Process for manufacturing an animal litter

Abstract

A process for manufacturing an animal litter product is provided. The process comprises: mixing filler material particles with a dust abatement agent slurry, such as a fluoropolymer slurry, in a first mixing device to obtain coated filler material particles, wherein the filler material is a mineral-based, non-absorbing, non-clay material; mixing the coated filler material particles with clay-based absorbing material particles to obtain the animal litter product. An animal litter product is provided, comprising: filler material particles comprising a mineral-based, non-absorbing, non-clay material, a dust abatement agent, such as a fluoropolymer, being selectively distributed onto the filler material particles; and a clay-based absorbing material particles, wherein the animal litter product comprises an effective amount of fluorine-containing filler material particles being of at least 50% of the filler material particles based on a total particle count of the filler material particles, measured by Scanning Electron Microscope – Energy-dispersive X-ray spectroscope analysis.

Description

PROCESS FOR MANUFACTURING AN ANIMAL LITTERFIELD

[0001] The technical field generally relates to animal litter and a method of making the same, and more particularly relates to an animal litter composition that includes non-clay filler material and a method of making the same.BACKGROUND

[0002] Mineral based animal litter, such as cat litter, can typically include absorbent or nonabsorbing materials, odor controlling agents, dust abatement agents, clumping agents and / or other functional or cosmetic enhancing additives. One of the main types of absorbent materials used in mineral based animal litter are clay-based absorbent materials such as sodium bentonite. One of the main drawbacks of mineral based animal litters is the airborne dust.

[0003] To reduce the composition of valuable absorbent clay in mineral-based animal litter, it is known to incorporate a permeating mineral-based, non-absorbent, non-clay material fillers such as calcium carbonate or calcium carbonate-based materials. However, the resulting litter materials often generate more dust than their all clay-based animal litter counterparts. Airborne dust generated by animal litter is a major inconvenience for the user. There is therefore a need to provide animal litter materials and / or process of manufacturing animal litter materials that generate less dust.SUMMARY

[0004] In one aspect, there is provided a process for manufacturing an animal litter product, the process comprising: mixing filler material particles with a fluoropolymer slurry in a first mixing device to obtain a coated filler material, wherein the filler material particles are made of a mineral-based, non-absorbing, non-clay material; mixing the coated filler material with clay-based absorbing material particles to obtain an animal litter mixture; and optionally dedusting the animal litter mixture,thereby obtaining the animal litter product, wherein fluorine derived from the fluoropolymer slurry is selectively distributed in the animal litter product to provide an effective amount of fluorine-containing filler material particles being at least 50% of the coated filler material based on a total particle count of the filler material particles, measured by Scanning Electron Microscope - Energy-dispersive X-ray spectroscope analysis (SEM-EDS).

[0005] In another aspect, there is provided an animal litter product, comprising: filler material particles comprising a mineral-based, non-absorbing, non-clay material, clay-based absorbing material particles and a dust abatement agent being selectively distributed onto the filler material particles, wherein the dust abatement agent is a fluoropolymer and wherein the animal litter product comprises an effective amount of fluorine-containing filler material particles being of at least 50% of the filler material particles based on a total particle count of the filler material particles, measured by Scanning Electron Microscope - Energy-dispersive X-ray spectroscope analysis (SEM-EDS).

[0006] In yet another aspect, there is provided an animal litter product, comprising: filler material particles comprising a mineral-based, non-absorbing, non-clay material, clay-based absorbing material particles and a dust abatement agent being selectively distributed onto the filler material particles, wherein the dust abatement agent is polytetrafluoroethylene (PTFE) and wherein the animal litter product comprises an effective amount of fluorine- containing filler material particles being of at least 50% of the filler material particles based on a total particle count of the filler material particles, measured by Scanning Electron Microscope - Energy-dispersive X-ray spectroscope analysis (SEM-EDS).

[0007] In yet another aspect, there is provided an animal litter product, comprising: coated filler material particles comprising a mineral-based, non-absorbing, non-clay material and a dust abatement agent being distributed onto at least the mineral-based, non-absorbing, non- clay material; and clay-based absorbing material particles, and wherein the animal litter product is characterized by an airborne dust ratio of at most about 0.50 and wherein the airborne dust ratio is defined as a mean dust area of the animal litter comprising the coated filler material over a mean dust area of an animal litter comprising an uncoated filler material being exempt of the dust abatement agent.BRIEF DESCRIPTION OF THE FIGURES

[0008] Figure 1 shows the SEM-EDS results of Entry 1 - control sample of limestone;

[0009] Figure 2 shows the SEM-EDS results of Entry 2 - 3.5% PTFE 2% coated limestone;

[0010] Figure 3 shows the SEM-EDS results of Entry 3 - 3.5% PTFE 20% coated limestone;

[0011] Figure 4 shows SEM images of Entries 1 to 3 at magnifications of x2,500 and x5,000;

[0012] Figure 5 is an optical microscopy image of Entry 4 - limestone control. The frame represents the SEM-EDS analysis site of Entry 4;

[0013] Figure 6 shows the SEM-EDS results of Entry 4 - limestone control;

[0014] Figure 7 is an optical microscopy image of Entry 6 - litter material obtained by process A. The frames represent the SEM-EDS analysis site 1 and site 2 of Entry 6;

[0015] Figure 8 shows the SEM-EDS results of Entry 6, Site 1 - litter material obtained by process A;

[0016] Figure 9 shows the SEM-EDS results of Entry 6, site 2 - litter material obtained by process A;

[0017] Figure 10 is an optical microscopy image of Entry 8 - litter material obtained by process C. The frames represent the SEM-EDS analysis site 1 and site 2 of Entry 8;

[0018] Figure 11 shows the SEM-EDS results of Entry 8, site 1 - litter material obtained by process C;

[0019] Figure 12 shows the SEM-EDS results of Entry 8, site 2 - litter material obtained by process C; and

[0020] Figure 13 is a process flow diagram showing a process of manufacturing a litter material according to one embodiment of the present description.

[0021] Figure 14 is a graph showing airborne dust levels for a 65 % sodium bentonite and 35 % limestone mixture on which, 0.25% (w / w) of a PTFE slurry at increasing concentrations was applied using Process A as described herein.

[0022] Figure 15 shows airborne dust levels for a 65% sodium bentonite and 35% limestone mixture on which, a constant amount of total PTFE was applied by Process A as described herein, using decreasing amounts of slurry with increasing PTFE concentrations. Red arrows indicate a process limitation as the limestone / PTFE slurry was stuck on the custom lab mixer walls.

[0023] Figure 16 shows a microscopy sample preparation with sorting of limestone and bentonite particles (particle separation by color) for Samples 1 , 2, 3 and 4.

[0024] Figures 17a and 17b show for Sample 1 (50:50 Process C) the limestone particles (a) and the bentonite particles (b) with corresponding spectrum numbers.

[0025] Figures 18a and 18b show for Sample 2 (50:50 Process A) the limestone particles (a) and the bentonite particles (b) with corresponding spectrum numbers.

[0026] Figures 19a and 19b show for Sample 3 (90:10 Process C) the limestone particles (a) and the bentonite particles (b) with corresponding spectrum numbers.

[0027] Figures 20a and 20b show for Sample 4 (90:10 Process A) the limestone particles (a) and the bentonite particles (b) with corresponding spectrum numbers.DETAILED DESCRIPTION

[0028] The materials, methods and techniques described herein relate to animal litter materials and methods of manufacturing the same. It was surprisingly found that mixing a mineral-based, non-absorbing, non-clay filler material, such as calcium carbonate, with a dust abatement agent slurry, such as a fluoropolymer slurry prior to adding a clay-based absorbing material allows obtaining a litter product that exhibits a lower airborne dust level than if all the components were mixed together at the same time, or if the dust abatement agent slurry was simply vaporized onto the filler material. For example, the fluoropolymer slurry can be a polytetrafluoroethylene (PTFE) slurry.

[0029] If some of the following definitions depart from the commonly used meaning of a term, the definitions provided herein are intended to be used, unless specifically indicated.

[0030] For the purposes of the present description, it is understood that the singular forms “a”, “an” and “the” include reference to the plural unless the context as presented herein clearly indicates otherwise.

[0031] In present description, it is understood that directional terms such as “top,” “bottom,” “upper,” “lower,” “above,” “below,” “left,” “right,” “horizontal,” “vertical,” “up,” “down,” etc., are used for convenience in describing the various embodiments of the present description. The embodiments of the present description may be oriented in various ways. For example, the diagrams, apparatuses, etc., shown in the drawing figures may be flipped over, rotated by 90° in any direction, reversed, etc.

[0032] The term “blend”, as used herein, refers to a uniform or substantially uniform mixture of two or more solid materials. One or more materials in a blend may be coated with one or more other materials.

[0033] The term “clumping additive”, as used herein, refers to a clumping agent other than the clay-based absorbing material in the instances where the clay-based absorbing material is or includes a clumping clay-based absorbing material. It is also understood that the term “clumping agent”, as used herein, refers to a material that increases the clump strength of a litter material. Non-limiting examples of clumping agents include clumping clays, polysaccharides, water-soluble gums such as guar gum or xanthan gum, dry particulate cellulosic ethers, water absorbing polymers, or mixture thereof.

[0034] The term “filler material”, as used herein, refers to a material in the litter product other than the clay-based absorbing material, the clumping additive, the fragrance or the odor control agent. The filler material can include mineral-based or organic-based materials. Optionally, the filler material can be a mineral-based, non-absorbing, non-clay material. Nonlimiting examples of mineral-based, non-absorbing, non-clay materials include calcium carbonate, dolomite, limestone, gypsum, sand, calcite, wollastonite, olivine, silica and blends thereof.

[0035] The term “fragrance”, as used herein, refers to a compound or additive which can impart a certain smell to the animal litter. The fragrance can for example include an essential oil, or any natural or synthetic compound or formulation which imparts a smell to the animal litter. Non-limiting examples of fragrances include citrus oil, lavender oil, musk, herbaceous fragrance, fruity fragrance, woody fragrance.

[0036] The term “odor control agent”, as used herein, refers to compounds of formulations which inhibit or mask the natural smell of the animal litter material. Non-limiting examples of odor control agents include biocides, urease inhibitors, iodine, chlorophyllin sodium coppersalts, probiotics, enzymes, baking soda, carbon, zeolites, salts, aldehydes (such as benzaldehyde, heptaldehyde, undecalcatone, benzyl cinnamate, cinnamaldehyde, citral, vanillin, coumarin, undecanal).

[0037] The expression “absorbing and clumping materials”, as used herein, refers to materials that exhibit liquid absorption properties while being clumping agents. Examples of absorbing and clumping materials include sodium bentonite and mixtures thereof. In some implementations, the absorbing and clumping material is sodium bentonite.

[0038] The expression “absorbing and non-clumping materials”, as used herein, refers to materials that combine liquid absorption properties as well as non-clumping properties. Examples of absorbing and non-clumping materials include sepiolite, calcium bentonite, clinoptilolite, diatomite, attapulgite, palygorskite, hydrous aluminum silicate, kaolinite, illite, halloysite, hormite, vermiculite, and mixtures thereof. In some implementations, the absorbing and non-clumping material is calcium bentonite or clinoptilolite.

[0039] The expression “non-absorbing and non-clumping materials”, as used herein, refers to filler materials that do not exhibit liquid absorption or retention, nor clumping properties. Examples of non-absorbing and non-clumping materials include limestone, dolomite, dolomitic limestone, wollastonite, olivine, silica sand, pumice and mixtures thereof. In some implementations, the non-absorbing and non-clumping material is limestone, dolomite, wollastonite, olivine or silica sand.

[0040] The term “clay-based absorbing material”, as used herein, refers to water-absorbing clay components of the animal litter. The clay-based absorbing material typically includes a clay soil or comminuted rock containing at least one water swellable clay mineral. Such clay mineral may be, for example, a montmorillonoid or smectite, having a three-layer, sheet structure crystal lattice with two layers of silicon / oxygen tetrahedrons between which is a central layer of aluminum and / or magnesium / oxygen dioctahedrons or trioctahedrons. Part of the silicon in the tetrahedral layers may be substituted with aluminum and part of the aluminum and / or magnesium in the central octahedral layer may be substituted with other elements such as lithium, chromium, zinc, or iron. Contemplated montmorillonoid clay minerals are montmorillonite and nontronite containing a dioctahedral central layer, and hectorite, saponite, and sauconite containing a trioctohedral central layer. Another clay mineral may be, for example, a comminuted bentonite, such as sodium bentonite, which contains a preponderant amount of montmorillonite clay mineral. Sodium bentonite is capable(as some other types of bentonite) of hydrating and swelling in the presence of water. The swelling properties of sodium bentonite are related to the exchangeable cations present in a particular bentonite ore. The water-swellable bentonite clays contain various exchangeable cations, including sodium, potassium, lithium, ammonium, calcium and magnesium. Although any of these cations can be the predominant exchangeable cation of the bentonite clay of the present description, it is understood that bentonite clays often include a variety of exchangeable cations. The water-swellable bentonite clays useful in the animal litter product of the present description include any water-swellable bentonite clay that hydrate in the presence of water, e.g., swell in the presence of water. The water-swellable bentonite clay is selected from the group consisting of sodium bentonite, potassium bentonite, lithium bentonite, calcium bentonite and magnesium bentonite, or combination thereof. The bentonite clay can be any member of the dioctahedral or trioctahedral smectite group, or a mixture thereof; examples include Montmorillonite, Beidellite, Nontronite, Hectorite and Saponite, or combinations thereof. The clay-based absorbing material can be a clumping clay such as sodium bentonite, or a non-clumping clay such as calcium bentonite, attapulgite, palygorskite, sepiolite, hydrous aluminum silicate, kaolinite, illite, halloysite, hormite, vermiculite and blends thereof.

[0041] The term “dust abatement agent”, as used herein, refers to a coating agent used to coat the filler material which mixed with a clay-based absorbing material results in dust reduction in an animal litter. In some embodiments, the dust abatement agent comprises at least one of the following: fluoropolymer, oils, water, glycerols, glycols, polyvinyl alcohol, polyvinyl acetate, polymers, silicones, celluloses, calcium chloride or foams. In some implementations, the dust abatement agent comprises at least one of polytetrafluoroethylene (PTFE), oils, water, glycerols, glycols, polyvinyl alcohol, polyvinyl acetate, polymers, silicones, hydroxypropylmethyl cellulose (HPMC), polyanionic cellulose (PAC), carboxymethyl cellulose (CMC), calcium chloride and foams. In some implementations, the dust abatement agent comprises PTFE, such as a PTFE slurry. In some embodiments, the dust abatement agent is a fluoropolymer or a fluoropolymer slurry. In some embodiments, the dust abatement agent is polytetrafluoroethylene (PTFE) or a PTFE slurry.

[0042] The terms “dust abatement” or “dust reduction” refer to the reduction of airborne dust levels in the animal litter in comparison to an airborne dust level measured in absence of a dust abatement agent. The airborne dust level is measured by light attenuation using a DustMon™ as detailed in the Examples section.

[0043] In some embodiments, the dust abatement agent can comprise or be a fluoropolymer. The fluoropolymer can be used as an aqueous suspension (i.e., suspended in an aqueous solution), also referred to as a fluoropolymer slurry, to coat various components of an animal litter product. For example, the filler material can be coated with the fluoropolymer slurry by mixing the filler material and the fluoropolymer slurry. In some scenarios, the fluoropolymer slurry can be a colloidal aqueous dispersion of the fluoropolymer. The fluoropolymer slurry can include nanosized fluoropolymer particles suspended in water. Optionally, the nanosized fluoropolymer particles can be spherical nanosized fluoropolymer particles.

[0044] In some implementations, the fluoropolymer is a polyvinylfluoride (PVF), a polyvinylidene fluoride (PVDF), a polytetrafluoroethylene (PTFE), a polychlorotrifluoroethylene (PCTFE), a perfluoroalkoxy polymer (PFA), a fluorinated ethylenepropylene (FEP), a polyethylenetetrafluoroethylene (ETFE), a polyethylenechlorotrifluoroethylene (ECTFE), or any copolymer thereof.

[0045] For example, the term “polytetrafluoroethylene” (PTFE), as used herein, refers to the fluoropolymer of tetrafluoroethylene. PTFE can be used as an aqueous suspension (i.e., suspended in an aqueous solution), also referred to as a PTFE slurry, to coat various components of an animal litter product. For example, the filler material can be coated with a PTFE slurry by mixing the filler material and the PTFE. In some scenarios, the PTFE slurry can be a colloidal aqueous dispersion of PTFE. The PTFE slurry can include nanosized PTFE particles suspended in water. Optionally, the nanosized PTFE particles can be spherical nanosized PTFE particles.

[0046] It is further noted that aspects of the process and composition described in relation to a PTFE slurry can be applied more generally to a fluoropolymer slurry encompassing any slurry being an aqueous suspension of the fluoropolymers listed herein.

[0047] In a first aspect of the present description, various embodiments of a process for manufacturing an animal litter product are presented. The process for manufacturing an animal litter product includes mixing a filler material which is a mineral-based, non-absorbing, non-clay filler material with a dust abatement agent slurry in a first mixing device, to obtain a coated filler material. The process further includes mixing the coated filler material with a claybased absorbing material to obtain an animal litter mixture. In some embodiments, the animal litter mixture can be directly used as the animal litter product. In other embodiments, the animal litter mixture can be subjected to an optional dedusting step. Optionally, the dedustingcan be performed by mechanical ventilation. In yet other embodiments, various additives such as an odor control agent, a fragrance and / or a clumping agent can be added to the animal litter mixture.

[0048] Now referring to Figure 13, a filler material 12 and a dust abatement agent slurry 14 are mixed in a first mixing step 16 to obtain a coated filler material 18. A clay-based absorbing material 20 is then mixed with the coated filler material 18 in a second mixing step 22 to obtain animal litter mixture 24. The animal mixture 24 can optionally be subjected to dedusting 26 and / or additives 28 can be added to the animal mixture 24, thereby obtaining an animal litter product 30.

[0049] In some implementations, the mixing step 16 is performed in a mixing device which can be a static mixer, a dynamic mixer, a grain mixer or a screw conveyor. The mixing step 16 is meant to provide enough shear forces for the filler material to be coated by the PTFE particles and obtain coated filler material 18. The coated filler material 18 can then be mixed in a mixing device which can be a static mixer, a dynamic mixer, a grain mixer or a screw conveyor. It is understood that mixing step 16 and mixing step 22 can be performed in the same mixer, or in two different mixers. For example, the mixing step 16 can be performed in a first mixing device and the mixing step 22 can be performed in a second mixing device.

[0050] In some implementations, the mixing steps 16 and / or 22 can be performed using a rotary mixer. In some implementations the rotary mixer is inclined to about 90°.

[0051] In some implementations, the mixing steps 16 and / or 22 are performed for a mixing duration of about 5 seconds or more, 10 seconds or more, 20 seconds or more, 30 seconds or more, 1 minute or more, 2 minutes or more, 3 minutes or more, 5 minutes or more or 10 minutes or more. In some implementations, the mixing steps 16 and / or 22 are performed for a mixing duration between about 10 seconds and about 3 minutes.

[0052] In some implementations, the mixing step 16 is performed for a mixing duration between 10 seconds and 120 seconds. In some implementations, the mixing step 22 is performed for a mixing duration between 10 seconds and 180 seconds.

[0053] The animal litter mixture 24 can be considered the animal litter product 30 in instances where no additional material or treatment step is performed on the animal litter mixture 24. It is understood that the animal litter mixture 24 can be further treated, or additional components can be added (28) to the animal litter mixture 24 before obtaining the animal litter product 30.

[0054] In some implementations, additional components 28 (also referred to as additives) include odor controlling agents, fragrances, clumping agents and / or other functional or cosmetic enhancing additives, or any mixtures thereof.

[0055] In some implementations, the process can include preparing the dust abatement agent slurry by mixing water and the dust abatement agent. For example, the PTFE slurry can be prepared as a slurry having a PTFE concentration in water of between about 0.2 wt% and about 10 wt%, or between about 0.5 wt% and about 10 wt%, or between about 0.5 wt% and about 6 wt%. In some implementations, the PTFE slurry preferably has a PTFE concentration in water between about 2 wt% and about 4 wt%.

[0056] In some implementations, the PTFE slurry amount being used with respect to the litter material amount (on a weight basis, w / w) is between about 0.05% and about 2%, or between about 0.08% and about 1%. In some implementations, the PTFE slurry amount being used with respect to the litter material amount (w / w) is at most about 0.083%, at most about 0.125%, at most about 0.25%, at most about 0.333%, at most about 0.5% or at most about 1%. In some implementations, the PTFE slurry amount being used with respect to the litter material amount (w / w) is about 0.25%.

[0057] In some implementations, a weight ratio PTFE slurry: filler material is between about 1 :999 and about 1:19.

[0058] The animal litter product can also be characterized by an airborne dust ratio being defined as a mean dust area of the animal litter product comprising the coated filler material (including the dust abatement agent) over a mean dust area of an animal litter product comprising an uncoated filler material (i.e. without a coating comprising the dust abatement agent).

[0059] The animal litter product defined herein yields a reduction in airborne dust in comparison to an animal litter product comprising an uncoated filler material (i.e. that would not include the dust abatement agent coated onto the filler material). The airborne dust ratio can be defined according to Equation (1):wherein,• Control is the mixture without the dust abatement agent; and• Sample is the mixture with the dust abatement agent.

[0060] In some embodiments, the animal litter product is characterized by an airborne dust ratio of at most 0.5 corresponding to a significant reduction of airborne dust level in comparison to the control litter being exempt of the dust abatement agent.

[0061] In some embodiments, the animal litter product is characterized by an airborne dust ratio of at most 0.45, or of at most 0.40, or of at most 0.35, or of at most 0.35 corresponding to a significant reduction of airborne dust level in comparison to the control litter being exempt of the dust abatement agent.

[0062] In some embodiments, the animal litter product is characterized by an airborne dust ratio of at most 0.33, corresponding to a significant reduction of airborne dust level in comparison to the control litter being exempt of the dust abatement agent.

[0063] It has been found that the fluoropolymer-based dust abatement agent is selectively distributed among particles of the animal litter product such that an effective amount of the filler material particles comprises the fluoropolymer-based dust abatement agent. More particularly, when mixing the filler material with the fluoropolymer slurry in a first mixing step to produce the coated filler material, and then mixing the coated filler material with the claybased absorbing material, the filler material particles surface in the animal litter product (i.e. , after the second mixing step and optionally the dedusting step) has been found to retain an effective fluorine content.

[0064] Presence of fluorine on particles of the animal litter product is detected based on elemental characterization of fluorine that is measured by Scanning Electron Microscope - Energy-dispersive X-ray spectroscope analysis (SEM-EDS): SEM-EDS spectra were obtained using a JEOL JSM-7600TFE Field Emission Scanning Electron Microscope (FE-SEM), chemical compositions were determined using an Oxford Instruments X-MaxN energy dispersive X-ray spectroscopy (EDS) detector and surface analysis was performed at an acceleration voltage of 5 keV, focusing on elements: O, F, Na, Mg, Al, Si, Ca, and Fe as standard elements of analysis. For deeper analysis, spectra can also be collected at 15 keV.

[0065] It is understood that fluorine is considered detected on a particle surface when a significant elemental characterization of fluorine is measured by SEM-EDS, i.e. where the measured error (o) is lower than 10% of the measured elemental value. Upon measuring asignificant elemental characterization of fluorine, said particle is said to be a fluorine- containing particle.

[0066] An effective amount of fluorine-containing filler material particles, i.e. comprising the fluoropolymer-based dust abatement agent, can refer to a count of the coated filler material particles comprising the dust abatement agent and displaying a significant elemental characterization of fluorine.

[0067] In some embodiments, the animal litter product includes an effective amount of fluorine-containing filler material particles that is at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, or at least 75% of the filler material particles count.

[0068] The fluorine being selectively distributed among particles of the animal litter product is to be understood as having more fluorine-containing filler material particles than fluorine- containing clay-based absorbing material particles in the animal litter product.

[0069] In some embodiments, the animal litter product includes an effective amount of fluorine-containing filler particles providing for a given airborne dust ratio, for example the airborne dust ratio of at most 0.50. For example, the effective amount of fluorine-containing filler particles can be of at least 50 % for a given airborne dust ratio of at most 0.50. In another example, the effective amount of fluorine-containing filler particles can be of at least 50 % for a given airborne dust ratio of at most 0.33. In another example, the effective amount of fluorine-containing filler particles can be of at least 30 % for a given airborne dust ratio of at most 0.33. In another example, the effective amount of fluorine-containing filler particles can be of at least 30 % for a given airborne dust ratio of at most 0.50.

[0070] It is further understood that the filler material particles count can refer to a count of the total number of filler material particles, at least a portion of which being “fluorine-containing”, i.e. exhibiting a significant elemental characterization of fluorine when measured by SEM- EDS. A fluorine-containing particle count can thus be performed based on the spectra acquired by SEM-EDS determining if a particle is a fluorine-containing particle. The total number of fluorine-containing particles and the total number of particles free of fluorine can then be counted, thereby allowing to provide a percentage of fluorine-containing particles on a sample with a determined number of particles randomly chosen. It is understood that filler material particles and clay-based absorbing material particles can be sorted beforehand inorder to facilitate counting and analysis. It is understood that a particle of the animal litter (i.e. a filler particle or a clay-based absorbing material particle) is a small portion of solid matter with sizes ranging from >0 to 3360 pm.

[0071] According to the processes described herein, the fluoropolymer can be mostly found on filler material particles while a remainder amount can be found onto the clay-based absorbing material. More particularly, the fluoropolymer-based dust abatement agent is further selectively distributed among particles of the animal litter product such that less than 50% of the clay-based absorbing material particle count displays a significant elemental characterization of fluorine that is measured according to the SEM-EDS analysis or an equivalent method. In some embodiments, less than 50% or less than 45% or less than 40% or less than 35% or less than 30% or less than 25% or less than 20% of the clay-based absorbing material particles count are said to be “fluorine-containing”. In other words, the animal litter product comprises a maximal amount of fluorine-containing clay-based absorbing material particles representing less than 50% of the clay-based absorbing material particles count.

[0072] It is further understood that the clay-based absorbing material particles count can refer to a count of the total number of clay-based material particles, a portion of which can be “fluorine-containing”, i.e. exhibiting a significant elemental characterization of fluorine when measured by SEM-EDS. A fluorine-containing particle count can thus be performed based on the spectra acquired by SEM-EDS determining if a particle is a fluorine-containing particle. The total number of fluorine-containing particles and the total number of particles free of fluorine can then be counted, thereby allowing to provide a percentage of fluorine-containing particles on a sample with a determined number of particles randomly chosen. It is understood that filler material particles and clay-based absorbing material particles can be sorted beforehand in order to facilitate counting and analysis. It is understood that a particle of the animal litter (i.e. a filler particle or a clay-based absorbing material particle) is a small portion of solid matter with sizes ranging from >0 to 3360 pm.

[0073] A particle is said to be “free of fluorine”, when the particle surface displays either no fluorine or a fluorine content that is below the noise level seen of the elemental composition measurement performed in the course of the SEM-EDS analysis (where the measured error (o) is greater than 10% of the measured elemental fluorine value). For example, based on the techniques described herein, the selective distribution of the fluoropolymer among the animal litter product particles can produce at least 50 % of the filler material particlesdisplaying the effective fluorine content (with respect to a total count of the filler material particles) and at least 50 % of the clay-based absorbing material particles being free of fluorine (with respect to a total count of the clay-based absorbing particles).

[0074] Some of the embodiments of the present description are outlined in the following items:

[0075] Item 1. A process for manufacturing an animal litter product, the process comprising: mixing filler material particles with a fluoropolymer slurry in a first mixing device to obtain a coated filler material, wherein the filler material particles are made of a mineral-based, non-absorbing, non-clay material; mixing the coated filler material with clay-based absorbing material particles to obtain an animal litter mixture; and optionally dedusting the animal litter mixture, thereby obtaining the animal litter product, wherein fluorine derived from the fluoropolymer slurry is selectively distributed in the animal litter product to provide an effective amount of fluorine-containing filler material particles being at least 50% of the coated filler material based on a total particle count of the filler material particles, measured by Scanning Electron Microscope - Energy- dispersive X-ray spectroscope analysis (SEM-EDS).

[0076] Item 2. The process of item 1 , further comprising introducing an odor control agent into the animal litter mixture.

[0077] Item 3. The process of item 1 or 2, further comprising introducing a fragrance into the animal litter mixture.

[0078] Item 4. The process of any one of items 1 to 3, further comprising introducing a clumping additive into the animal litter mixture.

[0079] Item 5. The process of any one of items 1 to 4, wherein the filler material particles are selected from the group consisting of calcium carbonate, dolomite, limestone, gypsum, sand, calcite, wollastonite, olivine, silica and blends thereof.

[0080] Item 6. The process of any one of items 1 to 5, wherein the first mixing device is selected from the group consisting of a static mixer, a dynamic mixer, a grain mixer and a screw conveyor.

[0081] Item 7. The process of any one of items 1 to 6, wherein mixing the coated filler material with the clay-based absorbing material particles is performed in a second mixing device which is different than the first mixing device.

[0082] Item 8. The process of item 7, wherein the second mixing device is selected from the group consisting of a static mixer, a dynamic mixer, and a screw conveyor.

[0083] Item 9. The process of any one of items 1 to 8, wherein the clay-based absorbing material particles comprises at least one of a clumping clay and a non-clumping clay.

[0084] Item 10. The process of any one of items 1 to 8, wherein the clay-based absorbing material particles comprises a clumping clay which is sodium bentonite.

[0085] Item 11. The process of item 9, wherein the clay-based absorbing material comprises a non-clumping clay selected from the group consisting of calcium bentonite, attapulgite, palygorskite, sepiolite, hydrous aluminum silicate, kaolinite, illite, halloysite, hormite, vermiculite, clinoptilolite, diatomite and blends thereof.

[0086] Item 12. The process of item 11 , wherein the clay-based absorbing material comprises a non-clumping clay selected from the group consisting of calcium bentonite, clinoptilolite and a blend thereof.

[0087] Item 13. The process of any one of items 1 to 12, wherein the fluoropolymer slurry is a polyvinylfluoride (PVF) slurry, a polyvinylidene fluoride (PVDF) slurry, a polytetrafluoroethylene (PTFE) slurry, a polychlorotrifluoroethylene (PCTFE) slurry, a perfluoroalkoxy polymer (PFA) slurry, a fluorinated ethylene-propylene (FEP) slurry, a polyethylenetetrafluoroethylene (ETFE) slurry, or a polyethylenechlorotrifluoroethylene (ECTFE) slurry, or a slurry of any copolymer thereof.

[0088] Item 14. The process of item 13, wherein the fluoropolymer slurry is a polytetrafluoroethylene (PTFE) slurry.

[0089] Item 15. The process of item 14, wherein the PTFE slurry is a colloidal aqueous dispersion of PTFE comprising nanosized PTFE particles suspended in water, preferably spherical or cylindrical rod-shaped nanosized PTFE particles suspended in water.

[0090] Item 16. The process of item 14 or 15, wherein the PTFE slurry has a PTFE concentration in water of between about 0.2 wt% and about 10 wt%.

[0091] Item 17. The process of item 16, wherein the PTFE slurry concentration is between about 0.5 wt% and about 6 wt%.

[0092] Item 18. The process of any one of items 14 to 17, wherein the PTFE slurry amount used with respect to the animal litter product (w / w) is between about 0.01% and about 5%.

[0093] Item 19. The process of item 18, wherein the PTFE slurry amount used with respect to the animal litter product (w / w) is between about 0.05% and about 2%.

[0094] Item 20. An animal litter product, comprising: filler material particles comprising a mineral-based, non-absorbing, non-clay material; clay-based absorbing material particles; and a dust abatement agent being selectively distributed onto the filler material particles, wherein the dust abatement agent is a fluoropolymer; wherein the animal litter product comprises an effective amount of fluorine-containing filler material particles being of at least 50% of the filler material particles based on a total particle count of the filler material particles, measured by Scanning Electron Microscope - Energy-dispersive X-ray spectroscope analysis (SEM-EDS).

[0095] Item 21 . The animal litter product of item 20, further comprising an odor control agent.

[0096] Item 22. The animal litter product of item 20 or 21 , further comprising a clumping additive.

[0097] Item 23. The animal litter product of any one of items 20 to 22, wherein the filler material particles are selected from the group consisting of calcium carbonate, dolomite, limestone, gypsum, sand, calcite, wollastonite, olivine, silica and blends thereof.

[0098] Item 24. The animal litter product of any one of items 20 to 23, wherein the clay-based absorbing material particles comprise at least one of a clumping clay and a non-clumping clay.

[0099] Item 25. The animal litter product of any one of items 20 to 24, the clay-based absorbing material particles comprise a clumping clay which is sodium bentonite.

[0100] Item 26. The animal litter product of any one of items 20 to 24, wherein the clay-based absorbing material comprises a non-clumping clay selected from the group consisting of calcium bentonite, attapulgite, palygorskite, sepiolite, hydrous aluminum silicate, kaolinite, illite, halloysite, hormite, vermiculite, clinoptilolite, diatomite and blends thereof.

[0101] Item 27. The animal litter of item 26, wherein the clay-based absorbing material comprises a non-clumping clay selected from the group consisting of calcium bentonite, clinoptilolite and a blend thereof.

[0102] Item 28. The animal litter of any one of items 20 to 27, wherein the fluoropolymer is a polyvinylfluoride (PVF), a polyvinylidene fluoride (PVDF), a polytetrafluoroethylene (PTFE), a polychlorotrifluoroethylene (PCTFE), a perfluoroalkoxy polymer (PFA), a fluorinated ethylene-propylene (FEP), a polyethylenetetrafluoroethylene (ETFE), a polyethylenechlorotrifluoroethylene (ECTFE), or any copolymer thereof.

[0103] Item 29. The animal litter product of any one of items 20 to 28, wherein the fluoropolymer is polytetrafluoroethylene (PTFE).

[0104] Item 30. The animal litter product of item 29, wherein the PTFE comprises nanosized PTFE particles, preferably spherical or cylindrical rod-shaped nanosized PTFE particles.

[0105] Item 31. The animal litter of any one of items 20 to 30, characterized by an airborne dust ratio of at most about 0.50 and wherein the airborne dust ratio is defined as a mean dust area of the animal litter comprising the coated filler material over a mean dust area of an animal litter comprising an uncoated filler material.

[0106] Item 32. The animal litter of item 31 , wherein the airborne dust ratio of at most about 0.33.

[0107] Item 33. The animal litter of any one of items 20 to 30, wherein the effective amount of fluorine-containing filler material particles is at least 60% of the filler material particlesbased on the total particle count of the filler material particles for a given airborne dust ratio of at most 0.50, and wherein the airborne dust ratio is defined as a mean dust area of the animal litter comprising the coated filler material over a mean dust area of an animal litter comprising an uncoated filler material.

[0108] Item 34. The animal litter of any one of items 20 to 30, wherein the effective amount of fluorine-containing filler material particles is at least 60% of the filler material particles based on the total particle count of the filler material particles for a given airborne dust ratio of at most 0.33 and wherein the airborne dust ratio is defined as a mean dust area of the animal litter comprising the coated filler material over a mean dust area of an animal litter comprising an uncoated filler material.

[0109] Item 35. The animal litter of any one of items 20 to 34, wherein less than 50% of the clay-based absorbing material particles are fluorine-containing clay-based absorbing material particles based on a total particle count of the clay-based absorbing material particles, measured by Scanning Electron Microscope - Energy-dispersive X-ray spectroscope analysis (SEM-EDS).

[0110] Item 36. The animal litter of any one of items 20 to 35, wherein the effective amount of fluorine-containing filler material particles is at least 65% of the filler material particles based on the total particle count of the filler material particles.

[0111] Item 37. The animal litter of any one of items 20 to 36, wherein the effective amount of fluorine-containing filler material particles is at least 75% of the filler material particles based on the total particle count of the filler material particles.

[0112] Item 38. The animal litter of item 35, wherein less than 35% of the clay-based absorbing material particles are fluorine-containing clay-based absorbing material particles based on the total particle count of the clay-based absorbing material particles

[0113] Item 39. The animal litter of item 35, wherein less than 20% of the clay-based absorbing material particles are fluorine-containing clay-based absorbing material particles based on the total particle count of the clay-based absorbing material particles.

[0114] Item 40. The animal litter of item 35, wherein at least 50% of the clay-based absorbing material particles, based on the total particle count of the clay-based absorbing materialparticles, is free of fluorine measured by Scanning Electron Microscope - Energy- dispersive X-ray spectroscope analysis (SEM-EDS).

[0115] Item 41. The animal litter of item 40, wherein at least 65% of the clay-based absorbing material particles, based on the total particle count of the clay-based absorbing material particles, is free of fluorine.

[0116] Item 42. The animal litter of item 40, wherein at least 80% of the clay-based absorbing material particles, based on the total particle count of the clay-based absorbing material particles, is free of fluorine.

[0117] Item 43. An animal litter product, comprising: coated filler material particles comprising a mineral-based, non-absorbing, non-clay material and a dust abatement agent being distributed onto at least the mineral-based, non-absorbing, non-clay material; clay-based absorbing material particles; and wherein the animal litter product is characterized by an airborne dust ratio of at most about 0.50 and wherein the airborne dust ratio is defined as a mean dust area of the animal litter comprising the coated filler material over a mean dust area of an animal litter comprising an uncoated filler material being exempt of the dust abatement agent.

[0118] Item 44. The animal litter product of item 43, wherein the dust abatement agent is selected from the group consisting of fluoropolymers, oils, water, glycerols, glycols, polyvinyl alcohol, polyvinyl acetate, polymers, silicones, celluloses, calcium chloride, foams and mixtures thereof.

[0119] Item 45. The animal litter product of item 43, wherein the dust abatement agent is selected from the group consisting of polytetrafluoroethylene (PTFE), hydroxypropylmethyl cellulose (HPMC), polyanionic cellulose (PAC), carboxymethyl cellulose (CMC), and mixtures thereof.

[0120] Item 46. The animal litter of any one of items 43 to 45, wherein the dust abatement agent is a slurry.

[0121] Item 47. The animal litter of any one of items 43 to 46, wherein the dust abatement agent is a slurry of HPMC, PAC, CMC or a mixture thereof.

[0122] Item 48. The animal litter of any one of items 43 to 46, wherein the dust abatement agent is a PTFE slurry.

[0123] Item 49. The animal litter of item 48, wherein the dust abatement agent is selectively distributed onto the filler material particles, and the animal litter product comprises an effective amount of fluorine-containing filler material particles being of at least 50% of the filler material particles based on a total particle count of the filler material particles, measured by Scanning Electron Microscope - Energy-dispersive X-ray spectroscope analysis (SEM-EDS).

[0124] Item 50. The animal litter of item 49, wherein less than 50% of the clay-based absorbing material particles are fluorine-containing clay-based absorbing material particles based on a total particle count of the clay-based absorbing material particles, measured by Scanning Electron Microscope - Energy-dispersive X-ray spectroscope analysis (SEM-EDS).

[0125] Item 51. The animal litter of any one of items 43 to 50, wherein the dust abatement slurry amount used with respect to the animal litter product (w / w) is between about 0.01% and about 5%.

[0126] Item 52. The animal litter of item 51 , wherein the dust abatement slurry amount used with respect to the animal litter product (w / w) is between about 0.05% and about 2%.

[0127] Item 53. The animal litter product of any one of items 43 to 52, further comprising at least one feature being defined in any one of items 1 to 42.EXAMPLESMaterials and Data AnalysisMaterialsRaw Materials Table:Data analysis

[0128] Airborne dust levels of the formulations described herein were determined as follows: 80-mL of litter material is added to the sample receptacle of a DustMon™. The sample was then analyzed for 45 seconds by attenuation of light intensity and then the final result is automatically corrected by a factor of 0.16; the dust area is reported in arbitrary units (A.U.). All materials were analyzed in triplicate.Example 1

[0129] The raw materials used include the following:- Sodium bentonite;- Calcium bentonite;- Calcium carbonate;- 60 % w / w PTFE suspension. An aqueous suspension of PTFE was prepared by mixing 1 :29 (60% w / w PTFE suspension: water), to obtain a 2% (w / w) aqueous PTFE suspension.

[0130] The formulations shown in Table 1 were prepared using either a comparative process or a process according to the present description. The materials prepared included sodium bentonite as the clay-based absorbing material and either calcium carbonate or calcium bentonite as the filler material, as well as a PTFE suspension (2% w / w). The calciumcarbonate is a mineral-based, non-absorbing, non-clay material. The calcium bentonite is a clay-based absorbing material which is non-clumping.Table 1 : Formulations and processes

[0131] Control Materials 1 and 2 (without PTFE suspension) were obtained by adding the components to a rotary mixer and blending for 3 minutes.

[0132] Process A: the filler material (calcium carbonate or calcium bentonite) was added to a rotary mixer and the PTFE suspension was poured directly onto the filler material. The two products are thoroughly mixed for 30 seconds. Sodium bentonite was then added to the filler / PTFE mixture and the resulting material was thoroughly mixed for 2.5 minutes. Process A is a laboratory simulation of a screw conveyor for mixing the filler and the PTFE suspension and is one embodiment of the processes of the present description.

[0133] Process B (comparative): the PTFE suspension was vaporized directly onto the filler material (calcium carbonate or calcium bentonite). The resulting material is then transferred into a rotary mixer along with sodium bentonite, before being thoroughly mixed for 3 minutes. Process B is a process as described in U.S. patent No. 11 ,026,397 and is presented herein for comparative purposes.

[0134] Process C (comparative): the control mixtures 1 and 2 were transferred to a rotary mixer and the PTFE suspension was then added by vaporization onto the mixtures. Theresulting material was thoroughly mixed for 3 minutes. Process C was added for comparative purposes.

[0135] The materials obtained by the various processes as well as the control materials without dust abatement agent slurry are analyzed to measure dusting as follows: the litter material (80 mL) is added to a DustMon™ to measure the airborne dust levels. Dust was analyzed for 45 seconds by attenuation of light intensity. Table 2 summarizes the airborne dust levels.

[0136] It was observed that when preparing the litter material with a calcium bentonite filler according to Process A, the use of an absorbing filler material did not allow for an optimal coating of the PTFE slurry onto the filler material. Aggregates were observed when mixing the calcium bentonite filler and the PTFE slurry, and these aggregates were also observed after adding and mixing in the sodium bentonite. This observation suggested that the use of a non-absorbing filler was preferred for Process A.Table 2: Airborne dust levels:

[0137] Table 3A summarizes the relative airborne dust levels between a litter material obtained by Process A and litter materials obtained by each of the other processes, for the calcium carbonate filler.Table 3A (lower value means less dusty)

[0138] Table 3B summarizes the relative airborne dust levels between a litter material obtained by Process A and litter materials obtained by each of the other processes, for the calcium bentonite filler.Table 3B (lower value means less dusty)

[0139] Table 3A shows that when the filler is calcium carbonate (i.e. , a mineral-based, nonabsorbing, non-clay material), Process A allowed obtaining the litter material having the lowest airborne dust levels. More specifically: the control material 1 without dust abatement agent slurry is 4.3 times dustier than litter material A3; comparative material B3 is 1.4 times dustier than litter material A3; and comparative material C1 is 2.3 times dustier than litter material A3.

[0140] Table 3B shows that when the filler is calcium bentonite (i.e., a clay-based absorbing material which is non-clumping), Process A did not allow obtaining a litter material with the lowest airborne dust levels. In such case, the litter materials obtained with processes B and C were less dusty than the litter material obtained with Process A.

[0141] It was surprisingly found that applying the dust abatement agent via Process A was advantageous compared to Process B and Process C when the filler material is a mineralbased, non-absorbing, non-clay filler material.Example 2

[0142] Experiments were conducted to identify the presence of PTFE on limestone and on cat litter products containing limestone.Materials and Methods

[0143] The following materials were used for the animal litter formulations manufactured in this Example:- Sodium Bentonite;Limestone; and- 60% PTFE Aqueous suspension.

[0144] In a first phase of this Example, PTFE was applied at two different concentrations on limestone and analyzed by SEM-EDS to identify the presence of PTFE on the solid matrix (via fluorine content).

[0145] Limestone was coated with increasing amounts of PTFE, using PTFE stock dispersions prepared at 2 wt% and 20 wt%, respectively, as shown in Table 4A below:Table 4A: Limestone samples formulated with PTFE

[0146] Limestone was added in the drum of a laboratory rotary mixer (0 25 cm) and PTFE was applied directly on limestone using a transfer pipette. The mixture was blended at 31 rpm for 30 seconds in the mixer, which was inclined at approximately 90°.

[0147] In a second phase of this Example, litter material was manufactured using two different PTFE application processes, namely Process A and Process C described in Example 1. The resulting litter materials were characterized by SEM-EDS to identify the presence of PTFE on the solid matrix (via fluorine content). The samples prepared are shown in Table 4B, below:Table 4B: Samples of litter products using different PTFE addition processes

[0148] Sample electrical conductivity was enhanced by coating with a thin layer of carbon (=25 nm) by evaporation using a Quorum Q150T US plus. Imaging was conducted on a JEOL JSM-7600TFE Field Emission Scanning Electron Microscope (FE-SEM). Chemical compositions were determined using an Oxford Instruments X-MaxN energy dispersive X-ray spectroscopy (EDS) detector. Analysis was performed at an acceleration voltage of 10 keV with automatic element selection or focusing on F.

[0149] Furthermore, optical microscopy images were taken using a Keyence optical microscope, in conjunction with EDS, to aid in the mapping of the observed sites on the respective limestone / sodium bentonite blends.Results and Discussion

[0150] The samples described at entries 1 to 3 (Table 4A) were prepared and analyzed using SEM-EDS. The SEM images and EDS results are presented in Figures 1 to 4. It is noted that the EDS analysis results highlighted in red in the Figures signify that the measured error (o) is greater than 10% of the measured elemental value, which means that the element is not meaningfully present.

[0151] Entry 1 (Figure 1) serves as a negative control and the EDS results confirm the absence of fluorine from the PTFE.

[0152] Entries 2 and 3 (Figures 2 and 3, respectively) show limestone on which was applied 3.5% of a PTFE suspension at 2% and 20%, respectively. EDS analysis of fluorine from the PTFE reveals that limestone produced with 2% PTFE exhibits an approximate 8 to 9 wt% fluorine content (Figure 2), while the sample produced with 20% PTFE displays a 20 to 30 wt% fluorine content (Figure 3).

[0153] Figure 4 shows the SEM images taken at x2,500 and x5,000 magnification for each sample (Entries 1-3, Table 4A). As opposed to the negative control, which does not exhibit any distinguishable features, this figure clearly reveals that limestone treated with PTFE exhibits the presence of clusters of elongated, cylindrical rod-shaped and occasionally,spherical structures (Entries 2-3, Figure 4A). Entry 2 displays scattered regions, whereas Entry 3 exhibits a denser distribution of these structures.

[0154] The combined SEM-EDS results suggest that the presence of a PTFE coating on the limestone is characterizable with SEM-EDS.

[0155] Entry 4 exhibits the control sample of a cat litter product made of sodium bentonite and limestone in the absence of PTFE (Figures 5 and 6). The EDS analysis indicates that spectra 16 and 18, displaying lower silicon and aluminium content with a higher calcium presence, can be attributed to the limestone particles, while spectra 15 and 17 are indicative of sodium bentonite composition (Figure 6). These observations are corroborated by the optical microscopy image (Figure 5), where limestone particles generally exhibit a darker appearance, while sodium bentonite particles generally exhibit a lighter appearance. EDS results confirm a lack of fluorine content in the formulation.

[0156] Entry 6 presents a sample of cat litter product made of sodium bentonite and limestone formulated with 0.35% PTFE 2% using Process A (Figures 7 to 9). EDS analysis revealed that fluorine was associated with the limestone particles, showing on spectra 24 (left), 25, and 27 (Figures 8 and 9) on calcium-rich and silicon / aluminium-poor particles. These spectra were obtained from the darker particles seen in the optical microscopy image (Figure 7), confirming their limestone nature. EDS analysis revealed that no fluorine-containing bentonite particles were found as shown on spectra 22, 23, 24 (right), 26 and 28 (Figures 8 and 9).

[0157] Entry 8 depicts a sample of cat litter product made of sodium bentonite and limestone formulated with 0.35% PTFE 2% using Process C (Figures 10 to 12). EDS analysis revealed that the fluorine detected was associated with sodium bentonite, characterized by spectra 43 and 46 (Figures 11 and 12), on silicon / aluminium rich particles. These spectra were obtained from the lighter particles seen in the optical microscopy image (Figure 10), confirming their sodium bentonite nature.

[0158] Clear differences between the litter materials obtained via Process A and Process C were observed with the SEM-EDS experiments. It was shown that vaporized application of PTFE (Process C) concentrates on the absorbing material (sodium bentonite), while precoating the limestone with the PTFE suspension, a non-absorbing and non-clumping material, better disperses the PTFE in the animal litter mixture, thereby enhancing the dustabatement effect.

[0159] 2% and 20% aqueous PTFE suspension applied at 3.5% on limestone were characterized using SEM-EDS. Distinguishable differences were observed on animal litter products depending on the application process; when precoated on limestone, PTFE was successfully identified on the limestone (Process A). Finally, when vaporized on a sodium bentonite and limestone mixture, PTFE was only observed on the sodium bentonite (Process C).

[0160] The results suggest that when vaporized, as in Process C, the PTFE seems to be concentrated on the absorbing material (sodium bentonite) with limited effect on the dust abatement process. However, pre-coating the limestone (mineral-based, non-absorbing, non-clay material) with the PTFE suspension allowed to better disperse the PTFE in the animal litter material, thus enhancing its dust-abatement effect.Example 3

[0161] The raw materials used include the following:- Calcium carbonate PC 3067;- 60% PTFE Aqueous suspension used to prepare a 2% (w / w) and a 6% (w / w) aqueous PTFE suspension by mixing with water.

[0162] Table 5: Formulations and processes

[0163] Process C (comparative) and process A were performed as detailed in Example 1 with the formulations of Table 5. However, it is noted that experiments for process A in Example 3 were performed using direct PTFE addition to the calcium carbonate via a screw conveyor (and not a laboratory scale rotary mixer).

[0164] The materials obtained for Test 1 to 9 as well as the control sample were analyzed to measure dusting as follows: the litter material (80 mL) is added to a DustMon™ to measurethe airborne dust levels. Dust was analyzed for 45 seconds by attenuation of light intensity.Table 6 summarizes the airborne dust levels.

[0165] Table 6: Airborne dust levels

[0166] The airborne dust levels in Table 6 that were obtained for Test 1-9 samples according to process A conditions including the use of a screw conveyor are comparable to airborne dust levels obtained in Example 1 for process A conditions simulated via the use of a rotary mixer.

[0167] In addition, the airborne dust levels in Table 6 that were obtained for Test 1-9 samples were similar and even better than airborne dust levels in Table 6 that were obtained for the control sample. It was found that applying the PTFE suspension directly on the filler material (calcium carbonate) by direct mixing (rotary mixer / screw conveyor) can provide similar and even better results than when the PTFE suspension is vaporized onto the litter mixture (calcium carbonate and sodium bentonite).General Methods for Examples 4-6

[0168] The airborne dust ratio values provided in experimental results were determined using Equation (1) as defined herein. A significant reduction in airborne dust (level) is characterized by an airborne dust ratio being lower than 0.5 (the lower the value, the lower the dust level).

[0169] Unless stated otherwise, the 60% PTFE aqueous slurry (% w / w) is diluted to 2% with water (PTFE@2%).

[0170] Unless stated otherwise, all formulations are produced with either one of the standard absorbing and clumping material (Sodium Bentonite, 65% w%) and / or non-absorbing and non-clumping filler (3067 limestone, 35% w%).

[0171] All formulations are mixed using a laboratory rotary mixer (0 25 cm) inclined to about 90° for a total of 3 minutes at a speed setting of 31 RPM.

[0172] Controls: Absorbing and filler materials are added to the mixer without a dust abatement agent and are mixed as described above.

[0173] Process A: The non-absorbing and non-clumping filler material is added to the mixer and 0.35% (w / w) of PTFE@2% slurry is then poured directly on it. The two compounds are mixed for 30 seconds. The absorbing material is then added to the mixer and mixed for an additional 2.5 minutes, as described above.

[0174] Process B (comparative): To simulate a conveyor belt, filler material is added onto a sheet of cardboard. The PTFE slurry is then uniformly sprayed directly onto the material, which is then transferred to the mixer. Absorbing is subsequently added to the mixer and mixed as described above.

[0175] Note: Since the amount of PTFE slurry added on animal litter blend is negligible relative to the whole, its weight was deliberately not accounted for in the final weight.Example 4

[0176] Experiments were conducted to optimize the dust abatement properties.PTFE slurry concentrations

[0177] As described in General Methods, the following formulations were prepared with Sodium Bentonite and limestone using 0.25% w / w PTFE slurry at different concentrations using Process A: a. Control (no dust abatement agent) b. 0.25% PTFE@0.5% c. 0.25% PTFE@1.0% d. 0.25% PTFE@1.5% e. 0.25% PTFE@2.0% f. 0.25% PTFE@4.0% g. 0.25% PTFE@6.0%

[0178] Table 7 and Figure 14 summarize the dust level measurements with formulations using a fixed amount of PTFE slurry while varying the PTFE concentration.Table 7: Airborne dust levels for a 65% sodium bentonite and 35% limestone mixture on which, 0.25% (w / w) of a PTFE slurry at increasing concentrations was applied using Process A

[0179] Figure 14 reveals that airborne dust levels decrease with increasing amount of PTFE added on the litter blend. Optimal dust level reduction is attained when 0.25% PTFE@2.0% is applied (Table 7, Entry 1.5) after which, we observe a plateau and no further significant decrease in dust level (Figure 14).Water content effect

[0180] As described in General Methods, the following formulations were prepared with Sodium Bentonite and limestone using Process A by applying a fixed amount of PTFE, using decreasing amounts of slurries with increasing PTFE concentrations, as described below:2.1 Control (no dust abatement)*2.2 1.0% PTFE@0.5%2.3 0.50% PTFE@1.0%2.4 0.333% PTFE@1.5%2.5 0.25% PTFE@2.0%*2.6 0.125% PTFE@4.0%2.7 0.083 % PTFE@6.0%*Note: entries 2.1 and 2.5 are the same as 1.1 and 1.5

[0181] Table 8 and Figure 15 summarize the airborne dust levels for litter formulations on which, a constant amount of PTFE was applied using lower amounts of slurries with increasing PTFE concentrations. Total PTFE concentration was based on the 0.25% PTFE@2.0% slurry (Table 1 , Entry 1.5), where we observe a dust level plateau.Table 8: Airborne dust levels for a 65% sodium bentonite and 35% limestone mixture on which, a constant amount of total PTFE was applied by process A, using decreasing amounts of slurry with increasing PTFE concentrations.

[0182] The results in Figure 15 shows the efficacy of PTFE as a dust abatement agent at this concentration in cat litter products. Furthermore, the data reveals that dust levels systematically decrease with increasing water content but exhibits a plateau at approximately 0.25% PTFE@2.0% (Table 8, Entry 2.5). Finally, the results suggest that the optimal water content is achieved when 0.25% (w / w) of PTFE slurry is applied on the litter formulation.Example 5

[0183] Experiments were conducted to evaluate the dust-abatement effect using various materials.Absorbing and clumping materials

[0184] As described in General Methods, the following formulations were prepared with corresponding absorbing and clumping materials and limestone using Process A: a. Gypsum and bentonite hybrid b. Sodium Bentonite (Source 1) c. Sodium Bentonite (Source 2) d. Sodium Bentonite (Source 3)Sodium Bentonites from different sources (i.e. different extraction sites and granulometry) were tested (Source 1 , Source 2 and Source 3).

[0185] Mass-based formulations containing 65% sodium bentonite-based absorbing and clumping materials, with different properties and 35% limestone were subjected to Process A using 0.35% PTFE@2.0% slurry. The resulting airborne dust levels for these formulations and their dust-unabated controls are summarized in Table 9.Table 9: Airborne dust levels for formulations containing 65% absorbing and clumping material and 35% limestone (w / w) prepared using Process A with a 0.35% PTFE@2.0% slurry.

[0186] Table 9 reveals that all formulations therein, subjected to Process A, exhibit lower dust levels compared to their controls, regardless of the nature of the absorbing and clumping material. However, the most significant airborne dust reduction was achieved when using sodium bentonite as the absorbing material (Table 9, Entries 3.2, 3.3, and 3.4).

[0187] It should be noted that despite an airborne dust ratio above 0.5, significant airborne dust reduction is nevertheless achieved using Gypsum and bentonite hybrid given that the material is not very dusty, therefore dust reduction is not as marked as with other materials (Entries 3.1c and 3.1, Table 9).Absorbing and non-clumping materials

[0188] As described in General Methods, formulations were prepared with limestone and the following absorbing and non-clumping materials using Process A: a. Sepiolite b. Calcium bentonite c. Clinoptilolite (zeolite) d. Diatomite (diatomaceous earth)

[0189] Mass-based formulations containing 65% absorbing and non-clumping materials and 35% limestone were subjected to Process A using 0.35% PTFE@2.0% slurry. The resulting airborne dust levels for these formulations and their dust-unabated controls are summarized in Table 10.Table 10: Airborne dust levels for formulations containing 65% absorbing and non-clumping material and 35% limestone (w / w) prepared using Process A with a 0.35% PTFE@2.0% slurry.

[0190] Table 10 reveals that all formulations subjected to Process A exhibit lower airborne dust levels compared to their dust-unabated controls. The most significant dust level reduction was achieved using calcium bentonite and clinoptilolite (Table 10, Entries 4.2 and 4.3). Furthermore, the dust abatement effect of PTFE was less pronounced with sepiolite (Table 10, Entry 4.1) but still afforded significant dust abatement. Finally, the dust abatement effect of PTFE was significantly less pronounced with diatomite (Table 10, Entry 4.4).Non-absorbing and non-clumping materials

[0191] As described in General Methods, the following formulations were prepared with Sodium Bentonite and the following non-absorbing and non-clumping filler materials using Process A: a. Dolomite; b. Wollastonite; c. Olivine; d. Silica sand; and e. Pumice.

[0192] Mass-based formulations containing 65% sodium bentonite and 35% non-absorbing and non-clumping filler material were subjected to Process A using 0.35% PTFE@2.0% slurry. The resulting airborne dust levels for these formulations and their dust-unabated controls are summarized in Table 11.Table 11 : Airborne dust levels for formulations containing 65% sodium bentonite and 35% non-absorbing and non-clumping filler material (w / w) prepared using Process A with a 0.35% PTFE@2.0% slurry.

[0193] Table 11 reveals that all non-absorbing materials in this study significantly had a positive effect in the dust abatement process with PTFE (Table 11, Entries 5.1-5.4). .Example 6

[0194] Experiments were conducted to compare Process A and Process B by applying different combinations of PTFE amounts / concentrations.

[0195] As described in General Methods, the following formulations were prepared with Sodium Bentonite and limestone using Process A and Process B with different amounts of PTFE@2.0% suspension:

[0196] Process A:6.1 Control (no dust abatement agent)6.2 0.05% PTFE@2.0%6.30.10% PTFE@2.0%6.40.15% PTFE@2.0%6.50.25% PTFE@2.0%6.60.35% PTFE@2.0%

[0197] Process B:7.1 Control (no dust abatement agent)7.2 0.05% PTFE@2.0%7.30.10% PTFE@2.0%7.40.15% PTFE@2.0%7.50.25% PTFE@2.0%7.60.35% PTFE@2.0%7.70.70% PTFE@1.0%

[0198] Tables 12 and 13 reveal the effect on dust levels for mass-based formulations containing 65% sodium bentonite and 35% limestone, which respectively underwent dust abatement using Processes A and B, with increasing amounts of PTFE@2.0% slurry.

[0199] The results show that Process A achieved significant dust abatement with a smaller amount of the more dilute PTFE@2.0% slurry compared to Process B; 0.15% (Table 12, Entry 6.4) and 0.25% (Table 13, Entry 7.5), respectively. Finally, all else being equal, Process A consistently showed superior dust reduction with PTFE. Therefore, Process A seems to permit a better distribution of the PTFE slurry in the cat litter product, thereby enhancing the dust abatement effect.Table 12: Airborne dust levels for mass-based formulations containing 65% sodium bentonite and 35% limestone, produced using Process A, with increasing amounts of PTFE2.0% slurry.Table 13: Airborne dust levels for mass-based formulations containing 65% sodium bentonite and 35% limestone using, produced Process B, with increasing amounts of PTFE@2.0% slurry.

[0200] Additionally, an experiment was conducted with Process B by adding double the amount of a diluted PTFE@1.0% slurry (Table 13, Entry 7.7); the result was very similar toits doubly concentrated counterpart (Table 13, Entry 7.6), thus suggesting that Process A provides more efficient dust abatement properties for a cat litter production.Example 7

[0201] This example compares two different processes for the application of the fluorine-rich dust abatement polymer, PTFE, onto mineral-based cat litter formulations, namely, Process A and Process C.

[0202] Formulations: Cat litter formulations were produced using processes A and C; in Process A, the stock PTFE aqueous slurry at 60% (% w / w) was diluted with water to a final concentration of 2% (PTFE@2%) while in Process C it is diluted with water to a final concentration of 6% (PTFE@6%). Briefly, 3 kg of cat litter formulations were produced using Processes A and B, respectively, as follows:Process A: Limestone was first introduced into the rotary mixer onto which was directly applied PTFE@2% followed by 30 seconds of mixing. Sodium bentonite was then added into the mixer and mixed for an additional 2.5 minutes.Process C: Sodium bentonite and limestone were both added into the rotary mixer. Once the mixing process was initiated, a PTFE@6% slurry was first uniformly sprayed onto the mixture and then mixed for a total duration of 3 minutes.Since the amount of PTFE slurry added on cat litter blend is negligible relative to the whole, its weight was deliberately not accounted for in the final weight.

[0203] Table 14: Cat litter formulations produced using dust abatement processes A and C

[0204] Microscopy sample preparation: Processed cat litter particles for each sample were separated by size to achieve reasonable uniformity; particles passing through the US #16 (mesh size of 1190 pm) sieve but retained on the US #20 (mesh size of 841 pm) sieve wereselected for this study. Bentonite (light gray) was then manually separated from the limestone (dark grey) based on their color differences. Finally, 30 - 50 particles of each material from each sample were then transferred onto carbon adhesive tape (Figure 16) for microscopic assessment.

[0205] Scanning Electron Microscopy (SEM) and Energy-Dispersive X-ray Spectroscopy (EDS): The SEM-EDS images and spectra were obtained at (CM)2- The Center for Characterization and Microscopy of Materials at Polytechnique Montreal.

[0206] Sample electrical conductivity was enhanced by coating with a thin layer of carbon (=25 nm) by evaporation using a Quorum Q150T US plus.

[0207] Imaging was conducted on a JEOL JSM-7600TFE Field Emission Scanning Electron Microscope (FE-SEM). Chemical compositions were determined using an Oxford Instruments X-MaxN energy dispersive X-ray spectroscopy (EDS) detector.

[0208] Surface analysis was performed at an acceleration voltage of 5 keV, focusing on elements: O, F, Na, Mg, Al, Si, Ca, and Fe as standard elements of analysis. For deeper analysis, spectra were also collected at 15 keV.

[0209] Each spectrum was acquired for 20 seconds. All EDS spectra results and their corresponding particles are shown in Tables 16-19.

[0210] EDS analyses were performed using an acceleration voltage of 5 keV to focus on the surface of the bentonite or limestone particles. Due to the limitations of the semi-quantitative EDS analysis, the focus was on identifying particles with an effective elemental characterization of fluorine, where the measured error (o) is lower than 10% of the measured elemental value. Every spectrum was analyzed, and the respective elemental results were tabulated in Tables 16-19; values underlined indicate measurement error greater than 10% of its nominal value. Finally, statistics for each sample were compiled in Table 15.

[0211] Table 15: Identification of the presence of fluorine on bentonite and limestone particles for cat litter samples produced using Processes A and C

[0212] Despite applying 3 times less PTFE than Process C, the results in Table 3 reveal that Process A seems to distribute the fluoropolymer more effectively on both particle types, moreso on limestone. For instance, Samples 1 (Figures 17a and 17b) and 2 (Figure 18a and 18b) were both formulated with 50:50 bentonite:limestone (w:w) but 3 times more PTFE was applied on Sample 1 than on Sample 2. However, Sample 2 shows that 76% of the limestone particles and 41% of the bentonite particles (based on a particle count) were coated with an effective amount of PTFE. In contrast, for Sample 1 , only 9% of the limestone particles and 26% of the bentonite particles were found coated with an effective amount of PTFE. A similar pattern was observed with a lower limestone content; Process A coated 86% of the limestone particles and 24% of the bentonite particles with an effective amount of fluoropolymer (Sample 4, Figures 20a and 20b), while Process C only coated 6% of the limestone particles and 8% of the bentonite particles (Sample 3, Figures 19a and 19b).

[0213] Accordingly, it seems that Process A provides a greater distribution of PTFE among the animal litter particles than Process C. Process A provides a greater distribution of PTFE onto the filler particles (limestone) than the absorbing particles (bentonite). Process A results in animal litter formulations having an enhanced dust abatement performance with respect to formulation resulting from Process C, let alone using lower amounts of PTFE.

[0214] Table 16a: EDS Spectra Results of Sample 1 - Limestone - 50:50 Process C at 5 keV (Figure 17a)

[0215] Table 16b: EDS Spectra Results of Sample 1 - Limestone - 50:50 Process C at 15 keV

[0216] Table 16c: EDS Spectra Results of Sample 1 - Bentonite - 50:50 Process C at 5 keV(Figure 17b)

[0217] Table 17a: EDS Spectra Results of Sample 2 - Limestone - 50:50 Process A at 5 keV(Figure 18a)

[0218] Table 17b: EDS Spectra Results of Sample 2 - Limestone - 50:50 Process A at 15 keV

[0219] Table 17c: EDS Spectra Results of Sample 2 - Bentonite - 50:50 Process A at 5 keV(Figure 18b)

[0220] Table 17d: EDS Spectra Results of Sample 2 - Bentonite - 50:50 Process A at 15 keVThe particle corresponding to spectrum 161 (144) is identified as limestone based on 15 keV EDS results.

[0221] Table 18a: EDS Spectra Results of Sample 3 - Limestone - 90:10 Process C at 5 keV (Figure 19a)

[0222] Table 18b: EDS Spectra Results of Sample 3 - Limestone - 90:10 Process C at 15 keV

[0223] Table 18c: EDS Spectra Results of Sample 3 - Bentonite - 90:10 Process C at 5 keV(Figure 19a)

[0224] Table 19a: EDS Spectra Results of Sample 4 - Limestone - 90:10 Process A at 5 keV(Figure 20a)

[0225] Table 19b: EDS Spectra Results of Sample 4 - Limestone - 90:10 Process A at 15 keVNote: The particles corresponding to spectra 270 (266) and 282 (276) are identified as bentonite based on 15 keV EDS results.

[0226] Table 19c: EDS Spectra Results of Sample 4 - Bentonite - 90:10 Process A at 5 keV(Figure 20b)

[0227] Table 19d: EDS Spectra Results of Sample 4 - Bentonite - 90:10 Process A at 15 keVNote: The particles corresponding to spectra 353 (348) and 361 (355) are identified as limestone based on 15 keV EDS results.Example 8

[0228] Experiments were conducted to evaluate the dust-abatement effect using celluloses as dust abatement agents.

[0229] A polyanionic cellulose (PAC), the carboxymethyl cellulose (CMC) highly derivatized with low viscosity and hydroxypropyl methylcellulose (HPMC) were tested in this example.

[0230] Process A: The non-absorbing and non-clumping filler material (i.e. limestone) is added to the mixer and 0.35% (w / w) of cellulose@2% slurry is then poured directly on it. The two compounds are mixed for 30 seconds. The absorbing material (i.e. sodium bentonite) is then added to the mixer and mixed for an additional 2.5 minutes, as described above.

[0231] The airborne dust ratio values provided in experimental results were determined using Equation (1) as defined herein. A significant reduction in airborne dust (level) is characterized by an airborne dust ratio being lower than 0.5 (the lower the value, the lower the dust level).

[0232] Table 20: Airborne dust levels for mass-based formulations containing 65% sodium bentonite and 35% limestone, produced using Process A, with increasing amounts of PAC@2.0% slurry (w / w 0.05% to 0.5% to the animal litter).The results show that Process A achieved significant dust abatement with amounts of PAC slurry starting at 0.15% PAC@2.0% and up to 0.50% PAC@2.0%.

[0233] Table 21 : Airborne dust levels for mass-based formulations containing 65% sodium bentonite and 35% limestone, produced using Process A, with increasing amounts of HPMC@2.0% slurry (w / w 0.05% to 0.5% to the animal litter).The results show that Process A achieved significant dust abatement with amounts of HPMC slurry starting at 0.25% HPMC@2.0% and up to 0.50% HPMC@2.0%.

Claims

CLAIMS1 . A process for manufacturing an animal litter product, the process comprising: mixing filler material particles with a fluoropolymer slurry in a first mixing device to obtain a coated filler material, wherein the filler material particles are made of a mineral-based, non-absorbing, non-clay material; mixing the coated filler material with clay-based absorbing material particles to obtain an animal litter mixture; and optionally dedusting the animal litter mixture, thereby obtaining the animal litter product, wherein fluorine derived from the fluoropolymer slurry is selectively distributed in the animal litter product to provide an effective amount of fluorine-containing filler material particles being at least 50% of the coated filler material based on a total particle count of the filler material particles, measured by Scanning Electron Microscope - Energy- dispersive X-ray spectroscope analysis (SEM-EDS).

2. The process of claim 1 , further comprising introducing an odor control agent into the animal litter mixture.

3. The process of claim 1 or 2, further comprising introducing a fragrance into the animal litter mixture.

4. The process of any one of claims 1 to 3, further comprising introducing a clumping additive into the animal litter mixture.

5. The process of any one of claims 1 to 4, wherein the filler material particles are selected from the group consisting of calcium carbonate, dolomite, limestone, gypsum, sand, calcite, wollastonite, olivine, silica and blends thereof.

6. The process of any one of claims 1 to 5, wherein the first mixing device is selected from the group consisting of a static mixer, a dynamic mixer, a grain mixer and a screw conveyor.

7. The process of any one of claims 1 to 6, wherein mixing the coated filler material with the clay-based absorbing material particles is performed in a second mixing device which is different than the first mixing device.

8. The process of claim 7, wherein the second mixing device is selected from the group consisting of a static mixer, a dynamic mixer, and a screw conveyor.

9. The process of any one of claims 1 to 8, wherein the clay-based absorbing material particles comprises at least one of a clumping clay and a non-clumping clay.

10. The process of any one of claims 1 to 8, wherein the clay-based absorbing material particles comprises a clumping clay which is sodium bentonite.

11. The process of claim 9, wherein the clay-based absorbing material comprises a nonclumping clay selected from the group consisting of calcium bentonite, attapulgite, palygorskite, sepiolite, hydrous aluminum silicate, kaolinite, illite, halloysite, hormite, vermiculite, clinoptilolite, diatomite and blends thereof.

12. The process of claim 11, wherein the clay-based absorbing material comprises a nonclumping clay selected from the group consisting of calcium bentonite, clinoptilolite and a blend thereof.

13. The process of any one of claims 1 to 12, wherein the fluoropolymer slurry is a polyvinylfluoride (PVF) slurry, a polyvinylidene fluoride (PVDF) slurry, a polytetrafluoroethylene (PTFE) slurry, a polychlorotrifluoroethylene (PCTFE) slurry, a perfluoroalkoxy polymer (PFA) slurry, a fluorinated ethylene-propylene (FEP) slurry, a polyethylenetetrafluoroethylene (ETFE) slurry, or a polyethylenechlorotrifluoroethylene (ECTFE) slurry, or a slurry of any copolymer thereof.

14. The process of claim 13, wherein the fluoropolymer slurry is a polytetrafluoroethylene (PTFE) slurry.

15. The process of claim 14, wherein the PTFE slurry is a colloidal aqueous dispersion of PTFE comprising nanosized PTFE particles suspended in water, preferably spherical or cylindrical rod-shaped nanosized PTFE particles suspended in water.

16. The process of claim 14 or 15, wherein the PTFE slurry has a PTFE concentration in water of between about 0.2 wt% and about 10 wt%.

17. The process of claim 16, wherein the PTFE slurry concentration is between about 0.5 wt% and about 6 wt%.

18. The process of any one of claims 14 to 17, wherein the PTFE slurry amount used with respect to the animal litter product (w / w) is between about 0.01% and about 5%.

19. The process of claim 18, wherein the PTFE slurry amount used with respect to the animal litter product (w / w) is between about 0.05% and about 2%.

20. An animal litter product, comprising: filler material particles comprising a mineral-based, non-absorbing, non-clay material; clay-based absorbing material particles; and a dust abatement agent being selectively distributed onto the filler material particles, wherein the dust abatement agent is a fluoropolymer; wherein the animal litter product comprises an effective amount of fluorine-containing filler material particles being of at least 50% of the filler material particles based on a total particle count of the filler material particles, measured by Scanning Electron Microscope - Energy-dispersive X-ray spectroscope analysis (SEM-EDS).21 . The animal litter product of claim 20, further comprising an odor control agent.

22. The animal litter product of claim 20 or 21 , further comprising a clumping additive.

23. The animal litter product of any one of claims 20 to 22, wherein the filler material particles are selected from the group consisting of calcium carbonate, dolomite, limestone, gypsum, sand, calcite, wollastonite, olivine, silica and blends thereof.

24. The animal litter product of any one of claims 20 to 23, wherein the clay-based absorbing material particles comprise at least one of a clumping clay and a non-clumping clay.

25. The animal litter product of any one of claims 20 to 24, the clay-based absorbing material particles comprise a clumping clay which is sodium bentonite.

26. The animal litter product of any one of claims 20 to 24, wherein the clay-based absorbing material comprises a non-clumping clay selected from the group consisting of calcium bentonite, attapulgite, palygorskite, sepiolite, hydrous aluminum silicate, kaolinite, illite, halloysite, hormite, vermiculite, clinoptilolite, diatomite and blends thereof.

27. The animal litter of claim 26, wherein the clay-based absorbing material comprises a nonclumping clay selected from the group consisting of calcium bentonite, clinoptilolite and a blend thereof.

28. The animal litter of any one of claims 20 to 27, wherein the fluoropolymer is a polyvinylfluoride (PVF), a polyvinylidene fluoride (PVDF), a polytetrafluoroethylene (PTFE), a polychlorotrifluoroethylene (PCTFE), a perfluoroalkoxy polymer (PFA), a fluorinated ethylene-propylene (FEP), a polyethylenetetrafluoroethylene (ETFE), a polyethylenechlorotrifluoroethylene (ECTFE), or any copolymer thereof.

29. The animal litter product of any one of claims 20 to 28, wherein the fluoropolymer is polytetrafluoroethylene (PTFE).

30. The animal litter product of claim 29, wherein the PTFE comprises nanosized PTFE particles, preferably spherical or cylindrical rod-shaped nanosized PTFE particles.31 . The animal litter of any one of claims 20 to 30, characterized by an airborne dust ratio of at most about 0.50 and wherein the airborne dust ratio is defined as a mean dust area of the animal litter comprising the coated filler material over a mean dust area of an animal litter comprising an uncoated filler material.

32. The animal litter of claim 31 , wherein the airborne dust ratio of at most about 0.33.

33. The animal litter of any one of claims 20 to 30, wherein the effective amount of fluorine- containing filler material particles is at least 60% of the filler material particles based on the total particle count of the filler material particles for a given airborne dust ratio of at most 0.50, and wherein the airborne dust ratio is defined as a mean dust area of the animal litter comprising the coated filler material over a mean dust area of an animal litter comprising an uncoated filler material.

34. The animal litter of any one of claims 20 to 30, wherein the effective amount of fluorine- containing filler material particles is at least 60% of the filler material particles based on the total particle count of the filler material particles for a given airborne dust ratio of at most 0.33 and wherein the airborne dust ratio is defined as a mean dust area of the animal litter comprising the coated filler material over a mean dust area of an animal litter comprising an uncoated filler material.

35. The animal litter of any one of claims 20 to 34, wherein less than 50% of the clay-based absorbing material particles are fluorine-containing clay-based absorbing material particles based on a total particle count of the clay-based absorbing material particles, measured by Scanning Electron Microscope - Energy-dispersive X-ray spectroscope analysis (SEM-EDS).

36. The animal litter of any one of claims 20 to 35, wherein the effective amount of fluorine- containing filler material particles is at least 65% of the filler material particles based on the total particle count of the filler material particles.

37. The animal litter of any one of claims 20 to 36, wherein the effective amount of fluorine- containing filler material particles is at least 75% of the filler material particles based on the total particle count of the filler material particles.

38. The animal litter of claim 35, wherein less than 35% of the clay-based absorbing material particles are fluorine-containing clay-based absorbing material particles based on the total particle count of the clay-based absorbing material particles39. The animal litter of claim 35, wherein less than 20% of the clay-based absorbing material particles are fluorine-containing clay-based absorbing material particles based on the total particle count of the clay-based absorbing material particles.

40. The animal litter of claim 35, wherein at least 50% of the clay-based absorbing material particles, based on the total particle count of the clay-based absorbing material particles, is free of fluorine measured by Scanning Electron Microscope - Energy-dispersive X-ray spectroscope analysis (SEM-EDS).

41. The animal litter of claim 40, wherein at least 65% of the clay-based absorbing material particles, based on the total particle count of the clay-based absorbing material particles, is free of fluorine.

42. The animal litter of claim 40, wherein at least 80% of the clay-based absorbing material particles, based on the total particle count of the clay-based absorbing material particles, is free of fluorine.

43. An animal litter product, comprising:coated filler material particles comprising a mineral-based, non-absorbing, non-clay material and a dust abatement agent being distributed onto at least the mineral-based, non-absorbing, non-clay material; clay-based absorbing material particles; and wherein the animal litter product is characterized by an airborne dust ratio of at most about 0.50 and wherein the airborne dust ratio is defined as a mean dust area of the animal litter comprising the coated filler material over a mean dust area of an animal litter comprising an uncoated filler material being exempt of the dust abatement agent.

44. The animal litter product of claim 43, wherein the dust abatement agent is selected from the group consisting of fluoropolymers, oils, water, glycerols, glycols, polyvinyl alcohol, polyvinyl acetate, polymers, silicones, celluloses, calcium chloride, foams and mixtures thereof.

45. The animal litter product of claim 43, wherein the dust abatement agent is selected from the group consisting of polytetrafluoroethylene (PTFE), hydroxypropylmethyl cellulose (HPMC), polyanionic cellulose (PAC), carboxymethyl cellulose (CMC), and mixtures thereof.

46. The animal litter of any one of claims 43 to 45, wherein the dust abatement agent is a slurry.

47. The animal litter of any one of claims 43 to 46, wherein the dust abatement agent is a slurry of HPMC, PAC, CMC or a mixture thereof.

48. The animal litter of any one of claims 43 to 46, wherein the dust abatement agent is a PTFE slurry.

49. The animal litter of claim 48, wherein the dust abatement agent is selectively distributed onto the filler material particles, and the animal litter product comprises an effective amount of fluorine-containing filler material particles being of at least 50% of the filler material particles based on a total particle count of the filler material particles, measured by Scanning Electron Microscope - Energy-dispersive X-ray spectroscope analysis (SEM-EDS).

50. The animal litter of claim 49, wherein less than 50% of the clay-based absorbing material particles are fluorine-containing clay-based absorbing material particles based on a totalparticle count of the clay-based absorbing material particles, measured by Scanning Electron Microscope - Energy-dispersive X-ray spectroscope analysis (SEM-EDS).51 . The animal litter of any one of claims 43 to 50, wherein the dust abatement slurry amount used with respect to the animal litter product (w / w) is between about 0.01% and about 5%.

52. The animal litter of claim 51 , wherein the dust abatement slurry amount used with respect to the animal litter product (w / w) is between about 0.05% and about 2%.

53. The animal litter product of any one of claims 43 to 52, further comprising at least one feature being defined in any one of claims 1 to 42.

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