Method for producing washing or cleaning agent dosage units

Abstract

The invention relates to a method for producing washing or cleaning agent dosage units, having the steps of: a) providing a mold with at least one mold cavity; b) supplying a first water-soluble film to the mold cavity; c) molding the first water-soluble film into the mold cavity, thereby forming a receiving chamber; d) at least partially filling the receiving chamber by d1) introducing at least one first gel former-containing liquid washing- or cleaning-active composition, thereby forming a first washing- or cleaning-active phase; d2) introducing at least one second liquid washing- or cleaning-active composition, which differs from the first composition, onto the upper face of the first washing- or cleaning-active phase in the receiving chamber, thereby forming a second washing- or cleaning-active phase which completely covers the upper face of the first washing- or cleaning-active phase; d3) introducing at least one third solid washing- or cleaning-active composition, which differs from the first and second composition, onto the upper face of the second washing- or cleaning-active phase in the receiving chamber, thereby forming a third washing- or cleaning-active phase which completely covers the upper face of the second washing- or cleaning-active phase; e) supplying a second water-soluble film; and f) sealing the at least partially filled receiving chamber using the second water-soluble film, thereby forming a washing or cleaning agent dosage unit comprising a water-soluble casing.

Description

[0001] Manufacturing process for detergent or cleaning agent portion units

[0002] The present invention relates to a process for producing washing or cleaning agent portion units wrapped with water-soluble film. In particular, the application relates to a multi-stage production process for producing multi-phase washing or cleaning agent portion units.

[0003] The packaging and distribution of detergents and cleaning agents are constantly evolving. For some time now, a key focus has been on convenient dosing of detergents and cleaning agents by the consumer and simplifying the steps required for a washing or cleaning process. One solution is pre-portioned detergents and cleaning agents, for example, foil pouches with one or more compartments for solid or liquid ingredients.

[0004] To be commercially successful, a detergent or cleaning agent portion unit must meet consumer interests in the best possible way. A key means of communicating product quality and product promise is the appearance and feel of the portion unit. This applies in particular to water-soluble film pouches, whose soluble films are generally transparent and reveal the solid or liquid detergent or cleaning agent contained within. Especially with multi-phase detergents or cleaning agents, the communication of product quality and product promise is supported by clear phase boundaries within a portion unit and a largely identical structural design and visual impression of identical portion units. The film pouches also preferably have a firm handle and low mechanical deformability, i.e. they are not flabby.

[0005] The production of detergent or cleaning agent portion units with water-soluble film packaging is usually carried out using a sequential process in which the water-soluble film and the detergent ingredients are combined to form a portion unit.

[0006] The international patent application WO 2002 / 16205 A1 describes processes for producing washing and cleaning agents in the form of tightly filled, water-soluble film bags.

[0007] The granted European patent EP 2 944 578 B1 describes a process for encasing washing or cleaning agent tablets using a shrunk-on water-soluble film.

[0008] The object of the present application was to provide an efficient process for producing multi-phase washing or cleaning agent portion units, the products of which are characterized by an appealing appearance and feel. To achieve this object, a process for producing a washing or cleaning agent portion unit is provided, comprising the steps: a) providing a mold with at least one mold cavity; b) feeding a first water-soluble film to the mold cavity; c) molding the first water-soluble film into the mold cavity to form a receiving chamber; d) at least partially filling the receiving chamber by d1) introducing at least one first gelling agent-containing, liquid washing or cleaning-active composition to form a first washing or cleaning-active phase;d2) introducing at least one second liquid washing or cleaning-active composition, different from the first composition, onto the top of the first washing or cleaning-active phase in the receiving chamber to form a second washing or cleaning-active phase that completely covers the top of the first washing or cleaning-active phase; d3) introducing at least one third solid washing or cleaning-active composition, different from the first and second compositions, onto the top of the second washing or cleaning-active phase in the receiving chamber to form a third washing or cleaning-active phase that completely covers the top of the second washing or cleaning-active phase; e) supplying a second water-soluble film;f) sealing the at least partially filled receiving chamber with the second water-soluble film to form a washing or cleaning agent portion unit comprising a water-soluble wrapping;

[0009] The process described in detail below is used to produce washing or cleaning agent portion units. Portioned washing or cleaning agents are referred to as washing or cleaning agent portion units. These portions are generally sufficient for carrying out a manual or mechanical, preferably machine, washing or cleaning process. Preferred washing or cleaning agent portion units have a weight of 10 to 35 g, preferably 12 to 28 g, and especially 14 to 22 g.

[0010] In a first step of the process, a mold with at least one mold cavity is provided. In a preferred process variant, a deep-drawing die with a cavity as the mold cavity is provided as the mold.

[0011] The thermoforming die itself can be designed in the form of a horizontally rotating belt or in the form of a rotating drum. The use of a thermoforming die with at least one cavity based on a horizontally rotating conveyor belt is preferred. In step b) of the process, a first water-soluble film is fed into the mold cavity. In a preferred embodiment, a thermoplastic water-soluble film is fed in step b).

[0012] The water-soluble film can be fed continuously or discontinuously. To increase process efficiency, a continuous process is preferred. In a particularly preferred embodiment of the process, the first water-soluble film is transported continuously in step b). With regard to process economy and process reliability, it is preferable to feed the first water-soluble film in step b) at a speed of 0.04 m / s, preferably above 0.08 m / s.

[0013] The water-soluble film may comprise one or more structurally different water-soluble polymers. Particularly suitable water-soluble polymers for the first water-soluble film are polymers from the group of (optionally acetalized) polyvinyl alcohols (PVAL) and their copolymers.

[0014] Water-soluble films for producing the portion unit are preferably based on a polyvinyl alcohol or a polyvinyl alcohol copolymer whose molecular weight is preferably in the range from 10,000 to 1,000,000 gmol-1, preferably from 20,000 to 500,000 gmol-1, particularly preferably from 30,000 to 100,000 gmol-1, and especially from 40,000 to 80,000 gmol-1. Preferred water-soluble films comprise at least 30 wt.%, preferably at least 50 wt.%, and especially at least 70 wt.% of polyvinyl alcohol or polyvinyl alcohol copolymers.

[0015] The production of polyvinyl alcohol and polyvinyl alcohol copolymers generally involves the hydrolysis of intermediate polyvinyl acetate. Preferred polyvinyl alcohols and polyvinyl alcohol copolymers have a degree of hydrolysis of 70 to 100 mol%, preferably 80 to 90 mol%, particularly preferably 81 to 89 mol%, and especially 82 to 88 mol%.

[0016] Preferred polyvinyl alcohol copolymers comprise, in addition to vinyl alcohol, an ethylenically unsaturated carboxylic acid, its salt, or its ester. Particularly preferably, such polyvinyl alcohol copolymers contain, in addition to vinyl alcohol, sulfonic acids such as 2-acrylamido-2-methyl-1-propanesulfonic acid (AMPS), acrylic acid, methacrylic acid, acrylic acid esters, methacrylic acid esters, or mixtures thereof; among the esters, C 1-4 alkyl esters or hydroxyalkyl esters are preferred. Other suitable monomers include ethylenically unsaturated dicarboxylic acids, for example, itaconic acid, maleic acid, fumaric acid, and mixtures thereof.

[0017] Suitable water-soluble films for use in the portion units according to the invention are films sold by MonoSol LLC, for example, under the designation M8630, M8720, M8310, C8400, or M8900. Other suitable films include films named Solublon® PT, Solublon® GA, Solublon® KC, or Solublon® KL from Aicello Chemical Europe GmbH, or the VF-HP films from Kuraray and the Hi-Selon series from Mitsubishi Chemical Corporation.

[0018] The first water-soluble film supplied in step b) preferably has a thickness of 60 to 2000 pm, preferably of 60 to 800 pm and in particular of 60 to 200 pm.

[0019] The water-soluble film can be formed into the mold cavity in step c) in a manner known to those skilled in the art. Both cold and hot forming processes can be used. The film can also be formed into the mold cavity under the influence of a force, for example, its weight, the force of a stamp, or a vacuum. Due to the advantageous process results achieved, it is preferred if the first water-soluble film is formed under the influence of heat in step c). Reproducibly good results have been achieved, in particular, by heating the first film and its subsequent vacuum forming.

[0020] The molding process is preferably preceded by an optional pretreatment of the film with heat and / or solvent. The water-soluble film can then be molded into the cavity, as described, using a tool, a vacuum, compressed air, and / or its own weight.

[0021] Among the thermoforming processes, those preferred are those in which the water-soluble film is transported above the cavities of a thermoforming die and is formed into the die recesses by the action of compressed air on the upper side of the film or by the action of a vacuum on the underside of the film, particularly preferably with the simultaneous action of compressed air and vacuum. Particularly advantageous processes are characterized by the fact that the film is pretreated with heat and / or solvents before forming.

[0022] The effect of heat and / or solvents on the water-soluble film serves to facilitate its plastic deformation. The film can be heated, for example, by thermal radiation, hot air or, particularly preferably, by direct contact with a hot plate. The duration of the heat treatment and the temperature of the thermal radiation, hot air or hot plate surface used naturally depend on the type of casing material used. For water-soluble or water-dispersible materials such as PVA-containing polymers or copolymers, a temperature between 90 and 130°C, in particular between 105 and 115°C, is preferred. The duration of the heat treatment, in particular the contact time when using a hot plate, is preferably between 0.1 and 7 seconds, particularly preferably between 0.2 and 6 seconds and in particular between 0.3 and 4 seconds.Contact times of less than one second, particularly in the range of 400 to 900 milliseconds, preferably between 500 and 800 milliseconds, have proven particularly advantageous for polyvinyl alcohol materials.

[0023] For reasons of process efficiency, the process according to the invention is designed such that not just a single detergent portion unit is produced in one process run, but rather a plurality of detergent portion units in parallel. Preferably, in step c), a sheet-like structure with at least 14, preferably at least 20, receptacles is formed from the first water-soluble film.

[0024] In this sheet-like structure, the receiving chambers formed are preferably arranged in rows. With regard to subsequent filling, the receiving chambers formed in step c) are arranged in rows that are orthogonal to the transport direction of the water-soluble film.

[0025] In an alternative embodiment, in step c) a sheet-like structure is formed in which the receiving chambers are arranged in rows which run orthogonally to the transport direction of the water-soluble film and are offset from one another by one third of the width of a receiving container, preferably by half the width of a receiving container.

[0026] In the sheet-like structure, the receiving chambers are preferably arranged such that each receiving container is adjacent to at least one intermediate region, which in turn is surrounded by three receiving chambers.

[0027] The production of detergent or cleaning agent portion units by filling a deformed, water-soluble film enables the production of a wide variety of spatial shapes and geometries. The production of detergent or cleaning agent portion units by filling a deformed, water-soluble film also enables the production of portion units with two or more phases, i.e., two or more areas with different fillings. The phases are preferably visually distinguishable from one another.

[0028] In a preferred process alternative, the receiving chamber formed in step c) has at least one, preferably two, three, or four, recesses in its base region. The formation of these recesses makes it possible to provide detergent or cleaning agent portion units with a differentiable appearance. If the recesses are filled with different compositions than the remaining volume of the receiving chamber, the formation of the recesses also allows the production of multi-phase detergent or cleaning agent portion units.

[0029] In a preferred process variant, the first composition introduced in step d1) is introduced into the depression(s) located in the bottom region of the receiving chamber. It is particularly preferred if the receiving chamber formed in step c) has two, preferably three or four, depressions in its bottom region, and the first composition is introduced into these depressions in step d1).

[0030] Particularly preferred are methods in which the receiving chamber formed in step c) has two, preferably three or four depressions in its bottom region and the first composition is introduced into these depressions in step d 1 ), wherein the first composition in one of the depressions differs from at least one first composition in a further depression.

[0031] Due to their appearance and the diverse possibilities for separating incompatible ingredients, particularly preferred process variants are those in which the receiving chamber formed in step c) has three or four depressions in its bottom region and the first composition is introduced into these depressions in step d1), wherein the first composition in each of the depressions differs from the first composition in each further depression.

[0032] The first composition introduced in step d 1 ) preferably has a liquefaction point at temperatures above 80°C (1013 mbar), particularly preferably above 100°C (1013 mbar), and especially above 115°C (1013 mbar). This high liquefaction point enables the liquid dosage of the first composition at the ambient temperatures typical for the large-scale production of detergent or cleaning agent portion units, while simultaneously rapidly solidifying the first composition in the receiving chamber.

[0033] Preferably, the first composition introduced in step d1) contains, based on its total weight, a) 4 to 40 wt.% gelling agent; b) 0.1 to 40 wt.% washing or cleaning agent; c) 30 to 90 wt.% organic solvent.

[0034] The rheological properties of this preferred first composition are influenced, among other components, in particular by the gelling agent it contains. In preferred first compositions, the weight fraction of the gelling agent in the total weight is 6 to 30 wt.%, preferably 7 to 24 wt.%, and in particular 8 to 22 wt.%.

[0035] Preferred gel formers are selected from the group of polymeric gel formers, preferably from the group of optionally acetalized polyvinyl alcohol, gelatin, and xanthan gum, or mixtures thereof. The use of optionally acetalized polyvinyl alcohol is particularly preferred.

[0036] Preferred gelling agents are based on a polyvinyl alcohol or a polyvinyl alcohol copolymer whose molecular weight is in the range of 10,000 to 1,000,000 gmol -1 , preferably from 20,000 to 500,000 gmol -1 , particularly preferably from 30,000 to 100,000 gmol -1and especially from 40,000 to 80,000 gmol -1 lies.

[0037] The production of polyvinyl alcohol and polyvinyl alcohol copolymers usually includes the

[0038] Hydrolysis of intermediate polyvinyl acetate. Preferred polyvinyl alcohols and polyvinyl alcohol copolymers have a degree of hydrolysis of 70 to 100 mol%, preferably 80 to 90 mol%, particularly preferably 81 to 89 mol%, and especially 82 to 88 mol%.

[0039] Preferred polyvinyl alcohol copolymers comprise, in addition to vinyl alcohol, an ethylenically unsaturated carboxylic acid, its salt, or its ester. Particularly preferably, such polyvinyl alcohol copolymers contain, in addition to vinyl alcohol, sulfonic acids such as 2-acrylamido-2-methyl-1-propanesulfonic acid (AMPS), acrylic acid, methacrylic acid, acrylic acid esters, methacrylic acid esters, or mixtures thereof; among the esters, C 1-4 alkyl esters or hydroxyalkyl esters are preferred. Other suitable monomers include ethylenically unsaturated dicarboxylic acids, for example, itaconic acid, maleic acid, fumaric acid, and mixtures thereof.

[0040] The gelling agent is preferably selected from the group of hydrolyzed polyvinyl alcohol homopolymers and polyvinyl alcohol copolymers having a molecular weight of 30,000 to 60,000 g / mol.

[0041] As a second component, the preparation, preferably used as the first composition, contains a washing or cleaning agent. The weight fraction of the washing or cleaning agent in relation to the total weight of the first composition is preferably 1 to 35% by weight, preferably 5 to 30% by weight, and in particular 10 to 25% by weight.

[0042] Even if the selection of the washing or cleaning active ingredient is not subject to any significant restriction, washing or cleaning active ingredients selected from the group of washing or cleaning active polymers, surfactants, corrosion inhibitors and mixtures thereof are preferred because of their ease of processing in the washing or cleaning agent.

[0043] The group of washing or cleaning-active polymers includes, in particular, polycarboxylates. The washing or cleaning-active agent is preferably selected from the group of polycarboxylates, in particular the copolymer polyacrylates, particularly preferably the copolymer polyacrylates containing sulfonic acid groups.

[0044] The copolymers can have two, three, four, or more different monomer units. Preferred copolymeric polysulfonates contain, in addition to monomer(s) containing sulfonic acid groups, at least one monomer from the group of unsaturated carboxylic acids.

[0045] The first composition particularly preferably comprises an anionic copolymer as a washing or cleaning active ingredient, the anionic copolymer comprising i) monomers containing carboxylic acid groups, ii) monomers containing sulfonic acid groups, and iii) non-ionic monomers, in particular hydrophobic monomers. Another group of preferred washing or cleaning active ingredients comprised in the first composition are non-ionic surfactants, preferably non-ionic surfactants with a melting point above 30°C, particularly preferably in the range from 40 to 60°C. The melting point of the surfactant (in °C) is determined using differential calorimetry (DSC) according to ISO Standard 11357. For the purposes of the invention, the melting point is considered to be the peak temperature determinable by DSC in the second heating run. This is the temperature at which the apex / maximum deflection (on the y-axis) in the DSC diagram is present.If several peaks - within 5% of the maximum deflection observed in the second heating run - are present in a surfactant (commercial product), the temperature of the first peak is considered to be the melting point according to the invention.

[0046] Suitable surfactants are in particular linear, saturated fatty acid alcohol ethoxylates with 14 to 18 C atoms in the alkyl chain and 10 to 100 ethylene oxide units, which are preferably not end-capped.

[0047] As a further preferred washing or cleaning active ingredient, preferred first compositions contain glass corrosion inhibitors, preferably from the group of water-soluble zinc salts, particularly preferably zinc sulfate and zinc acetate, in particular zinc acetate.

[0048] The first compositions introduced in step d1) preferably further contain a bodying agent from the group of polyethylene glycols, preferably from the group of polyethylene glycols with an average molecular weight of 200 to 600 g / mol, preferably from the group of polyethylene glycols with an average molecular weight of 300 to 500 g / mol. When reference is made to the "average molecular weight of polyalkylene glycols" in this application, these figures refer to the number-average molecular weights (Mn), which are calculated from the OH number measured according to DIN 53240-1:2012-07.

[0049] The weight proportion of the consistency agent in the total weight of the first composition is preferably 5 to 30 wt.%, preferably 8 to 26 wt.% and in particular 10 to 22 wt.%.

[0050] As a third essential component, the first compositions preferably introduced in step d1) contain an organic solvent. The weight fraction of the organic solvent in the total weight of the first composition is preferably 35 to 80 wt.% and in particular 40 to 70 wt.%.

[0051] The use of an organic solvent from the group of polyhydric alcohols has proven particularly advantageous for processability and setting behavior. Polyhydric alcohols within the meaning of the present invention are hydrocarbons in which two, three or more hydrogen atoms are replaced by OH groups. The OH groups are bonded to different carbon atoms. A carbon atom does not have two OH groups. The first composition particularly preferably comprises at least one alkanetriol and / or at least one alkanediol, in particular at least one C3- to C10-alkanetriol and / or at least one C3- to C10-alkanediol, preferably at least one C3- to C8-alkanetriol and / or at least one C3- to C8-alkanediol, in particular at least one C3- to C10-alkanetriol and / or at least one C3- to C8-alkanediol as polyhydric alcohol.The combination of a C3- to C10-alkanediol with a C3- to C10-alkanetriol is particularly preferred. The use of an organic solvent selected from the group consisting of 1,3-propanediol and glycerol is very particularly preferred.

[0052] The amount by weight of the first composition introduced in step d1) is preferably 0.1 g to 4 g, particularly preferably 0.4 to 3 g and especially preferably 0.7 to 2.5 g.

[0053] The first composition solidifies at least partially, preferably completely, after step d1) and before step d2).

[0054] The second composition introduced in step d2) preferably has a liquefaction point at temperatures in the range from 40 to 80°C (1013 mbar), particularly preferably in the range from 45 to 75°C (1013 mbar) and in particular in the range from 50 to 70°C (1013 mbar). For the process control, the curing of the first and second compositions and the appearance of the washing or cleaning agent portion unit, it has proven advantageous if the liquefaction point of the first composition and the second composition differ by at least 10°C (1013 mbar), preferably by at least 20°C (1013 mbar) and in particular by at least 30°C (1013 mbar).

[0055] The rheological properties of the second composition can be influenced, for example, by the choice of a suitable carrier. In preferred process variants, the second composition contains, in addition to the washing or cleaning active ingredient, a meltable carrier with a melting point in the range of 40 to 80°C (1013 mbar), particularly preferably in the range of 45 to 75°C (1013 mbar), and especially in the range of 50 to 70°C (1013 mbar).

[0056] Preferred processes are characterized in that the second composition contains, based on its total weight, a) 40 to 95 wt.% of meltable carrier; b) 0.1 to 40 wt.% of washing or cleaning active ingredient.

[0057] The second composition preferably contains a meltable carrier from the group of polyethylene glycols, particularly preferably from the group of polyethylene glycols with an average molecular weight (Mn) of >1500 g / mol, preferably an average molecular weight between 3,000 and 15,000, even more preferably with an average molecular weight between 4,000 and 13,000, further preferably with an average molecular weight between 4,000 and 6,000, 6,000 and 8,000 or 9,000 and 12,000 and particularly preferably with an average molecular weight of 4,000 to 6,000 g / mol.

[0058] The weight proportion of the washing or cleaning active ingredient in the total weight of the second composition is 1 to 40 wt.%, preferably 5 to 35 wt.% and in particular 10 to 30 wt.%.

[0059] The weight of the second composition introduced in step d2) is preferably between 0.5 g and 12 g, preferably between 1 and 9 g and particularly preferably between 2 and 7 g.

[0060] For better perception, the first composition and the second composition preferably contain dye, wherein it is particularly preferred if the dyes of the first and second composition differ.

[0061] The second composition solidifies at least partially, preferably completely, after step d2) and before step d3). The cured second composition stabilizes the receiving chamber, but in particular the final process product.

[0062] In step d3), a third composition is preferably introduced in powder form. By eliminating the need for a further melt, the cooling time of the intermediate product is reduced and the process efficiency is increased.

[0063] For the efficient filling of the receiving chamber with the powder, it has proven advantageous if the powder has a flowability of greater than 40%, preferably greater than 50%, in particular greater than 60%, based on the standard.

[0064] The flowability of the powder refers to its ability to flow freely under its own weight. The flowability is determined by measuring the flow time of 1000 ml of cleaning agent powder from a standardised trickle test funnel that is initially closed at the outlet direction and has an outlet of 16.5 mm in diameter. The time required for the granular mixture, in particular the powdery phase, preferably the powder and / or granules, e.g. the powder, to flow completely out after the outlet has been opened is measured and compared with the flow rate (in seconds) of a standard test sand, the flow rate of which is defined as 100%. The defined sand mixture for calibrating the trickle apparatus is dry sea sand. Sea sand with a particle diameter of 0.4 to 0.8 mm is used; this is available, for example, from Carl Roth, Germany CAS No.[14808-60-7], For drying, the sea sand is dried for 24 h at 60 °C in a drying cabinet on a plate with a maximum layer height of 2 cm before measurement.

[0065] The filling level of the receiving chamber following step d3) is preferably from 60 to 120 vol.%, particularly from 80 to 110 vol.% and in particular from 90 to 100 vol.%. Surprisingly, the second composition is characterized by higher adhesion to the inner wall of the receiving chamber than the first composition, which is why the third composition introduced in step d3) does not infiltrate the two previously introduced compositions, i.e. does not enter the space between the inner wall of the receiving chamber and the composition. The first composition is not infiltrated by the third composition because this first composition is completely covered by the second composition. The second composition is not infiltrated due to its high adhesion to the inner wall.

[0066] In summary, a particularly preferred variant of the method comprises the steps: a) providing a mold with at least one mold cavity; b) feeding a first water-soluble film to the mold cavity; c) molding the first water-soluble film into the mold cavity to form a receiving chamber; d) at least partially filling the receiving chamber by d1) introducing at least one first gel-forming agent-containing, liquid washing or cleaning-active composition to form a first washing or cleaning-active phase, wherein the first composition, based on its total weight a) 4 to 40 wt. % gel-forming agent; b) 0.1 to 40 wt. % washing or cleaning-active active ingredient; c) 30 to 90 wt.-% organic solvent; d2) introducing at least one second liquid washing or cleaning-active composition, which is different from the first composition, onto the upper side of the first washing or cleaning-active phase in the receiving chamber to form a second washing or cleaning-active phase which completely covers the upper side of the first washing or cleaning-active phase, wherein the second composition, based on its total weight, contains a) 40 to 95 wt.% meltable carrier; b) 0.1 to 40 wt.-% washing or cleaning active ingredient; d3) introducing at least one third solid washing or cleaning active composition, different from the first and the second composition, onto the top side of the second washing or cleaning active phase in the receiving chamber to form a third washing or cleaning active phase that completely covers the top side of the second washing or cleaning active phase, wherein the third composition is in the form of a powder; e) feeding a second water-soluble film; f) sealing the at least partially filled receiving chamber with the second water-soluble film to form a washing or cleaning agent portion unit comprising a water-soluble wrapping. In step e) of the method, a second water-soluble film is fed.As in step b), in a preferred embodiment the film supplied in step e) is also a thermoplastic water-soluble film.

[0067] The water-soluble film can be fed continuously or discontinuously. To increase process efficiency, a continuous process is preferred. In a particularly preferred embodiment of the process, the second water-soluble film is transported continuously in step e). With regard to process economy and process reliability, it is preferred to feed the second water-soluble film in step e) at a speed of 0.04 m / s, preferably above 0.08 m / s.

[0068] The water-soluble film added in step e) may comprise one or more structurally different water-soluble polymers. Particularly suitable water-soluble polymers for the second water-soluble film are polymers from the group of (optionally acetalized) polyvinyl alcohols (PVAL) and their copolymers.

[0069] The second water-soluble film supplied in step e) preferably has a thickness of 80 pm or less, in particular of 65 pm or less, most preferably of 55 pm or less.

[0070] With regard to the mechanical stability of the cleaning agent portion unit while simultaneously minimizing the use of packaging materials, it is preferred if the ratio of the thickness of the first water-soluble film to the thickness of the second water-soluble film is from 3:1 to 1:1, preferably from 2.5:1 to 1.1:1, in particular from 2:1 to 1.2:1. Preferably, the second water-soluble film added in step e) is thinner than the first water-soluble film added in step a).

[0071] The at least partially filled receiving chamber is sealed in step f) of the process. Sealing is preferably carried out under the influence of a solvent or heat.

[0072] Following sealing, the water-soluble film of the detergent or cleaning agent portion unit is shrunk in a preferred variant of the process. The shrinking of the water-soluble film takes place in a device designed for this purpose, known as a shrink tunnel. A shrink tunnel enables the targeted heating of the water-soluble film surrounding the detergent or cleaning agent portion unit.

[0073] The shrink tunnel has a conveyor system with which the detergent or cleaning agent portion unit is transported through the shrink tunnel. This conveyor system can be, for example, a circulating conveyor belt. Heat transfer in the shrink tunnel can occur, for example, through thermal radiation or hot air. In processes according to the invention, the water-soluble film is preferably shrunk by exposure to hot air following step f). The hot air preferably has a temperature of 120 to 290°C, preferably 140 to 260°C, and in particular 175 to 230°C.

[0074] For the purposes of transport, storage, and marketing, the sealed detergent or cleaning agent portion units are packaged in bulk in secondary packaging following step f) and, if necessary, after shrinking the water-soluble film. It has been proven that the portion units produced according to the invention have a high level of mechanical stability, which is why no sorted packaging is required. Furthermore, due to their stability, the portion units do not necessarily require mechanically strong secondary packaging. To reduce packaging costs while simultaneously ensuring mechanical stability, manufacturing processes are preferred in which the detergent or cleaning agent portion units are packaged in bulk in a stand-up pouch following step f) and, if necessary, after shrinking the water-soluble film.

[0075] In summary, a particularly preferred variant of the method comprises the steps: a) providing a mold with at least one mold cavity; b) feeding a first water-soluble film to the mold cavity; c) molding the first water-soluble film into the mold cavity to form a receiving chamber; d) at least partially filling the receiving chamber by d1) introducing at least one first gel-forming agent-containing, liquid washing or cleaning-active composition to form a first washing or cleaning-active phase, wherein the first composition, based on its total weight a) 4 to 40 wt. % gel-forming agent; b) 0.1 to 40 wt. % washing or cleaning-active active ingredient; c) 30 to 90 wt.-% organic solvent; d2) introducing at least one second liquid washing or cleaning-active composition, which is different from the first composition, onto the upper side of the first washing or cleaning-active phase in the receiving chamber to form a second washing or cleaning-active phase which completely covers the upper side of the first washing or cleaning-active phase, wherein the second composition, based on its total weight, contains a) 40 to 95 wt.% meltable carrier; b) 0.1 to 40 wt.-% washing or cleaning active ingredient; d3) introducing at least one third solid washing or cleaning active composition, different from the first and the second composition, onto the top of the second washing or cleaning active phase in the receiving chamber to form a third washing or cleaning active phase that completely covers the top of the second washing or cleaning active phase, the third composition being in the form of a powder; e) supplying a second water-soluble film; f) sealing the at least partially filled receiving chamber with the second water-soluble film to form a washing or cleaning agent portion unit comprising a water-soluble wrapping. g) shrinking the water-soluble film h) packaging the washing or cleaning agent portion unit in bulk in a stand-up pouch.

[0076] This registration provides, among other things, the following items:

[0077] 1. A method for producing a washing or cleaning agent portion unit, comprising the steps: a) providing a mold with at least one mold cavity; b) feeding a first water-soluble film to the mold cavity; c) molding the first water-soluble film into the mold cavity to form a receiving chamber; d) at least partially filling the receiving chamber by d1) introducing at least one first gel-forming agent-containing, liquid washing or cleaning-active composition to form a first washing or cleaning-active phase; d2) introducing at least one second, liquid washing or cleaning-active composition, different from the first composition, onto the top of the first washing or cleaning-active phase in the receiving chamber to form a second washing or cleaning-active phase completely covering the top of the first washing or cleaning-active phase;d3) introducing at least one third solid washing or cleaning-active composition, different from the first and second compositions, onto the top of the second washing or cleaning-active phase in the receiving chamber to form a third washing or cleaning-active phase completely covering the top of the second washing or cleaning-active phase; e) supplying a second water-soluble film; f) sealing the at least partially filled receiving chamber with the second water-soluble film to form a washing or cleaning agent portion unit comprising a water-soluble wrapper;

[0078] 2. The method according to item 1, wherein the washing or cleaning agent portion unit has a weight of 10 to 35 g, preferably 12 to 28 g, and in particular 14 to 22 g. 3. The method according to any one of the preceding items, wherein in step a) a deep-drawing die with at least one cavity is provided.

[0079] 4. Method according to item 3, wherein the deep-drawing die has a horizontally circulating conveyor belt with at least one cavity.

[0080] 5. Process according to one of the preceding points, wherein in step b) a thermoplastic water-soluble film is fed.

[0081] 6. Process according to one of the preceding points, wherein the water-soluble film in step b) is selected from the group of films of optionally acetalized polyvinyl alcohols or copolymers thereof.

[0082] 7. The method according to any one of the preceding points, wherein the first water-soluble film supplied in step b) has a thickness of 60 to 2000 pm, preferably of 60 to 800 pm and in particular of 60 to 200 pm.

[0083] 8. Method according to one of the preceding points, wherein the first water-soluble film is formed in step c) under the influence of heat.

[0084] 9. Method according to one of the preceding points, wherein the receiving chamber formed in step c) has at least one, preferably two, three or four depressions in its bottom region.

[0085] 10. The method according to item 9, wherein the first composition introduced in step d1) is introduced into the depression(s) located in the bottom region of the receiving chamber.

[0086] 11. Method according to one of points 9 or 10, wherein the receiving chamber formed in step c) has two, preferably three or four depressions in its bottom region and the first composition is introduced into these depressions in step d1).

[0087] 12. Method according to one of points 9 or 10, wherein the receiving chamber formed in step c) has two, preferably three or four depressions in its bottom region and the first composition is introduced into these depressions in step d1), wherein the first composition in one of the depressions differs from at least one first composition in a further depression.

[0088] 13. The method according to item 12, wherein the receiving chamber formed in step c) has three or four depressions in its base region, and the first composition is introduced into these depressions in step d1), wherein the first composition in each of the depressions differs from the first composition in each further depression. 14. The method according to any one of the preceding items, wherein the first composition has a liquefaction point at temperatures above 80°C (1013 mbar), particularly preferably above 100°C (1013 mbar), and in particular above 115°C (1013 mbar).

[0089] 15. A process according to any one of the preceding points, wherein the first composition contains, based on its total weight, a) 4 to 40% by weight of gelling agent; b) 0.1 to 40% by weight of washing or cleaning active ingredient; c) 30 to 90% by weight of organic solvent.

[0090] 16. Process according to any one of the preceding points, wherein the first composition contains, based on its total weight, 6 to 30 wt.%, preferably 7 to 24 wt.% and in particular 8 to 22 wt.% of gelling agent.

[0091] 17. Method according to one of the preceding points, wherein the first composition contains gelling agents from the group of polymeric gelling agents, preferably from the group of polyvinyl alcohol, gelatin and xanthan or mixtures thereof.

[0092] 18. Process according to one of the preceding points, wherein the first composition contains gelling agents from the group of hydrolyzed polyvinyl alcohol homopolymers and polyvinyl alcohol copolymers having a molecular weight of 30,000 to 60,000 g / mol.

[0093] 19. Process according to one of the preceding points, wherein the first composition contains, based on its total weight, 1 to 35% by weight, preferably 5 to 30% by weight and in particular 10 to 25% by weight of washing or cleaning active ingredient.

[0094] 20. Process according to any one of the preceding points, wherein the first composition contains, based on its total weight, 35 to 80 wt.%, preferably 40 to 70 wt.% of organic solvent.

[0095] 21. Process according to one of the preceding points, wherein the first composition contains organic solvent from the group of polyhydric alcohols, preferably from the group of C3- to C10-alkanediols and Cs- to C10-alkanetriols.

[0096] 22. The method according to any one of the preceding points, wherein the first composition contains organic solvent from the group 1,3-propanediol and glycerol.

[0097] 23. The method according to any one of the preceding points, wherein the first composition, based on its total weight, contains water in an amount below 5 wt.%, preferably below 2 wt.%, and in particular below 0.5 wt.%. 24. The method according to any one of the preceding points, wherein the first composition, based on its total weight, contains 5 to 30 wt.%, preferably 8 to 26 wt.%, and in particular 10 to 22 wt.% of bodying agent.

[0098] 25. Process according to one of the preceding points, wherein the first composition contains consistency regulators from the group of polyethylene glycols, preferably from the group of polyethylene glycols with an average molecular weight (Mn) of 200 to 600 g / mol, preferably from the group of polyethylene glycols with an average molecular weight (Mn) of 300 to 500 g / mol.

[0099] 26. Method according to one of the preceding points, wherein in step d1) a weight amount of 0.1 g to 4 g, preferably from 0.4 to 3 g, particularly preferably 0.7 to 2.5 g of the first composition is introduced.

[0100] 27. Method according to one of the preceding points, wherein the first composition solidifies at least partially, preferably completely, after step d1) and before step d2).

[0101] 28. A process according to any one of the preceding points, wherein the second composition has a liquefaction point at temperatures in the range of 40 to 80°C (1013 mbar), more preferably in the range of 45 to 75°C (1013 mbar) and in particular in the range of 50 to 70°C (1013 mbar).

[0102] 29. Process according to one of the preceding points, wherein the liquefaction point of the first composition and the second composition differ by at least 10°C (1013 mbar), preferably by at least 20°C (1013 mbar) and in particular by at least 30°C (1013 mbar).

[0103] 30. Method according to one of the preceding points, wherein the second composition comprises a meltable carrier having a melting point in the range of 40 to 80°C (1013 mbar), particularly preferably in the range of 45 to 75°C (1013 mbar) and in particular in the range of 50 to 70°C (1013 mbar) and contains a washing or cleaning active ingredient.

[0104] 31. A process according to any one of the preceding points, wherein the second composition contains, based on its total weight, a) 40 to 95% by weight of meltable carrier; b) 0.1 to 40% by weight of washing or cleaning active ingredient.

[0105] 32. Process according to one of the preceding points, wherein the second composition contains a meltable carrier from the group of polyethylene glycols, preferably from the group of polyethylene glycols with an average molecular weight (Mn) of >1500 g / mol, preferably an average molecular weight between 3,000 and 15,000, more preferably with an average molecular weight between 4,000 and 13,000, further preferably with an average molecular weight between 4,000 and 6,000, 6,000 and 8,000 or 9,000 and 12,000 and particularly preferably with an average molecular weight of 4,000 to 6,000 g / mol.

[0106] 33. Process according to one of the preceding points, wherein the second composition contains, based on its total weight, 1 to 40 wt.%, preferably 5 to 35 wt.% and in particular 10 to 30 wt.% of washing or cleaning active ingredient.

[0107] 34. Method according to one of the preceding points, wherein in step d2) a weight amount of 0.5 g to 12 g, preferably from 1 to 9 g, particularly preferably 2 to 7 g of the second composition is introduced.

[0108] 35. Method according to one of the preceding points, wherein the first composition and the second composition contain dye, preferably different dye.

[0109] 36. Method according to one of the preceding points, wherein the second composition solidifies at least partially, preferably completely, after step d2) and before step d3).

[0110] 37. A method according to any one of the preceding points, wherein the third composition is in the form of a powder.

[0111] 38. Process according to item 37, wherein the powder has a flowability of greater than 40%, preferably greater than 50%, in particular greater than 60%, based on the standard.

[0112] 39. Method according to one of the preceding points, wherein the receiving chamber following step d3) has a filling level of 60 to 120 vol.%, preferably of 80 to 110 vol.% and in particular of 90 to 100 vol.%.

[0113] 40. Process according to one of the preceding points, wherein in step e) a thermoplastic water-soluble film is fed.

[0114] 41. Process according to one of the preceding points, wherein the second water-soluble film supplied in step e) is selected from the group of films of optionally acetalized polyvinyl alcohols or copolymers thereof.

[0115] 42. The method according to any one of the preceding points, wherein the second water-soluble film supplied in step e) has a thickness of 80 pm or less, in particular of 65 pm or less, most preferably of 55 pm or less. 43. The method according to any one of the preceding points, wherein the ratio of the thickness of the first water-soluble film supplied in step a) to the thickness of the second water-soluble film supplied in step e) is 3:1 to 1:1, preferably 2.5:1 to 1.1:1, and in particular 2:1 to 1.2:1.

[0116] 44. Method according to one of the preceding points, wherein the second water-soluble film fed in step e) is thinner than the first water-soluble film fed in step a).

[0117] 45. Method according to one of the preceding points, wherein the sealing in step f) is carried out under the influence of solvent.

[0118] 46. ​​Method according to one of the preceding points, wherein the sealing in step f) is carried out under the influence of heat.

[0119] 47. A process according to any one of the preceding points, wherein the water-soluble film is shrunk by exposure to hot air following step f).

[0120] 48. The process according to item 47, wherein the hot air has a temperature of 120 to 290°C, preferably 140 to 260°C and in particular 175 to 230°C.

[0121] 49. A process according to any one of the preceding points, wherein the washing or cleaning agent portion unit is packed in bulk in a secondary packaging following step f).

[0122] 50. Process according to one of the preceding points, wherein the washing or cleaning agent portion unit is packed in bulk in a stand-up pouch following step f).

Claims

Patent claims 1. A method for producing a washing or cleaning agent portion unit, comprising the steps: a) providing a mold with at least one mold cavity; b) feeding a first water-soluble film to the mold cavity; c) molding the first water-soluble film into the mold cavity to form a receiving chamber; d) at least partially filling the receiving chamber by d1) introducing at least one first gel-forming agent-containing, liquid washing or cleaning-active composition to form a first washing or cleaning-active phase; d2) introducing at least one second, liquid washing or cleaning-active composition, different from the first composition, onto the top of the first washing or cleaning-active phase in the receiving chamber to form a second washing or cleaning-active phase completely covering the top of the first washing or cleaning-active phase;d3) introducing at least one third solid washing or cleaning-active composition, different from the first and second compositions, onto the top of the second washing or cleaning-active phase in the receiving chamber to form a third washing or cleaning-active phase completely covering the top of the second washing or cleaning-active phase; e) supplying a second water-soluble film; f) sealing the at least partially filled receiving chamber with the second water-soluble film to form a washing or cleaning agent portion unit comprising a water-soluble wrapping; 2. The method according to claim 1, wherein the receiving chamber formed in step c) has at least one, preferably two, three or four depressions in its bottom region.

3. Method according to one of the preceding claims, wherein the receiving chamber formed in step c) has two, preferably three or four depressions in its bottom region and the first composition is introduced into these depressions in step d1), wherein the first composition in one of the depressions differs from at least one first composition in a further depression.

4. A process according to any one of the preceding claims, wherein the first composition has a liquefaction point at temperatures above 80°C (1013 mbar), more preferably above 100°C (1013 mbar) and in particular above 115°C (1013 mbar).

5. A process according to any one of the preceding claims, wherein the first composition contains, based on its total weight, a) 4 to 40% by weight of gelling agent; b) 0.1 to 40% by weight of washing or cleaning active ingredient; c) 30 to 90% by weight of organic solvent.

6. A process according to any one of the preceding claims, wherein the second composition has a liquefaction point at temperatures in the range of 40 to 80°C (1013 mbar), more preferably in the range of 45 to 75°C (1013 mbar) and in particular in the range of 50 to 70°C (1013 mbar).

7. A process according to any one of the preceding claims, wherein the second composition contains, based on its total weight, a) 40 to 95% by weight of meltable carrier; b) 0.1 to 40% by weight of washing or cleaning active ingredient.

8. The method according to any one of the preceding claims, wherein the second composition solidifies at least partially, preferably completely, after step d2) and before step d3).

9. A method according to any one of the preceding claims, wherein the third composition is in the form of a powder.

10. A process according to any one of the preceding claims, wherein the water-soluble film is shrunk by exposure to hot air following step f).