 hours, or from about 1 minute to about 2 hours.

[0146] The method of any one of paragraphs 34 to 37, wherein removal of the stain does not require additional mechanical force. [Example]

[0147] Embodiments of the present disclosure are further defined in the following non-limiting examples. These examples, while illustrating certain specific embodiments of the present disclosure, should be understood to be given by way of illustration only. From the above discussion and these examples, those skilled in the art can ascertain the essential features of the present disclosure and can make various changes and modifications to the embodiments of the present disclosure to adapt them to various uses and conditions without departing from the spirit and scope thereof. Thus, various modifications of the embodiments of the present disclosure, in addition to those shown and described herein, will be apparent to those skilled in the art from the foregoing description. Such modifications are also intended to fall within the scope of the appended claims.

[0148] Example 1 Solid compositions of benzyl oxide and SXS were formed by combining the reagents shown in Table 4. The inclusion of SXS as a carrier resulted in the formation of a flowable solid, with the SXS remaining as an inert carrier. [Table 4]

[0149] Examples that form sodium benzyl oxide without SXS did not provide a flowable solid, but instead formed a paste-like composition.

[0150] Example 2 The solid compositions in Table 4 were used to make exemplary solid cleaning compositions shown in Table 5 using various acids. Stability evaluations were completed at approximately 40° C. and 65% relative humidity, and at 50° C. with no humidity. High humidity conditions were more difficult to produce stable solids than the elevated temperatures of 50° C. [Table 5]

[0151] Observation of various cleaning compositions made with the solid compositions in Table 4 indicates that solid compositions made with non-hygroscopic solid acids provide the most stable solids. Without being limited to a particular mechanism of action, more hygroscopic acids attract water and further react with residual caustic in the solid composition, resulting in a less stable composition, or in the evaluated embodiments, an unstable composition. Furthermore, hygroscopic solid acids also beneficially reduce pH to provide non-PPE solid compositions. The acids evaluated, EDTA and glutamic acid, provide these results of a lower pH for non-PPE applications while also providing stable powders.

[0152] Example 3 Corn oil panels were prepared to evaluate the degreaser performance on polymerized corn oil panels and how quickly the formulation penetrated the soiled surface.

[0153] Preparation of Polymerized Corn Oil Panels. Corn oil stains were prepared on 3 x 5 inch stainless steel panels by lightly coating the corn oil with a 2-inch polyurethane brush. The panels were coated to ensure no streaks remained on the bare steel, and excess oil was removed using only the weight of the brush. The panels were then placed on an aluminum tray and cooked in a 375°F oven for approximately 20 minutes until the polymerized oil was no longer tacky and exhibited a light amber color. After approximately 10 minutes of cooking, the oil began to polymerize and thicken, resulting in the release of smoke. The pan should be rotated to ensure the panel was heated evenly in the oven. The panels were then allowed to cool overnight before being tested with the cleaning / degreasing formulation.

[0154] Solid compositions (granules) of sodium benzyl oxide were diluted to 15% and 10% use solutions, and the pH of each was adjusted with sulfuric acid. The formulations were tested according to application and soil removal from the corn oil panel described above, compared to a commercial control formulation (a liquid caustic-free, solvent-based, ready-to-use (RTU) composition of benzyl alcohol, linear alkylbenzene sulfonate, 2-(2-aminoethoxy)ethanol, and monoethanolamine). Three drops of each formulation were added to the bottom of a row of coupons, each representing a contact time with the soil (30, 60, or 120 seconds). At each time point, the chemical was wiped off. The coupons were allowed to dry, and all formulations were compared to qualitatively assess penetration of the polymerized corn oil. Visual observations were made, and images were also taken to quantify the amount of oil removed using the FUJI analysis.

[0155] The results are summarized in Figure 1, which shows that solid compositions (granules) of sodium benzyl oxide at use solution pHs (tested at pH 10.5-11) that do not require PPE provided substantially similar (and in some cases improved) cleaning performance to controls with more alkaline pHs that require PPE. Cleaning performance is shown according to the average value from image analysis, which analyzes areas on coupons where soil remains and uses image analysis to estimate soil removal or cleaning effectiveness. A lower average value indicates improved soil removal.

[0156] Performance improved with increasing pH and concentration, but at pHs of 10.5-11, the sodium benzyl oxide evaluated beneficially removed polymerized soils after 60 seconds and 2 minutes equivalent to the control RTU, but offered the benefits of lower pH use conditions.

[0157] Example 4 Compositions with benzyl alcohol to sodium hydroxide molar ratios of 1:1, 1:2, and 1:4 did not form stable solids. Instead, pastes were made with these different benzyl alcohol to sodium hydroxide molar ratios. Even with a 1:1 benzyl alcohol to sodium hydroxide molar ratio, a stable solid was obtained only when a sulfonate carrier was added.

[0158] An exemplary calculation of the molar ratio of sodium benzyl alcohol to sodium hydroxide is shown in the table below. [Table 6] [Table 7]

[0159] Example 5 Additional testing was performed to evaluate the stability of solids. Dimensional stability of tablet solids is often performed using a qualitative assessment, for example, to ensure that the tablet does not swell, crumble, or otherwise lose shape. For powder or granular solids, dimensional stability is assessed qualitatively to ensure that the solid remains flowable and does not clump or discolor. This differs from quantitative assessment of dimensional stability of larger solid blocks, where the change in dimension (e.g., height, width) is measured over time to calculate the percent change in dimension. Additional testing performed was completed on powders and tablet solids made from the powders, and therefore, a qualitative assessment was used.

[0160] Initial testing was performed comparing compositions 1, 2, and 3 (see Table 5), where tablets were placed in plastic cups and exposed to high temperature and humidity (40°C / 65% humidity) and high temperature (50°C, less than 55% ambient humidity) conditions for up to 5 days for observation. Testing revealed some swelling and disintegration of the compositions, with a less pronounced impact on stability for compositions 2 and 3.

[0161] The results of the plastic cup test were continued by testing a wider range of compositions, but the tablets were placed in foil packets to provide additional protection from temperature / humidity conditions, and the test was continued for 8 weeks to further demonstrate the storage and shipping conditions (compared to the plastic cup test) of unit dose packaged solid compositions. A summary of the test compositions and observations over time are provided herein: Composition 3 was evaluated over an 8 week period. No substantial changes in tablet stability or condition were detected up to 4 weeks in either the high temperature / high humidity or hot foil packets.

[0162] Composition 3, which used granular sodium benzyl oxide (instead of powder), was evaluated over an 8-week period. No substantial change in tablet stability or condition was detected in either the hot / humidity or hot foil packets up to 2 weeks, at which point the hot foil tablets showed some disintegration, while the hot / humidity packets showed no disintegration until approximately 6 weeks.

[0163] Composition 4 in powder form was evaluated over an 8 week period, with some aggregation detected at 2 weeks in both the hot / humid and hot foil packets, indicating that adipic acid alone was not sufficient to stabilize the benzyl oxide solids.

[0164] Composition 4 was evaluated over an 8-week period, with swelling detected in both the hot / humid and hot foil packets after one week, indicating that adipic acid alone is not sufficient to stabilize the benzyl oxide solid. Composition 5 was evaluated over an 8-week period in both powder packages and solid tablets. The powder remained flowable over the 8-week period, and the tablets did not swell significantly.

[0165] Composition 6 was evaluated in tablets over an 8-week period. No substantial change in tablet stability or condition was detected up to 6 weeks in either the high temperature / humidity or hot foil packets. However, slight disintegration or swelling up to 8 weeks indicated that the tablet still passed the stability evaluation.

[0166] Composition 6 in powder form was also evaluated over an 8 week period. Some clumping of the powder in the hot foil packet was observed after the second week.

[0167] Composition 7 was evaluated in tablets over an 8 week period. Some swelling was detected in the hot foil packets at 2 weeks, indicating that tartaric acid alone was not sufficient to stabilize the benzyl oxide solids.

[0168] Composition 7 was also evaluated in powder form in foil packets over an 8 week period. Some clumping of the powder in the hot foil packets was observed after 2 weeks, and after 4 weeks at high temperature / high humidity.

[0169] Composition 8 was evaluated over an 8-week period using tablets and powder. No substantial changes were detected in the stability or condition of the tablets and the flowability of the powder over the 8-week period in either high temperature / humidity or hot foil packets, demonstrating the enhanced stabilizing effect of glutamic acid.

[0170] While the present invention has been described in conjunction with its detailed description, it should be understood that the foregoing description is intended to be illustrative, and not limiting, of the scope of the invention, which is defined by the scope of the appended claims. Other embodiments, advantages, and modifications are within the scope of the following claims. Any references to the accompanying drawings that form a part of this specification are made by way of illustration only. It is understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present disclosure. All publications discussed and / or referenced herein are incorporated herein in their entirety.

[0171] The features disclosed in the foregoing specification, or the following claims, or the accompanying drawings, whether presented in a particular form or in terms of means for performing a disclosed function, or a method or process for achieving a disclosed result, may be utilized, as appropriate, separately or in any combination of such features, to realize the invention in diverse forms thereof.

Claims

1. an alkali metal benzyl oxide; a sulfonate carrier; a non-hygroscopic solid acid; and 1. A solid composition, wherein the solid is a tablet, block, powder, or granule, said solid being a dimensionally stable solid or a flowable solid, and said solid not requiring personal protective equipment (PPE) for handling.

2. 10. The solid composition of claim 1, wherein the alkali metal benzyl oxide comprises sodium benzyl oxide.

3. 3. The solid composition of claim 1 or 2, wherein the sulfonate carrier is a short chain alkylbenzene or alkylnaphthalene hydrotrope.

4. 4. The solid composition of claim 1, wherein the sulfonate carrier comprises one or more of sodium xylene sulfonate, sodium toluene sulfonate, sodium cumene sulfonate, potassium toluene sulfonate, ammonium xylene sulfonate, calcium xylene sulfonate, sodium alkyl naphthalene sulfonate, and sodium butyl naphthalene sulfonate.

5. 5. The solid composition according to any one of claims 1 to 4, wherein the non-hygroscopic solid acid is the acid EDTA and / or glutamic acid, optionally the non-hygroscopic solid acid being further combined with an additional solid acid.

6. 6. The solid composition of claim 5, wherein the non-hygroscopic solid acid is an acid further combined with an additional solid acid, preferably an additional non-hygroscopic solid acid.

7. (a) the alkali metal benzyl oxide comprises about 10-60% by weight of the composition, the sulfonate carrier comprises about 5-40% by weight of the composition, and the non-hygroscopic solid acid comprises about 20-60% by weight of the composition; or (b) the alkali metal benzyl oxide comprises about 20-50% by weight of the composition, the sulfonate carrier comprises about 10-30% by weight of the composition, and the non-hygroscopic solid acid comprises about 25-50% by weight of the composition; or (c) the alkali metal benzyl oxide and the sulfonate carrier are provided in a premix comprising about 40 to 80 weight percent of the composition, and the non-hygroscopic solid acid comprises about 20 to 60 weight percent of the composition; or (d) the alkali metal benzyl oxide and the sulfonate carrier are provided in a premix that comprises about 50-70% by weight of the composition, and the non-hygroscopic solid acid comprises about 30-50% by weight of the composition.

8. 8. The solid composition of claim 1, wherein the solid consists of the alkali metal benzyl oxide, optionally an alkali metal hydroxide, the sulfonate carrier, and the non-hygroscopic solid acid, and is substantially free of water or free of water.

9. 9. The solid composition of any one of claims 1 to 8, further comprising at least one additional functional ingredient suitable for solid cleaning and / or degreasing compositions.

10. 1. A method for producing a solid composition, the method comprising: (i) combining an alkali metal hydroxide, benzyl alcohol, and a sulfonate carrier with a non-hygroscopic solid acid to form a solid composition in situ, or (ii) combining a premix comprising an alkali metal benzyl oxide and a sulfonate carrier with a non-hygroscopic solid acid, wherein the molar ratio of alkali metal hydroxide to benzyl alcohol is at least about 2:1 to about 5:1, or preferably about 2:1 to about 4:1; adding a non-hygroscopic solid acid to form the solid composition, wherein the solid is a tablet, block, powder, or granule, and the solid is a dimensionally stable solid or a flowable solid; A method comprising:

11. 11. The method of claim 10, wherein in the first step, the alkali metal hydroxide is added in an amount of about 10% to about 50% by weight, the benzyl alcohol is added in an amount of about 1% to about 30% by weight, and the sulfonate carrier is added in an amount of about 30% to about 60% by weight.

12. 11. The method of claim 10, wherein the alkali metal hydroxide comprises one or more of a liquid alkali metal hydroxide and a solid alkali metal (e.g., caustic beads), and optionally the alkali metal hydroxide comprises 20 to 74% (active matter basis) alkali metal hydroxide liquid.

13. The method according to any one of claims 10 to 12, further comprising a spray drying step and / or a granulation step.

14. 1. A method of using a solid cleaning composition, the method comprising: Producing a use solution of a cleaning composition according to any one of claims 1 to 9 or a composition made by the method according to any one of claims 10 to 13; contacting a surface or item requiring cleaning, degreasing, and / or stripping with said use solution; removing soil from the surface; The method wherein the pH of the use solution is from about 8 to less than about 11, or preferably from about 8 to about 10.5 for non-personal protective equipment (PPE) applications.

15. 15. The method of claim 14, wherein the surface is a hard surface or article soiled with polymerized greasy soil.

16. 16. The method of claim 14 or 15, wherein the dilution range of the use solution is about 5-20%, or about 10-15%.

17. 17. The method of any one of claims 14 to 16, wherein said contacting of said surface is for an amount of time from about 1 second to about 24 hours, or from about 1 minute to about 2 hours.

18. The method of any one of claims 14 to 18, wherein the removal of the stain does not require additional mechanical force.

19. an alkali metal benzyl oxide; a sulfonate carrier; and a solid composition comprising: A solid composition wherein the solid is a free-flowing powder or granules, or a compacted solid.

20. 20. The solid composition of claim 19, comprising about 40% to about 80% by weight of said alkali metal benzyl oxide comprising sodium benzyl oxide.

21. 21. The solid composition of claim 19 or 20, comprising about 20% to about 60% by weight of said sulfonate carrier, said sulfonate carrier being a short chain alkyl benzene or alkyl naphthalene hydrotrope.

22. 22. The solid composition of any one of claims 19 to 21, wherein the sulfonate carrier comprises one or more of sodium xylene sulfonate, sodium toluene sulfonate, sodium cumene sulfonate, potassium toluene sulfonate, ammonium xylene sulfonate, calcium xylene sulfonate, sodium alkyl naphthalene sulfonate, and sodium butyl naphthalene sulfonate.

23. 23. The solid composition of any one of claims 19 to 22, wherein the solid composition is substantially free of water or free of water, and optionally further comprises an alkali metal hydroxide.

24. 1. A method for producing a solid composition, the method comprising: combining an alkali metal hydroxide, benzyl alcohol, and a sulfonate carrier to form a solid composition in situ; the solid is a free-flowing powder or free-flowing granules; A process wherein the molar ratio of alkali metal hydroxide to benzyl alcohol is at least about 2:1 to about 5:1, or preferably about 2:1 to about 4:

1.

25. 25. The method of claim 24, wherein the alkali metal hydroxide comprises one or more of a liquid alkali metal hydroxide and a solid alkali metal, and optionally the alkali metal hydroxide comprises 20 to 74% (active matter basis) alkali metal hydroxide liquid.

26. 26. The method of claim 24 or 25, further comprising adding a solid acid to provide a pH at a non-PPE level.

27. The method according to any one of claims 24 to 26, further comprising a spray drying step and / or a granulation step.

28. 28. The method of any one of claims 24 to 27, further comprising compressing the free-flowing powder or granules into a solid.

29. 1. A method of using a solid cleaning composition, the method comprising: Producing a use solution of a cleaning composition according to any one of claims 19 to 23 or a composition made by the method according to any one of claims 24 to 27; contacting a surface or item requiring cleaning, degreasing, and / or stripping with said use solution; and removing the soil from said surface.

30. 30. The method of claim 29, wherein the surface is a hard surface or article soiled with polymerized greasy soil.

31. 31. The method of claim 29 or 30, wherein the dilution range of the use solution is about 5-20%, or about 10-15%.

32. 32. The method of any one of claims 29 to 31, wherein said contacting of said surface is for an amount of time from about 1 second to about 24 hours, or from about 1 minute to about 2 hours.

33. 33. The method of any one of claims 29 to 32, wherein the removal of the stain does not require additional mechanical force.

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