A cast solid comprising a wetting surfactant, and a method for producing it

Abstract

Methods and compositions for forming stable cast solids are provided. Methods and compositions that incorporate a wetting agent to provide fast wetting and dispersing of granular raw materials in cast composition processing to ensure non-cracked solids post chilling are provided.

Description

PATENT APPLICATION Docket No. E12168WOU1- P14776WO00 TITLE: USE OF WETTING SURFACTANTS FOR CAST SOLID INTEGRITY CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority under 35 U.S.C. § 119 to provisional patent application U.S. Serial No. 63 / 664,785, filed June 27, 2024. The provisional patent application is herein incorporated by reference in its entirety. TECHNICAL FIELD

[0002] The disclosure relates generally to methods and compositions for forming stable cast solids. More particularly, but not exclusively, the present disclosure relates to methods of forming stable caustic cast solid compositions with the incorporation of a low foam wetting agent to provide fast wetting and dispersing of granular raw materials in the compositions during the cast processing to ensure non-cracked solids post chilling step of the production of the cast solid. BACKGROUND

[0003] Cast solids are commonly used in making solid block compositions, such as solid detergent compositions. For caustic cast solids, in many exemplary embodiments a substantial portion of sodium hydroxide (i.e. caustic) are cast and solidified. This process involves mixing the active components of the detergent with molten sodium hydroxide monohydrate (or molten caustic at higher temperatures) and thereafter cooling the composition to solidify. The resultant solid is a matrix of the solid sodium hydroxide with the additional ingredients that are either dissolved or suspended therein. Cast solids can incorporate an extensive number of actives into the composition. Casting can also be used for other solids in addition to caustic cast solids, such as other hydroxides, alkoxides, carbonates, PEG, and combinations of thereof.

[0004] The manufacturing of cast solids, such as caustic-based cast solids often incorporate a high level of functional granular raw materials that present processing challenges during its manufacture. If is common to see cast solids with poor post-cooling solid integrity and uniformity resulting in undesirable appearances and uniformity of the cast solids. Thus, there exists a need in the art for methods of improving cast solid integrity.PATENT APPLICATION Docket No. E12168WOU1- P14776WO00

[0005] It is therefore an object of this disclosure to provide methods of forming stable cast solid compositions that do not crack past chilling step in the cast solid manufacture.

[0006] It is another object of this disclosure to formulate stable cast solid compositions.

[0007] The fundamental reason is that molten sodium hydroxide monohydrate is a harsh environment (extremely high ionic strength) for the wetting, let alone dispersing or dissolution, of MGDA granules, resulting in post-chilling cracking and other integrity issue due to Rayleigh Bernard Convection effect. We have found low foam wetting surfactants that are not salted-out by the molten sodium hydroxide monohydrate matrix and provide fast wetting and even dispersing of the granular MGDA, allowing the MGDA to better achieve its true density, thus mitigating Rayleigh Bernard Convection.

[0008] Other objects, embodiments and advantages of this disclosure will be apparent to one skilled in the art in view of the following disclosure, the drawings, and the appended claims. SUMMARY

[0009] The following objects, features, advantages, aspects, and / or embodiments, are not exhaustive and do not limit the overall disclosure. No single embodiment need provide each and every object, feature, or advantage. Any of the objects, features, advantages, aspects, and / or embodiments disclosed herein can be integrated with one another, either in full or in part. It is a primary object, feature, and / or advantage of the present disclosure to improve on or overcome the deficiencies in the art with respect to manufacturing cast solids without solid integrity, namely post-chilling in the manufacturing process.

[0010] It is a further object, feature, and / or advantage of the present disclosure to provide stable solid cast compositions that do not crack post chilling and instead maintain solid integrity with the incorporation of a low foaming wetting agent in the compositions and methods of making the compositions.

[0011] According to some aspects of the present disclosure, cast solid compositions comprise: a concentrated caustic source; one or more granular raw materials, and a wetting agent comprising a short chain (C10 or less) linear or branched alkylpolyglucoside, anionic surfactant and / or amphoteric surfactant, wherein the composition is a cast solid and has an overall caustic to water weight ratio of 60 / 40 to 80 / 20 when a concentrated caustic source is present, and the wetting agent provides fast wetting and dispersing or dissolving of thePATENT APPLICATION Docket No. E12168WOU1- P14776WO00 granular raw materials during the cast processing, resulting in non-cracked post chilling solid integrity.

[0012] According to additional aspects of the present disclosure, methods of forming stable cast solid compositions comprise: combining a molten concentrated caustic source, preferably sodium hydroxide monohydrate, and a wetting agent to form a solution; and thereafter adding one or more granular raw materials to disperse or dissolve within the solution, wherein the composition is a cast solid and has an overall caustic to water ratio of about 60 / 40 to about 80 / 20 if the caustic source is present, and does not crack during post chilling of the cast solid.

[0013] According to additional aspects of the disclosure, methods of use comprising: generating a use solution of the cast solid composition as described herein; and contacting an article or surface in need of cleaning.

[0014] While multiple embodiments are disclosed, still other embodiments will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive. DETAILED DESCRIPTION

[0015] The present disclosure is not to be limited to that described herein, which can vary and are understood by skilled artisans. No features shown or described are essential to permit basic operation of the present disclosure unless otherwise indicated. It has been found that incorporating a wetting agent, such as a low foam wetting agent into cast solid compositions that employ one or more functional granular raw materials provides solid integrity of the cast composition post-chilling in the manufacturing process.

[0016] It is further to be understood that all terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting in any manner or scope. For example, as used in this specification and the appended claims, the singular forms “a,” “an” and “the” can include plural referents unless the content clearly indicates otherwise. Further, all units, prefixes, and symbols may be denoted in its SI accepted form.

[0017] Numeric ranges recited within the specification are inclusive of the numbers defining the range and include each integer within the defined range. Throughout this disclosure, various aspects of this disclosure are presented in a range format. It should be understoodPATENT APPLICATION Docket No. E12168WOU1- P14776WO00 that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the disclosure. Accordingly, the description of a range should be considered to have specifically disclosed all the possible sub- ranges, fractions, and individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed sub-ranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6, and decimals and fractions, for example, 1.2, 3.8, 1½, and 4¾. This applies regardless of the breadth of the range.

[0018] All publications, including all patents, patent applications and other patent and non- patent publications cited or mentioned herein are incorporated herein by reference for at least the purposes that they are cited; including for example, for the disclosure or descriptions of methods of materials which may be used. Nothing herein is to be construed as an admission that a publication or other reference (including any reference cited in the Background section) is prior art to the invention or that the invention is not entitled to antedate such disclosure, for example, by virtue of prior invention.

[0019] As used herein, the term “and / or”, e.g., “X and / or Y” shall be understood to mean either “X and Y” or “X or Y” and shall be taken to provide explicit support for both meanings or for either meaning, e.g. A and / or B includes the options i) A, ii) B or iii) A and B.

[0020] It is to be appreciated that certain features that are, for clarity, described herein in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any sub-combination.

[0021] The methods and compositions of the present disclosure may comprise, consist essentially of, or consist of the components and ingredients of the present disclosure as well as other ingredients described herein. As used herein, “consisting essentially of” means that the methods, systems, apparatuses and compositions may include additional steps, components or ingredients, but only if the additional steps, components or ingredients do not materially alter the basic and novel characteristics of the claimed methods, systems, apparatuses, and compositions.PATENT APPLICATION Docket No. E12168WOU1- P14776WO00

[0022] Unless defined otherwise, all technical and scientific terms used above have the same meaning as commonly understood by one of ordinary skill in the art to which embodiments of the present disclosure pertain.

[0023] The terms “invention” or “present invention” are not intended to refer to any single embodiment of the particular invention but encompass all possible embodiments as described in the specification and the claims.

[0024] The term “about,” as used herein, refers to variation in the numerical quantity that can occur, for example, through typical measuring techniques and equipment, with respect to any quantifiable variable, including, but not limited to, concentration, mass, volume, time, molecular weight, temperatures, melting enthalpy, density, pH, humidity, molar ratios, log counts, and the like. Further, given solid and liquid handling procedures used in the real world, there is certain inadvertent error and variation that is likely through differences in the manufacture, source, or purity of the ingredients used to make the compositions or carry out the methods and the like. The term “about” also encompasses these variations. Whether or not modified by the term “about,” the claims include equivalents to the quantities.

[0025] The term “actives” or “percent actives” or “percent by weight actives” or “actives concentration” are used interchangeably herein and refers to the concentration of those ingredients involved in cleaning expressed as a percentage minus inert ingredients such as water or salts. It is also sometimes indicated by a percentage in parentheses, for example, “chemical (10%).”

[0026] As used herein, the term “alkyl” or “alkyl groups” refers to saturated hydrocarbons having one or more carbon atoms, including straight-chain alkyl groups (e.g., methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, etc.), cyclic alkyl groups (or “cycloalkyl” or “alicyclic” or “carbocyclic” groups) (e.g., cyclopropyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, etc.), branched-chain alkyl groups (e.g., isopropyl, tert- butyl, sec-butyl, isobutyl, etc.), and alkyl-substituted alkyl groups (e.g., alkyl-substituted cycloalkyl groups and cycloalkyl-substituted alkyl groups).

[0027] Unless otherwise specified, the term “alkyl” includes both “unsubstituted alkyls” and “substituted alkyls.” As used herein, the term “substituted alkyls” refers to alkyl groups having substituents replacing one or more hydrogens on one or more carbons of the hydrocarbon backbone. Such substituents may include, for example, alkenyl, alkynyl, halogeno, hydroxyl, alkylcarbonyloxy, arylcarbonyloxy, alkoxycarbonyloxy, aryloxy,PATENT APPLICATION Docket No. E12168WOU1- P14776WO00 aryloxycarbonyloxy, carboxylate, alkylcarbonyl, arylcarbonyl, alkoxycarbonyl, aminocarbonyl, alkylaminocarbonyl, dialkylaminocarbonyl, alkylthiocarbonyl, alkoxyl, phosphate, phosphonato, phosphinato, cyano, amino (including alkyl amino, dialkylamino, arylamino, diarylamino, and alkylarylamino), acylamino (including alkylcarbonylamino, arylcarbonylamino, carbamoyl and ureido), imino, sulfhydryl, alkylthio, arylthio, thiocarboxylate, sulfates, alkylsulfinyl, sulfonates, sulfamoyl, sulfonamido, nitro, trifluoromethyl, cyano, azido, heterocyclic, alkylaryl, or aromatic (including heteroaromatic) groups.

[0028] As used herein, the term "analog" means a molecular derivative of a molecule. The term is synonymous with the terms "structural analog" or "chemical analog."

[0029] As used herein, the term “between” is inclusive of any endpoints noted relative to a described range.

[0030] The term “configured” describes structure capable of performing a task or adopting a particular configuration. The term “configured” can be used interchangeably with other similar phrases, such as constructed, arranged, adapted, manufactured, and the like.

[0031] Terms characterizing sequential order, a position, and / or an orientation are not limiting and are only referenced according to the views presented.

[0032] As used herein, the term “exemplary” refers to an example, an instance, or an illustration, and does not indicate a most preferred embodiment unless otherwise stated.

[0033] The term “generally” encompasses both “about” and “substantially.”

[0034] As used herein the term “ionic strength” refers to a measure of the concentration of charges in a solution.

[0035] As used herein the term “polymer” refers to a molecular complex comprised of a more than ten monomeric units and generally includes, but is not limited to, homopolymers, copolymers, such as for example, block, graft, random and alternating copolymers, terpolymers, and higher “x”mers, further including their analogs, derivatives, combinations, and blends thereof. Furthermore, unless otherwise specifically limited, the term “polymer” shall include all possible isomeric configurations of the molecule, including, but are not limited to isotactic, syndiotactic and random symmetries, and combinations thereof. Furthermore, unless otherwise specifically limited, the term “polymer” shall include all possible geometrical configurations of the molecule.PATENT APPLICATION Docket No. E12168WOU1- P14776WO00

[0036] The term “Rayleigh Bernard Convection effect” or “Rayleigh Bernard effect” as referred to herein is a convection effect with a buoyance-driven flow in a container with a temperature gradient. The effect is seen as the fluid at the bottom heats up, its density decreases, so buoyant forces push the less-dense fluid up toward the cooler end of the container.

[0037] The “scope” of the present disclosure is defined by the appended claims, along with the full scope of equivalents to which such claims are entitled. The scope of the disclosure is further qualified as including any possible modification to any of the aspects and / or embodiments disclosed herein which would result in other embodiments, combinations, subcombinations, or the like that would be obvious to those skilled in the art.

[0038] The term “substantially” refers to a great or significant extent. “Substantially” can thus refer to a plurality, majority, and / or a supermajority of said quantifiable variable, given proper context.

[0039] The term “surfactant” or “surface active agent” refers to an organic chemical that when added to a liquid changes the properties of that liquid at a surface.

[0040] The term “weight percent,” “wt-%,” “percent by weight,” “% by weight,” and variations thereof, as used herein, refer to the concentration of a substance as the weight of that substance divided by the total weight of the composition and multiplied by 100. It is understood that, as used here, “percent,” “%,” and the like are intended to be synonymous with “weight percent,” “wt-%,” etc. CAST SOLID COMPOSITIONS

[0041] According to embodiments, stable cast solid compositions and methods of making the stable cast solid compositions are provided. These compositions and methods utilize a wetting agent, such as a low foaming wetting surfactant, to aid wetting and dispersion of granular materials into the molten cast solution. As referred to herein dispersion is a mixture of particles of one compound evenly dispersed throughout a continuous phase of another component. The wetting agent can overcome the fundamental challenge in cast processing, namely harsh environments of the molten solution, such as a molten sodium hydroxide monohydrate (or molten caustic at higher temperatures) having extremely high ionic strength, to provide for the wetting and dispersing or dissolution of the granular materials into the molten sodium hydroxide monohydrate. The compositions and methods describe beneficiallyPATENT APPLICATION Docket No. E12168WOU1- P14776WO00 overcome any undesirable post-chilling cracking and other integrity issues in the cast solid composition.

[0042] Without being limited to a particular mechanism of action, the use of the wetting agent overcomes disparities in density between the granular materials and the molten solution of a cast solid forming composition due to Rayleigh Bernard Convection effect. Beneficially, use of a wetting agent, such as a low foaming wetting surfactant, ensures that the granulate materials are not salted-out by the molten solution, such as a sodium hydroxide monohydrate . Moreover, as a further benefit the wetting agent provides fast wetting and even dispersion or dissolution of the granular material to better achieve its true density, thus mitigating Rayleigh Bernard Convection and providing for a cast solid composition that is stable and does not crack in the 24 hours post chilling of the molten solution.

[0043] Caustic, Carbonate and / or PEG Molten Solutions

[0044] The compositions and methods are suitable for use in a variety of types of cast solids employing granular raw materials. Cast compositions can employ molten solutions of concentrated caustic source, preferably sodium hydroxide monohydrate (or molten caustic at higher temperatures), carbonate source and / or PEG source.

[0045] Examples of concentrated caustic sources include an alkali metal hydroxide monohydrate (e.g. sodium hydroxide monohydrate), combinations of an alkali metal hydroxide monohydrate and alkali metal hydroxide dihydrate, and / or an alkali metal alkoxide. As referred to herein, caustic is synonymous to hydroxide. Any suitable source of caustic may be used. In an embodiment, an alkali metal caustic source may be used. For example, caustic sources may be in the form of sodium hydroxide, potassium hydroxide, lithium hydroxide, derivatives thereof, or and combinations thereof. An example of a derivative of a caustic source is a preformed alkoxide or an alkoxide generated in-situ.

[0046] In embodiments employing a concentrated caustic source the cast solid has an overall caustic to water weight ratio of 60:40 to 80:20. In embodiments employing an alkoxide as the concentrated caustic source the cast solid can have an overall caustic to water weight ratio less than about 70:30.

[0047] In certain embodiments an alkoxide can be used to form or in the concentrated caustic. In certain embodiments, an alkali metal hydroxide is reacted with an organic molecule having one or more hydroxyl-groups or an alkylene carbonate to form an alkoxide, as disclosed in U.S. Patent Application No.18 / 606,681 titled “Alkoxide-Based SolidificationPATENT APPLICATION Docket No. E12168WOU1- P14776WO00 Via Control of Reaction Equilibrium and Kinetics”, which is incorporated by reference in its entirety. As disclosed therein in certain embodiments a higher active caustic liquid is preferred for the control of equilibrium reaction and kinetics for the generation of an alkoxide. In an embodiment, the molar ratio of caustic to reagent (e.g. polyol such as propylene glycol) is about 1:1 to about 10:1 molar ratio, about 1:1 to about 8:1 molar ratio, about 1:1 to about 6:1 molar ratio, and preferably about 1:1.

[0048] In certain embodiments a concentrated caustic can be used in the methods of making an alkoxide and / or methods of making the molten sodium hydroxide monohydrate solution. In an embodiment, 70% NaOH is preferred over a 50% NaOH to provide the 1:1 (or greater) molar ratio of caustic to reagent. In preferred embodiments, a concentrated alkali metal hydroxide comprises greater than 50% (actives basis) liquid alkali metal hydroxide. In some embodiments, the concentrated alkali metal hydroxide is from about 69% to about 74% (actives basis) liquid alkali metal hydroxide, preferably from about 70% to about 73% (actives basis) liquid alkali metal hydroxide.

[0049] Granular Raw Materials

[0050] Granular raw materials can vary across cast solid compositions. Cast solids with a higher concentration of the granular raw materials will benefit most from the use of the wetting agent and methods of making the cast solids described herein. In some embodiments, cast solid compositions comprise granular materials (including one or more different granular materials) in an amount of at least about 10 wt-%, 11 wt-%, 12 wt-%, 13 wt-%, 14 wt-%, 15 wt-%, 16 wt-%, 17 wt-%, 18 wt-%, 19 wt-%, 20 wt-%, 21 wt-%, 22 wt-%, 23 wt-%, 24 wt- %, 25 wt-%, or more in the cast solid.

[0051] A variety of granular materials can be employed in cast solid compositions. A commonly used granular raw material for cast solids is a chelant and / or threshold agent. In general, a chelating agent is a molecule capable of coordinating (i.e., binding) the metal ions commonly found in natural water to prevent the metal ions from interfering with the action of the other detersive ingredients of a cleaning composition. In an aspect, the chelant is an aminocarboxylic acid and / or salt, also referred to herein as an aminocarboxylate. Beneficially, aminocarboxylates may include aminocarboxylic acids and / or salts of the aminocarboxylic acids. These are commonly used chelants as they do not contain phosphorus and / or contain little to no nitrilotriacetic acid (NTA). Exemplary aminocarboxylates (or acids thereof) include, but are not limited to: methylglycinediacetic acid (MGDA), glutamic acid-PATENT APPLICATION Docket No. E12168WOU1- P14776WO00 N,N-diacetic acid (GLDA), N-hydroxyethylaminodiacetic acid, ethylenediaminetetraacetic acid (EDTA), hydroxyethylenediaminetetraacetic acid, diethylenetriaminepentaacetic acid, N-hydroxyethyl-ethylenediaminetriacetic acid (HEDTA), diethylenetriaminepentaacetic acid (DTPA), ethylenediaminesuccinic acid (EDDS), 2-hydroxyethyliminodiacetic acid (HEIDA), iminodisuccinic acid (IDS), 3-hydroxy-2-2′-iminodisuccinic acid (HIDS) and other similar acids or salts thereof having an amino group with a carboxylic acid substituent. Additional description of suitable aminocarboxylates suitable for use as chelating agents and / or sequestrants is set forth in Kirk-Othmer, Encyclopedia of Chemical Technology, Third Edition, volume 5, pages 339-366 and volume 23, pages 319-320, the disclosure of which is incorporated by reference herein.

[0052] Additional granular raw materials used in cast solids are enzymes. It may be desirable to include enzymes in granular format to survive the harsh conditions of the cast solid processing. Examples of suitable enzymes include, but are not limited to, hemicellulases, peroxidases, proteases, cellulases, xylanases, lipases, phospholipases, esterases, cutinases, pectinases, keratinases, reductases, oxidases, phenoloxidases, lipoxygenases, ligninases, pullulanases, tannases, pentosanases, malanases, β-glucanases, arabinosidases, hyaluronidase, chondroitinase, laccase, amylases, or combinations thereof and may be of any suitable origin. The choice of enzyme(s) takes into account factors such as pH-activity, stability optima, thermostability, stability versus active detergents, chelants, builders, etc.

[0053] Additional granular raw materials used in cast solids can include acids, such as for example carboxylic acids such as citric acid anhydrous, or sulfamic acid.

[0054] Wetting Agent

[0055] Cast compositions employ a wetting agent to wet and then disperse or dissolve the granular raw materials in the cast solid molten solution of the concentrated sodium hydroxide monohydrate, carbonate monohydrate and / or PEG. The wetting agent ensures that the methods described herein product a stable cast solid composition where the granulate material is sufficiently dispersed or dissolved and therefore does not present formulation and / or processing limitations, such as cracking post chilling causing a lack of solid integrity of the cast solid composition.

[0056] Wetting agents can comprise a short chain linear or branched surfactant including an alkylpolyglycoside (APG) surfactant including alkylpolyglucoside surfactants, anionic surfactant and / or amphoteric surfactant. The short chain length provides hydrophobicity toPATENT APPLICATION Docket No. E12168WOU1- P14776WO00 wet the granular materials. In certain embodiments a branched structure is preferred to decrease foaming as well as enhance the wetting of the granular materials. As referred to herein, short chain includes less than C10, from C2-C10, from C4-C10, from C6-C10, from C8-C10, from C2-C8, from C4-C8, from C6-C8, from C2-C6, from C4-C6, or any ranges therebetween.

[0057] Examples of commercially-available short chain APG include for example from BASF Glucopon 215 UP (C8-C10 APG) and Glucopon 225 DK (C8-C10 APG), from Dow Triton BG-10 (C8-C10 APG), Triton CG-50 (C8-C10 APG), Triton CG-110 (C8-C10 APG), from Akzonobel AG 6202 (C8 APG), AG 6206 (C6 APG), as well as other commercial sources. In preferred embodiments the APG is a C6-C10 APG, a C6-C8 APG, an ethylhexyl alkylpolyglucoside, C6 alkylpolyglucoside or a C8 alkylpolyglucoside.

[0058] Additional Components

[0059] Various other additional functional ingredients can be incorporated into the cast solid compositions and methods of making the same based on the particular application of use of the cast solid compositions. In some embodiments, the cast solid compositions including the concentrated caustic source, carbonate source and / or PEG source, the granular raw materials, and the wetting agent provide for a stable cast solid and make up a large amount, or even substantially all of the total weight of the cast solid compositions. For example, in some embodiments few or no additional functional ingredients are disposed therein.

[0060] In other embodiments additional components can be incorporated into the cast solid compositions and methods of making the same. For example, the cast solid compositions can include a water conditioning polymer (e.g. and / or chelant, a detersive surfactant, and / or a processing and / or solidification agent in addition to the concentrated caustic source, carbonate source and / or PEG source, the granular raw materials, and the wetting agent. The processing and / or solidification agents can comprise an alkali metal sulfate and / or polyol, such as sodium sulfate and / or glycerin.

[0061] In embodiments the cast solid compositions comprise between about 0 wt-% and about 20 wt-%, between about 0.1 wt-% and about 20 wt-%, or between about 1 wt-% and about 10 wt-% of the processing and / or solidification agents. In addition, without being limited according to the disclosure, all ranges recited are inclusive of the numbers defining the range and include each integer within the defined range.PATENT APPLICATION Docket No. E12168WOU1- P14776WO00

[0062] In other embodiments, additional functional ingredients may be included in the cast solid compositions. The functional ingredients provide desired properties and functionalities to the compositions. For the purpose of this application, the term “functional ingredient” includes a material that when dispersed or dissolved in the molten cast solution and thereafter are incorporated into the cast solid provide a beneficial property in a particular use. In some embodiments, the cast solid compositions may include optical brighteners, defoaming agents (defoaming nonionic surfactants), etch protectors (e.g. sodium aluminate), anti-redeposition agents, bleaching agents, solubility modifiers, dispersants, metal protecting agents, soil antiredeposition agents, stabilizing agents, corrosion inhibitors, builders / sequestrants / chelating agents, aesthetic enhancing agents including fragrances and / or dyes, additional rheology and / or solubility modifiers, hydrotropes or couplers, buffers, additional wetting agents, additional solidification and / or processing agents, additional cleaning agents and the like.

[0063] In embodiments the cast solid compositions comprise between about 0 wt-% and about 40 wt-%, between about 0.1 wt-% and about 40 wt-%, between about 0.1 wt-% and about 35 wt-%, or between about 0.1 wt-% and about 30 wt-% of the additional functional ingredients. In addition, without being limited according to the disclosure, all ranges recited are inclusive of the numbers defining the range and include each integer within the defined range.

[0064] Additional description of suitable additional functional ingredients are included for example in U.S. Application Publication No.2024 / 0309295, which is incorporated by reference herein.

[0065] These additional ingredients can be included in the molten cast solution before or after the addition of the granular raw materials.

[0066] In some embodiments the composition as well as the additional functional ingredients do not include urea for the cast solids.

[0067] Water Scavengers

[0068] Cast compositions can further employ a water scavenger comprising an alkali metal sulfate. In an embodiment the water scavenger comprises sodium sulfate or sodium bisulfate, and preferably anhydrous sodium sulfate or anhydrous sodium bisulfate. Sodium sulfate, anhydrous sodium sulfate, sodium bisulfate, and anhydrous sodium bisulfate are commercially available from various sources.PATENT APPLICATION Docket No. E12168WOU1- P14776WO00

[0069] In some embodiments the water scavenger provides a single salt and does not combine multiple sats, such as potassium and sodium salts, which in some formulations are used to prevent premature solidification of solids. In such embodiments, which are not encompassed in the compositions and methods of the present invention, combinations of salts such as potassium and sodium hydroxide salts and amino carboxylate salts are used for solidification. Instead the compositions and methods of the present invention provide a water scavenger, preferably as a single salt, in an amount up to about 10 wt-% in a concentrated caustic source, preferably sodium hydroxide monohydrate and / or PEG source as the molten solution and thereafter combining with a granular raw material during the cast processing to ensure non-cracked solids post chilling step of the production of the cast solid.

[0070] In embodiments the cast solid compositions comprise at least about 0.5 wt-%, or at least about 1 wt-% of the water scavenger, or at least about 2 wt-% of the water scavenger. In embodiments the cast solid compositions comprise between about 1 wt-% and about 10 wt- %, between about 2 wt-% and about 10 wt-%, or between about 2 wt-% and about 5 wt-% of the water scavenger. In addition, without being limited according to the disclosure, all ranges recited are inclusive of the numbers defining the range and include each integer within the defined range.

[0071] Water Conditioning Agents

[0072] Cast compositions can further employ a water conditioning agent. The term “water conditioning agent” refers to a compound that inhibits crystallization of water hardness ions from solution or disperses mineral scale including but not limited to calcium carbonate. Water conditioning agents can include polymeric and small molecule water conditioning agents. Organic small molecule water conditioning agents are typically organocarboxylate compounds or organophosphate water conditioning agents. Polymeric water conditioning agents commonly comprise polyanionic compositions such as polyacrylic acid compounds.

[0073] Additional examples of water conditioning polymers includes polyacrylic acid homopolymer or alkali metal salt thereof, i.e., sodium polyacrylate. The polyacrylic acid homopolymers can contains a polymerization unit derived from the monomer selected from the group consisting of acrylic acid, methacrylic acid, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, butyl acrylate, butyl methacrylate, iso-butyl acrylate, iso- butyl methacrylate, iso-octyl acrylate, iso-octyl methacrylate, cyclohexyl acrylate, cyclohexyl methacrylate, glycidyl acrylate, glycidyl methacrylate, hydroxyethyl acrylate, hydroxypropylPATENT APPLICATION Docket No. E12168WOU1- P14776WO00 acrylate, 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl acrylate, 2- hydroxypropyl methacrylate. and hydroxypropyl methacrylate and a mixture thereof, among which acrylic acid. methacrylic acid, methyl acrylate, methyl methacrylate, butyl acrylate, butyl methacrylate, iso-butyl acrylate, iso-butyl methacrylate, hydroxyethyl acrylate, 2- hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl acrylate, and 2- hydroxypropyl methacrylate, and a mixture thereof are preferred.

[0074] Preferred are polyacrylic acids, (C3H4O2)n or 2-Propenoic acid homopolymers;Acrylic acid polymer; Poly(acrylic acid); Propenoic acid polymer; PAA have the following structural formula:any integer. One source of commercially available polyacrylates (polyacrylic acid homopolymers) includes the Acusol® 445 series from The Dow Chemical Company, Wilmington Delaware, USA, including, for example, Acusol® 445 (acrylic acid polymer, 48% total solids) (4500 MW), Acusol® 445N (sodium acrylate homopolymer, 45% total solids)(4500MW), and Acusol® 445ND (powdered sodium acrylate homopolymer, 93% total solids)(4500MW) Other polyacrylates (polyacrylic acid homopolymers) commercially available from Dow Chemical Company include, but are not limited to Acusol 929 (10,000 MW) and Acumer® 1510. Yet another example of a commercially available polyacrylic acid is AQUATREAT® AR-6 (100,000 MW) from AkzoNobel Strawinskylaan 25551077 ZZ Amsterdam Postbus 757301070 AS Amsterdam. Other suitable polyacrylates (polyacrylic acid homopolymers) include, but are not limited to those obtained from additional suppliers such as Aldrich Chemicals, Milwaukee, Wis., and ACROS Organics and Fine Chemicals, Pittsburg, Pa, BASF Corporation and SNF Inc. The homopolymers, copolymers, and / or terpolymers may be present in a composition from about 0.01 wt-% to about 30 wt-%.

[0075] Maleic anhydride / olefin copolymers are copolymers of polymaleic anhydrides andolefins. Maleic anhydride (C2H2(CO)2O has the following structure:part of the maleic anhydride can be replaced by maleimide, N- alkyl(C1–4) maleimides, N-phenyl-maleimide, fumaric acid, itaconic acid, citraconic acid,PATENT APPLICATION Docket No. E12168WOU1- P14776WO00 aconitic acid, crotonic acid, cinnamic 10 acid, alkyl (C1–18) esters of the foregoing acids, cycloalkyl(C3–8) esters of the foregoing acids, sulfated castor oil, or the like. At least 95 wt% of the maleic anhydride polymers, copolymers, or terpolymers have a number average molecular weight of in the range between about 700 and about 20,000, preferably between about 1000 and about 100,000. A variety of linear and branched chain alpha-olefins can be used for the purposes of this disclosure. Particularly useful alpha-olefins are dienes containing 4 to 18 carbon atoms, such as butadiene, chloroprene, isoprene, and 2-methyl-1,5- hexadiene; 1-alkenes containing 4 to 8 carbon atoms, preferably C4–10, such as isobutylene, 1- butene, 1-hexene, 1-octene, and the like.

[0076] In a preferred embodiment, particularly suitable maleic anhydride / olefin copolymers have a molecular weight between about 1000 and about 50,000, in a preferred embodiment between about 5000 and about 20,000, and in a most preferred embodiment between about 7500 and about 12,500. Examples of maleic anhydride / olefin copolymers which may be used include, but are not limited to, Acusol 460N from The Dow Chemical Company, Wilmington Delaware, USA. The maleic anhydride / olefin copolymer may be present in a composition from about 0.01 wt-% to about 30 wt-%.

[0077] Additional polymers include polycarboxylic acid polymers, include, but are not limited to, polymaleic acid homopolymers, polyacrylic acid copolymers, and maleic anhydride / olefin copolymers. Polymaleic acid (C4H2O3)x or hydrolyzed polymaleic anhydride or cis-2-butenedioic acid homopolymer, has the structural formula:n and m are any integer. Examples of polymaleic acid homopolymers, copolymers, and / or terpolymers (and salts thereof) which may be used are particularly preferred are those with a molecular weight of about 0 and about 5000, more preferably between about 200 and about 2000 (can you confirm these MWs). Commercially available polymaleic acid homopolymers include the Belclene 200 series of maleic acid homopolymers from BWATMWater Additives, 979 Lakeside Parkway, Suite 925 Tucker, GA 30084, USA and Aquatreat AR-801 available from AkzoNobel. The polymaleic acid homopolymers, copolymers, and / or terpolymers may be present in a composition from about 0.01 wt-% to about 30 wt-%.PATENT APPLICATION Docket No. E12168WOU1- P14776WO00

[0078] Inorganic water conditioning agents include, but are not limited to, sodium tripolyphosphate and other higher linear and cyclic polyphosphates species. Suitable condensed phosphates include sodium and potassium orthophosphate, sodium and potassium pyrophosphate, sodium tripolyphosphate, and sodium hexametaphosphate. A condensed phosphate may also assist, to a limited extent, in solidification of the solid detergent composition by fixing the free water present in the composition as water of hydration. Examples of phosphonates included, but are not limited to: 1-hydroxyethane-1,1- diphosphonic acid, CH3C(OH)[PO(OH)2]2; aminotri(methylenephosphonic acid), N[CH2PO(OH)2]3; aminotri(methylenephosphonate), sodium salt (ATMP), N[CH2PO(ONa)2]3; 2-hydroxyethyliminobis(methylenephosphonic acid), HOCH2CH2N[CH2PO(OH)2]2; diethylenetriaminepenta(methylenephosphonic acid), (HO)2POCH2N[CH2CH2N[CH2PO(OH)2]2]2; diethylenetriaminepenta(methylenephosphonate), sodium salt (DTPMP), C9H28-xN3NaxO15P5(x=7); hexamethylenediamine(tetramethylenephosphonate), potassium salt, C10H28-xN2KxO12P4(x=6); bis(hexamethylene)triamine(pentamethylenephosphonic acid),and phosphorus acid, H3PO3. A preferred phosphonate combination is ATMP and DTPMP. A neutralized or alkaline phosphonate, or a combination of the phosphonate with an alkali source before being added into the mixture such that there is little or no heat or gas generated by a neutralization reaction when the phosphonate is added is preferred.

[0079] According to embodiments, the compositions include the following components to make the cast solid compositions: a concentrated caustic source, one or more granular raw materials, and a wetting agent comprising a short chain (C10 or less) linear or branched alkylpolyglucoside, anionic surfactant and / or amphoteric surfactant. In additional embodiments the cast solid compositions can include additional functional ingredients. Exemplary components used to make the cast solid compositions are shown in Table 1 and 2 in weight percentages. These component ranges to make the cast solid compositions result in the cast solids having the attributes as described herein, including a cast solid with an overall caustic to water weight ratio of 60:40 to 80:20, or a cast solid with an overall caustic to water weight ratio less than about 70:30.

[0080] While the components may have a percent actives of 100%, it is noted that Table 1 and Table 2 do not recite the percent actives of the components, but rather, recites the totalPATENT APPLICATION Docket No. E12168WOU1- P14776WO00 weight percentage of the raw materials (i.e. active concentration plus inert ingredients, such as water).

[0081] TABLE 1

[0082] TABLE 2METHODS OF MAKING STABLE CAST SOLIDS

[0083] Methods of making stable cast solid compositions include combining a molten sodium hydroxide monohydrate, carbonate monohydrate and / or PEG and a wetting agent to form a solution, and thereafter adding one or more granular raw materials to disperse withinPATENT APPLICATION Docket No. E12168WOU1- P14776WO00 the molten cast solution. Without being limited to a particular mechanism of action the granular material is added to the molten solution last to avoid premature solidification within a mix tank for the cast solids. The methods utilize the wetting agent, such as a low foaming wetting surfactant, to aid wetting and dispersion of the granular materials into the molten cast solution.

[0084] It has beneficially been found that the wetting agent when employed according to the methods described overcomes the key challenge in cast processing, namely the harsh environments of the molten solution, such as a sodium hydroxide monohydrate having extremely high ionic strength, to provide for the wetting and dispersing or dissolution of the granular materials into the molten cast solution. Without the inclusion of the wetting agent in the methods of making the cast solids various granular materials are unable to dissolve or disperse evenly throughout the molten solution, even with forced mixing. As a result of the methods described herein, the granular materials are wetted and thereafter dispersed or dissolved into the molten solution to overcome any undesirable post-chilling cracking and other integrity issues in the cast solid composition. The compositions made according to the methods do not crack during the post chilling step or thereafter as a stable cast solid.

[0085] In embodiments the cast solids further have a desirable dimensional stability. Dimensionally stability refers to a measurement of any change in dimension of a solid over a period of time under elevated temperature and humidity storage conditions as measured over an 8 week period to assess stability over longer period of time such as during transport and storage during which it is undesirable for a solid to swell or otherwise change dimensions over time. As referred to herein, a cast solid has a dimensional stability with less than about 3% change in any measured dimension when stored at a temperature of 50°C and 70% relative humidity for a period of one month.

[0086] The step of combining a wetting agent with the molten sodium hydroxide monohydrate, carbonate monohydrate and / or PEG to form a solution before adding the granular raw materials to disperse or dissolve therein beneficially overcomes disparities in density between the granular materials and the molten solution effectively preventing solid instability resulting from the Rayleigh Bernard Convection effect. This beneficially ensures that the granulate materials are dispersed or dissolved within the molten solution and do not salt-out from the molten solution, such as a caustic monohydrate matrix. In embodiments, this is the result of wetting a granular raw material having a lower density than the density of thePATENT APPLICATION Docket No. E12168WOU1- P14776WO00 molten solution to ensure dispersion or dissolution of the wetted granular raw material into the molten solution by increasing the density of the granular raw material closer to its true density (in non-granular form that more closely approximates the density of the molten solution).

[0087] In some embodiments the wetting agent provides fast wetting and even dispersion or dissolution of the granular material within the molten solution. In embodiments the dispersion or dissolution of the granular material within the molten solution is within about 10 minutes or less, or preferably within about 5 to about 10 minutes.

[0088] The step of adding the wetting agent to the molten sodium hydroxide monohydrate solution or other molten solution then involves mixing until a relatively homogeneous mixture is formed. This can take a matter of minutes, such as about 10 minutes. The temperature of this this solution is typically between about 90°F-120°F for PEG cast solids or between about 140°F-170°F for caustic cast solids (with higher peaks for these reaction temperatures possible). In embodiments where the cast solid composition employs acidic polymers in the composition, the only source of heating can be the exothermic reaction between the liquid caustic and acidic polymers. In other embodiments heat may be applied to the molten solution. In embodiments where the cast solid composition employs caustic beads (solids), the caustic beads can be added to the molten solution and an exothermic and thickening reaction take place.

[0089] The granular materials, such as the chelant, is added as the last step in the method of forming stable cast solid compositions. The granular material can be added over about 30 to about 60 minutes, while maintain a constant temperature, such as about 140°F-170°F for a molten sodium hydroxide monohydrate solution. The methods can further include adding additional functional ingredients into the composition. In an embodiment, the method further comprises adding to the solution one or more of water conditioning polymers, chelants, detersive surfactants, processing aids and / or solidification agents.

[0090] The methods of combining the materials within the molten solution are mixed within a vessel. The methods are often mixed using propeller blades or other mixing apparatus. Once the molten solution is mixed it is placed into a capsule having the desired shape and size of the cast solid.

[0091] The methods further include a chilling step to rapidly lower the temperature of the molten solution to solidify the composition after the molten solution is packed into capsules.PATENT APPLICATION Docket No. E12168WOU1- P14776WO00 The chiller step can include a chiller, such as a 0°F chiller for about 45 minutes to about an hour. Once the capsules are removed from the chiller they will have a molten core with solidified edges. The capsules are thereafter cooled further at a temperature between about 70°F-110°F and during the next 24 hours the capsules are evaluated visually for any cracking.

[0092] The cast solids exhibit solid integrity and do not crack in the post-chilling step, including for the 24 hours post chilling of the molten solution. In further embodiments the solids further exhibit dimensional stability. In embodiments the cast solids further have a desirable dimensional stability. Dimensionally stability refers to a measurement of any change in dimension of a solid over a period of time under elevated temperature and humidity storage conditions as measured over an 8 week period to assess stability over longer period of time such as during transport and storage during which it is undesirable for a solid to swell or otherwise change dimensions over time. As referred to herein, a cast solid has a dimensional stability with less than about 3% change in any measured dimension when stored at a temperature of 50°C and 70% relative humidity for a period of one month.

[0093] The cast solids prepared according to the methods described herein can be made into various shapes and sizes as one skilled in the art will ascertain from the disclosure here, which is practically limited by packaging and dispensing equipment. In an embodiment, a cast solid can have a per unit size of up to approximately 8 pounds, 9 pounds, 10 pounds, or larger.

[0094] The cast solids prepared according to the methods described herein can provide various benefits including decreasing carbon footprint through the significant reduction of packaging waste. Further the ability to make the cast solids into various multi-use packaging of the solid also eases operational compliance for providing safe to handle, spillproof packaging, as well as ease for users to change out dispensers with the cast solids. METHODS OF USE

[0095] The cast solids are suitable for use in various water conditions to provide warewashing efficacy and benefits of providing a first pass clean to provide spotless ware, glasses and other treated surfaces, as well as providing a scale free machine in which the cast solids are used. These benefits provide significant operational efficiency, including reduction in labor due to eliminating the need to hand polish and treated ware or surfaces, as well as eliminating deliming steps.PATENT APPLICATION Docket No. E12168WOU1- P14776WO00

[0096] However the solid cast compositions described herein can be used for methods of using various cleaning applications. These cleaning compositions can operate on an article, surface, or the like, by contacting it with a use solution of the cast solid composition described herein. Contacting can include any of numerous methods for applying a cleaning composition of the disclosure, such as spraying the compositions, immersing the article in compositions, circulating through a warewashing machine, or the like, or a combination thereof.

[0097] It should be understood that the concentration of the ingredients in the compositions will vary depending on whether the cleaning composition is provided as a concentrate or as a use solution. A use solution may be prepared from the concentrate by diluting the concentrate with water at a dilution ratio that provides a use solution having desired detersive properties.

[0098] Exemplary industries in which the present methods can be used include, but are not limited to: food service industry; food and beverage industry; the pharmaceutical manufacturing industry; laundry and textile care; and any other alkaline cleaning applications of use. Suitable uses for the compositions and methods may include, for example, bottle washing, machine warewashing, laundry and textile care, and the like.

[0099] The present methods can also be used to remove various types of soils. Such other soils include, but are not limited to, starch, cellulosic fiber, protein, simple carbohydrates and combinations of any of these soil types with mineral complexes.

[0100] In further embodiments, the methods of employing cleaning compositions are particularly suited for use in closed systems, e.g. dish or ware washing systems for cleaning, bottle washing systems and processes, sanitizing and / or disinfecting articles and surfaces.

[0101] The method includes contacting an article or surface with a cleaning composition or a cleaning use composition to wash the surface. The method can contact the liquid to any of a variety of surfaces or objects including surfaces or articles including those made of glass, ceramic, plastic, porcelain, aluminum, or the like.

[0102] The phrase “washing a surface with a wash solution (or a use solution or a cleaning composition)” refers to the circulation of a cleaning composition solution to remove substantially all soil from the treated surfaces (e.g. ware) and to keep that soil suspended or dissolved. In an embodiment, this step may be conducted where the temperature of the rinse water is up to about 140°F, preferably in the range of 100°F to 140°F, preferably in the range of 110°F to 140°F, and most preferably in the range of 120°F to 140°F. As referred to herein,PATENT APPLICATION Docket No. E12168WOU1- P14776WO00 “low temperature” refers to those rinse water temperatures below about 140°F. For example, conventional rinse temperature for ware washing occurs above 140°F., such as from about 140°F to about 190°F, particularly between about 145°F to about 180°F. In an aspect, the methods employing a low temperature further employ a sanitizer.

[0103] Contacting can include any of numerous methods for applying a cleaning composition, such as spraying the composition, immersing the object in the composition, or a combination thereof. A concentrate or use concentration of a composition can be applied to or brought into contact with an article by any conventional method or apparatus for applying a cleaning composition to an object. For example, the object can be wiped with, sprayed with, and / or immersed in the composition, or a use solution made from the composition. The composition can be sprayed, or wiped onto a surface; the composition can be caused to flow over the surface, or the surface can be dipped into the composition. Contacting can be manual or by machine.

[0104] Before contacting an article or surface, a concentrate cleaning composition may be first diluted with water at the location of use to provide the use solution. When the composition is used in an automatic warewashing or dishwashing machine, it is expected that that the location of use will be inside the automatic warewashing machine. Depending on the machine, the composition may be provided in a unit dose form or in a multi-use form. In larger warewashing machines, a large quantity of composition may be provided in a compartment that allows for the release of a single dose amount of the composition for each wash cycle. Such a compartment may be provided as part of the warewashing machine or as a separate structure connected to the warewashing machine.

[0105] The cleaning composition may also be dispensed from a spray-type dispenser, such as that disclosed in U.S. Pat. Nos.4,826,661, 4,690,305, 4,687,121, 4,426,362 and in U.S. Pat. Nos. Reissue 32,763 and 32,818, the disclosures of which are incorporated by reference herein. Briefly, a spray-type dispenser functions by impinging a water spray upon an exposed surface of the composition, and then immediately directing the use solution out of the dispenser to a storage reservoir or directly to a point of use. If necessary, in some embodiments, when used, the product may be removed from the packaging and inserted into the dispenser.

[0106] The methods may further employ one or more rinse steps for the treated articles or surfaces.PATENT APPLICATION Docket No. E12168WOU1- P14776WO00

[0107] In some embodiments, the cleaning compositions include killing one or more of the pathogenic bacteria associated with health care surfaces and environments including, but not limited to, Salmonella typhimurium, Staphylococcus aureus, methicillin resistant Staphylococcus aureus, Salmonella choleraesurus, Pseudomonas aeruginosa, Escherichia coli, mycobacteria, yeast, and mold. The cleaning compositions have activity against a wide variety of microorganisms such as Gram positive (for example, Listeria monocytogenes or Staphylococcus aureus) and Gram negative (for example, Escherichia coli or Pseudomonas aeruginosa) bacteria, yeast, molds, bacterial spores, viruses, etc. The compositions as described above, have activity against a wide variety of human pathogens. The cleaning compositions can kill a wide variety of microorganisms on a food processing surface, on the surface of a food product, in water used for washing or processing of food product, on a health care surface, or in a health care environment.

[0108] The present methods can be used to achieve any suitable reduction of the microbial population in and / or on the target or the treated target composition. In some embodiments, the present methods can be used to reduce the microbial population in and / or on the target or the treated target composition by at least one log10. In other embodiments, the present methods can be used to reduce the microbial population in and / or on the target or the treated target composition by at least two log10. In still other embodiments, the present methods can be used to reduce the microbial population in and / or on the target or the treated target composition by at least three log10. In still other embodiments, the present methods can be used to reduce the microbial population in and / or on the target or the treated target composition by at least five log10. Without limiting the scope of disclosure, the numeric ranges are inclusive of the numbers defining the range and include each integer within the defined range.

[0109] The cleaning compositions can be used for a variety of domestic or industrial applications, e.g., to reduce microbial or viral populations on a surface or object or in a body or stream of water. The cleaning compositions can be applied in a variety of areas including kitchens, bathrooms, factories, hospitals, dental offices and food plants, and can be applied to a variety of hard or soft surfaces having smooth, irregular or porous topography. Suitable hard surfaces include, for example, architectural surfaces (e.g., floors, walls, windows, sinks, tables, counters and signs); eating utensils; hard-surface medical or surgical instruments and devices; and hard-surface packaging. Such hard surfaces can be made from a variety ofPATENT APPLICATION Docket No. E12168WOU1- P14776WO00 materials including, for example, ceramic, metal, glass, wood or hard plastic. Suitable soft surfaces include, for example paper; filter media; hospital and surgical linens and garments; soft-surface medical or surgical instruments and devices; and soft-surface packaging. Such soft surfaces can be made from a variety of materials including, for example, paper, fiber, woven or nonwoven fabric, soft plastics and elastomers. The cleaning compositions can also be applied to soft surfaces such as food and skin (e.g., a hand). The present compounds can be employed as a non-foaming environmental sanitizer or disinfectant.

[0110] The cleaning compositions can be applied to microbes or to soiled or cleaned surfaces using a variety of methods. These methods can operate on an object, surface, in a body or stream of water or a gas, or the like, by contacting the object, surface, body, or stream with a compound of the disclosure. Contacting can include any of numerous methods for applying a compound, such as spraying the compound, immersing the object in the compound, foam or gel treating the object with the compound, or a combination thereof. EMBODIMENTS

[0111] The present disclosure is further defined by the following numbered embodiments:

[0112] 1. A cast solid composition comprising: a) a concentrated caustic source, preferably sodium hydroxide monohydrate, carbonate source and / or PEG source; b) one or more granular raw materials, and c) a wetting agent comprising a short chain (C10 or less) linear or branched alkylpolyglucoside, anionic surfactant and / or amphoteric surfactant, wherein the composition is a cast solid and has an overall caustic to water weight ratio of 60 / 40 to 80 / 20 when a concentrated caustic source is present, and the wetting agent provides fast wetting and dispersing or dissolving of the granular raw materials during the cast processing, resulting in non-cracked post chilling solid integrity.

[0113] 2. The composition of paragraph 1, wherein the wetting agent is a low foam wetting surfactant.

[0114] 3. The composition of any one of paragraphs 1-2, wherein the wetting agent is a C6 alkylpolyglucoside or an C8 ethylhexyl alkylpolyglucoside.

[0115] 4. The composition of any one of paragraphs 1-3, wherein the composition comprises at least about 2 wt-% of the wetting agent.PATENT APPLICATION Docket No. E12168WOU1- P14776WO00

[0116] 5. The composition of any one of paragraphs 1-54 wherein the granular raw material comprises at least about 15 wt-% of the cast solid and / or the granular raw material is an aminocarboxylate.

[0117] 6. The composition of paragraph 5, wherein the aminocarboxylate comprises methyl glycine diacetic acid (MGDA).

[0118] 7. The composition of any one of paragraphs 1-6, further comprising a water conditioning polymer and / or chelant, a detersive surfactant, and / or a processing and / or solidification agent.

[0119] 8. The composition of paragraph 7, wherein the processing and / or solidification agent comprises an alkali metal sulfate or bisulfate and / or polyol, preferably glycerin.

[0120] 9. The composition of any one of paragraphs 1-8, wherein the composition is free of urea.

[0121] 10. The composition of any one of paragraphs 1-9, wherein the concentrated caustic source is an alkali metal hydroxide monohydrate and / or an alkali metal alkoxide.

[0122] 11. The composition of any one of paragraphs 1-10, wherein the composition is formed by combining from about 30 wt-% to about 80 wt-% of the concentrated caustic source, from about 10 wt-% to about 30 wt-% of the granular raw materials, from about 0.5 wt-% to about 10 wt-% of the wetting agent, and optionally further comprising from about 0.5 wt-% to about 10 wt-% of the water scavenger.

[0123] 12. A method of forming stable cast solid compositions comprising: combining a molten concentrated caustic source, preferably sodium hydroxide monohydrate, a carbonate source, preferably carbonate monohydrate, and / or PEG source and a wetting agent to form a solution, wherein the wetting agent comprises a short chain (C10 or less) linear or branched alkylpolyglucoside, anionic surfactant and / or amphoteric surfactant; and thereafter adding one or more granular raw materials to disperse or dissolve within the solution, wherein the composition is a cast solid and has an overall caustic to water ratio of about 60 / 40 to about 80 / 20 if the caustic source is present, and does not crack during post chilling of the cast solid.

[0124] 13. The method of paragraph 12, wherein the method further comprises adding to the solution one or more of water conditioning polymers, chelants, detersive surfactants, processing aids and / or solidification agents.PATENT APPLICATION Docket No. E12168WOU1- P14776WO00

[0125] 14. The method of any one of paragraphs 12-13, wherein the cast solid has a solid integrity as measured by lack of cracking in the solid for at least 24 hours post chilling of the cast solid.

[0126] 15. The method of any one of paragraphs 12-14, wherein the one or more granular raw materials is the last material added in the method of forming the stable cast solid compositions.

[0127] 16. The method of any one of paragraphs 12-15, wherein the one or more granular raw materials are added to the molten solution and mixed for at least about 30 minutes.

[0128] 17. The method of any one of paragraphs 12-16, wherein the wetting agent is a low foam wetting surfactant, preferably a C6 alkylpolyglucoside or a C8 ethylhexyl alkylpolyglucoside.

[0129] 18. The method of any one of paragraphs 12-17, wherein the composition comprises at least about 2 wt-% of the wetting agent.

[0130] 19. The method of any one of paragraphs 12-18, wherein the granular raw material comprises at least about 15 wt-% of the cast solid.

[0131] 20. The method of any one of paragraphs 12-19, wherein the granular raw material is an aminocarboxylate.

[0132] 21. A method of use comprising: generating a use solution of the cast solid composition according to any one of paragraphs 1- 11; and contacting an article or surface in need of cleaning. EXAMPLES

[0133] Embodiments of the present disclosure are further defined in the following non- limiting Examples. It should be understood that these Examples, while indicating certain embodiments of the disclosure, are given by way of illustration only. From the above discussion and these Examples, one skilled in the art can ascertain the essential characteristics of this disclosure, and without departing from the spirit and scope thereof, can make various changes and modifications of the embodiments of the disclosure to adapt it to various usages and conditions. Thus, various modifications of the embodiments of the disclosure, in addition to those shown and described herein, will be apparent to those skilled in the art from the foregoing description. Such modifications are also intended to fall within the scope of the appended claims.PATENT APPLICATION Docket No. E12168WOU1- P14776WO00

[0134] The following materials were utilized in the Examples:

[0135] NaOH (liquid): sodium hydroxide.

[0136] Caustic beads: solid sodium hydroxide beads.

[0137] Trilon M / MGDA: trisodium salt of methyl glycine diacetic acid.

[0138] GLDA: Tetrasodium N,N-biscarboxylatomethyl-L-glutamate.

[0139] Pluronic N-3: nonionic wetting surfactant, ethylene oxide / propylene block copolymers.

[0140] APG: general class of nonionic surfactants referred to as alkylpolyglucosides.

[0141] Triton BG: C8-C10 APG.

[0142] AG 6206: C6 alkylpolyglycoside available from Nouryon.

[0143] AG 6202: C8 Ethyl Hexyl branched APG.

[0144] Glucopon 215: C8-10 APG.

[0145] Texapon EHS: Sodium Ethyl Hexyl Sulfate 40%.

[0146] Barlox 8S: C8 Amine Oxide, 40%.

[0147] Acusol 448: acrylic acid polymers.

[0148] Acusol 445N: polyacrylic acid polymers.

[0149] Bayhibit AM: 50 % aq. solution of 2-Phosphonobutane-1,2,4-tricarboxylic acid (PBTC). EXAMPLE 1

[0150] Cracking of cast solid blocks was observed across various product lines, including use of caustic based cast products. Most cracking was observed within 24 hours of the processing. Cracking was observed to relate to physical chemical properties of various components in the solid blocks and was most prevalent in solids that included a high level of granular raw materials with lower density that its liquid component having a higher density. These cast solids faced unique challenges during processing that resulted in poor post-cooling solid integrity and uniformity.

[0151] Physical chemical properties of raw materials that may be incorporated into caustic cast solid composition were compared as reported in literature, including melting enthalpy (latent heat of fusion), melting temperature, and density. These are summarized in Table 3.

[0152] TABLE 3PATENT APPLICATION Docket No. E12168WOU1- P14776WO00

[0153] In addition to the characteristics reported in Table 3, the latent heat of fusion values for a granular raw material to be determined by DSC measurement is shown in Table 4. The formulation of materials in Table 3 and Table 4 with similar densities will have minimal Rayleigh Bernard Convention effect leading to cracking of the cast solids. However as densities differ more significantly the Rayleigh Bernard Convention effect leading toPATENT APPLICATION Docket No. E12168WOU1- P14776WO00 cracking of the cast solids will be significant and will need the benefit of wetting agents as described herein.

[0154] TABLE 3

[0155] The materials summarized with its physical characteristics in Tables 3-4 are common components in caustic-based (non-alkoxide) cast solid products having a caustic / water ratio of at least about 69% caustic. This results in a solidification matrix that is a caustic monohydrate with a high density (1.83 g / cc). Processing of these cast solid products, namely during the cooling process from the molten stage, can result in migration of raw materials upward as a result of disparity between density of the ingredient and the caustic monohydrate (i.e. buoyancy effect explained by Rayleigh Bernerd Convection).

[0156] Most raw materials that are aqueous based, such as 40% MGDA, do not present a challenge as the MGDA has its true density of 1.4-1.5 g / cc. However, in cast solids where such a raw material is provided in a granulate form, such as 18% MGDA that requires the use of MGDA granules have a lower density (0.7 g / cc) as shown in Table 2. Other granulated or agglomerated functional ingredients have similar decreased densities due to the granulation or agglomeration processes introducing voids with trapped air, resulting in lower density, resulting in the Rayleigh Bernard Convention effect leading to cracking of the cast solids.

[0157] In processing these materials in a molten sodium hydroxide monohydrate which is a harsh environment due to its high ionic strength, the granulate material is not sufficiently dispersed or dissolved and present a significant formulation and processing challenge that results in cast solids with insufficient cast integrity, and often exhibits cracking of the solid during the chilling stage. EXAMPLE 2PATENT APPLICATION Docket No. E12168WOU1- P14776WO00

[0158] For use in caustic cast solid compositions containing components summarized in Example 1, wetting agents were evaluated to mitigate the 24 hours cracking issue seem in processing the cast solid. Wetting agents capable of use in the molten sodium hydroxide monohydrate phase of the processing were evaluated to wet and disperse the 18% granular MGDA into the cast solid composition. Initially a polyol – glycerin was evaluated. However this did not overcome the 24-hour post chilling cracking.

[0159] Next, low foaming wetting agents were evaluated as the caustic cast solid composition is used in machine warewashing where significant foaming is not desirable. This presented a challenge, as most low foaming surfactants are hydrophobic in nature, and they readily “salted out” under molten sodium hydroxide monohydrate conditions during the processing of the cast solid. This was initially observed with the wetting agent Pluronic N-3. During manufacturing process, Pluronic N-3 was completely “salted out” by the molten sodium hydroxide monohydrate matrix into oily droplets and failed to provide any wetting to MGDA granules.

[0160] Thereafter additional wetting agents with shorter chain (< C10) and / or branched structure surfactants were evaluated, such as APG, anionics, and amphoterics. The APGs were evaluated as these nonionics would not be expected to “salt out” by molten sodium hydroxide monohydrate as a result of the structures large hydrophilic heads. In addition the use of shorter chain and / or branched structures were evaluated in order to maintain lower foaming. Examples included ethylhexyl APG, C8 APG, and C6 APG. These materials were then evaluated using a wetting quantification test method.

[0161] To choose a wetting surfactant to be used in solution, two candidates were initially screened and their solubility in 50% NaOH was observed. These candidates were Triton BG and AG 6206, both alkylpolyglucosides (APGs). After an overnight mix, the Triton BG showed some undissolved clumps, while the AG 6206 was homogeneously dispersed in the solution. For this reason, AG 6206 was chosen for further testing as summarized in Table 5. The raw material in grams was the same between the Control and APG formula with the exception of the inclusion of the AG 6206.

[0162] TABLE 5PATENT APPLICATION Docket No. E12168WOU1- P14776WO00

[0163] Thirty seconds after the MGDA addition, with light agitation, a visual inspection showed a difference in MGDA dispersion in solution pursuant to a visual inspection, which showed the Control formula that did not contain any APG failed to disperse the MGDA into solution at all, whereas the formula containing the APG did. The MGDA could be seen dispersing in the solution quicker in the APG formula, indicating enhanced wetting. EXAMPLE 3

[0164] Additional surfactants were also tested for their MGDA wetting capabilities in 50% NaOH. The beakers were lightly agitated for about 1 minute after the MGDA was added. The time for the granulate material to be dispersed or dissolved is a key factor. These had the same formula as APG (Table 3) with substituted wetting surfactants for the AG 6206 surfactant as follows with the following surfactants: Barlox 8S – C8 Amine Oxide 40%; Glucopon 215 – C8-10 APG; Texapon EHS – Sodium Ethyl Hexyl Sulfate 40%; and AG 6202 – C8 Ethyl Hexyl branched APG.

[0165] The results of the wetting experiment were assessed pursuant to a visual inspection showing that the Barlox 8S provided the fastest wetting of the MGDA of the surfactants tested, wherein the wetting refers to the material dispersing into the solution. The Glucopon 215 was inconclusive since the surfactant led to significant viscosity increases which led to unquantifiable wetting. The Texapon EHS was eliminated due to insolubility in the solution. The AG 6202 provided the same wetting performance as AG 6206, quickly dispersing the MGDA. The Control did not include any APG and the material was unable to disperse into the solution. EXAMPLE 4PATENT APPLICATION Docket No. E12168WOU1- P14776WO00

[0166] Based on the wetting data in prior Examples, four surfactants were tested to assess foaming, as the particular finished product that was analyzed in Example 1 as mentioned is a caustic-based warewash detergent cast solid where low foaming is desired. The procedure tested used a Glewwe machine and included a 3-minute agitation of 3000 mL solution of approximately 25 ppm wetting surfactant and 12.5 ppm defoaming surfactant in water. The defoaming surfactant included was Pluronic N3. Three data sets were taken for each surfactant at 80°F and 140°F with no milk powder, and then at 140°F with 20g of milk powder added. The measured foam heights are shown in Tables 6-8.

[0167] TABLE 6 - 80°F test – Foam height in inches

[0168] TABLE 7 - 140°F test – Foam height in inches

[0169] AG 6206, AG 6202, and Barlox 8S effectively defoamed almost all foam by the time the solution reached 100°F. The Glucopon 215 effectively defoamed almost all foam by the time the solution reached 125°F. The Glucopon 215 was eliminated from testing due to high foam levels up to 125°F.

[0170] TABLE 8 - 140°F test + 20 g milk powder – Foam height in inches

[0171] AG 6206, AG 6202, and Barlox 8S all were sufficiently defoamed by Pluronic N3 and were chosen to be tested in cast solid batches.PATENT APPLICATION Docket No. E12168WOU1- P14776WO00 EXAMPLE 5

[0172] Nearly identical 1000 g lab scale batches were made for a caustic-based warewashing detergent cast solid formula, which only varied in wetting surfactant amount, and were tested under cast processing conditions. The formulations are shown in Table 9 with the difference being the 1 wt-% included for the AG 6206 and remaining components adjusted for the 1% and otherwise the same between the formulations.

[0173] TABLE 9

[0174] The AG0 (Control with no APG wetting surfactant) thickened into paste before bead addition. Thereafter even with manual mixing in of some caustic beads the composition was thin and then thickened over time to an appropriate viscosity. Some bubbling was seen at the end of the mix on the surface indicating an aerated composition. Thereafter a void opened up on cooling. Even though the cast solid was a homogeneous cast solid the cracking post chilling is an undesirable processing outcome.

[0175] The AG1 was mixed in and there was some gooping on the walls. The composition turned deep amber color. The viscosity build was good. No bubbling was seen on the surface. No void opened up, although some faint lines were seen throughout. Overall the processing outcome was an acceptable complete cast solid.

[0176] A visual comparison of these results was made, where the AG0 and AG1 were both observed after cooling to room temperature. The Control AG0 developed a void, which has been indicative of capsules that crack when scaled up. AG0 also showed some bubbles on thePATENT APPLICATION Docket No. E12168WOU1- P14776WO00 surface, implying convection cooling and inhomogeneity. AG1 did not have a void and showed more complete mixing. EXAMPLE 6

[0177] Based on the positive lab scale results in Example 5, a 5-gallon batch scale up was completed to further compare the two formulas in Table 9. Both the control (AG0) and the APG batch (AG1) processed similarly, with slightly low viscosity (~900 cP) and density within specifications between 1.5 and 1.6 g / cm3. The AG1 batch turned a deeper amber color due to the dark surfactant, which is acceptable for the solid. Upon cooling, the AG0 showed small cracks and cooled bubbles on the surface, while the AG1 batch appeared more homogeneous.

[0178] Based on this scale up data, benefits are clearly seen by using a wetting surfactant in the cast solid processing to increase MGDA granule wetting. EXAMPLE 7

[0179] Additional laboratory testing was conducted to evaluate alternate wetting surfactants as summarized in Table 10 with the compositions being the same with the exception of the AG 6202 or the Barlox 8S inclusion.

[0180] TABLE 10PATENT APPLICATION Docket No. E12168WOU1- P14776WO00

[0181] The AG 6202 achieved good mixing. There were no hex patterns seen upon cooling. There was some gel phase that was overcome by increasing agitation slightly. Overall, there were good results that were similar to AG 6206.

[0182] The Barlox 8S did not go into solution well. MGDA did not incorporate well either. Barlox 8S seemed to not disperse but stayed around the mixer. Viscosity very low leading to excessive dripping on pouring.

[0183] Since the Barlox 8S showed poor processing in the tested formula it does not provide the desired activity of a wetting surfactant for cast processing to provide solid integrity. However, the AG 6202 showed very positive performance and is an acceptable alternative for AG 6206. EXAMPLE 8

[0184] Further formulation evaluations were conducted to analyze additional conditions of the cast solid processing utilizing the wetting surfactant. The factors that were tested were the Acusol 448 amount added before the gel phase, the Acusol 445N amount added before the gel phase, the AG 6206 amount added, the sodium sulfate amount added, the free water amount added, and the tank. The response variables were the gel phase ranking, the average agitation rate to incorporate the MGDA, the final viscosity, the final bulk density, and the 24 hour cracking ranking.

[0185] The base formula is shown in Table 11, and then the factors slightly adjust the composition of each formula.

[0186] TABLE 11Docket No. E12168WOU1- P14776WO00Trilon M Granule (MGDA) 18-20 Total 100

[0187] The results are summarized in Table 12. For the gel phase ranking, 1 is the best and 7 is the worst, but anywhere from 1-5 is acceptable. For the cracking ranking, 1 is the best and means no cracked capsules and 7 is the worst. [ [ ow Run 1 adjusted t arious runs, but the i [ BPATENT APPLICATION Docket No. E12168WOU1- P14776WO00 Acusol 445N 1-3 Caustic Bead 12-15 Acusol 448 1-3 A l 445N 12Trilon M Granule (MGDA) 18-20 Soft Water 0 Total 100

[0191] The results overall demonstrated that 2% AG-6205 (C8 Ethyl Hexyl branched APG) resulted in best cast solid integrity with no cracking. More cracking was exhibited when less than 2 wt-% of the wetting agent was used.

[0192] There were no differences seen in agitation rate needed to incorporate MGDA into the 5-gallon scale ups tests, nor was there any significant impact of the wetting surfactant on viscosity or density. The benefit was seen in lack of cracking results in the cast solids. EXAMPLE 9

[0193] Testing of the cast solid composition in Table 14 was used in commercial restaurants in back of house warewashing to evaluate efficacy in comparison to a commercial control with higher alkalinity without the granular materials and the wetting agent incorporated according to the methods and compositions as described herein.

[0194] TABLE 14 Description Control Test wt% Composition wt% NaOH 50% Liquid 17-20 17-20 Caustic Bead 52-56 42-46 GLDA 0 1-3 MGDA 0 18-20 Sodium Gluconate 7-10 0 Bayhibit AM 0 1-3 Acusol 448 / 445N 7-10 7-10 Phosphinic Acid 4-6 0 Pluronic N3 0.5-2 1-3 Etch protectant 4-6 0PATENT APPLICATION Docket No. E12168WOU1- P14776WO00 1-2 2-5 <1 0 100 d to the Test Composition into cast blocks resulted the Control Formulation exhibited more compared to the Test Composition. sitions used over 6 months at varying waterconditions resulted in majority of accounts preferring the Test Composition over the Control, predominantly as a result of the reduction of rewashing or hand polishing of glasses and ware required when the Test Composition was used. There were also observed benefits of enhanced soil removal including from challenging soils (e.g. cheese, eggs, butter). Similarly, the Test Compositions resulted in visible improvements in cleaning of coffee cups, glassware, machines and a decrease in delime frequency. Visual images of the observed differences were also recorded.

[0197] It is to be understood that while the invention has been described in conjunction with the detailed description thereof, the foregoing description is intended to illustrate, and not limit the scope of the invention, which is defined by the scope of the appended claims. Other embodiments, advantages, and modifications are within the scope of the following claims. Any reference to accompanying drawings which form a part hereof, are shown, by way of s may be utilized and structural of the present disclosure. on, or the following claims, or the ms or in terms of a means for ss for attaining the disclosed result, as uch features, be utilized for realizing

[0195] Processing of the Control compared to the Test Composition into cast blocks resulted in clear distinction of cast solids, wherein the Control Formulation exhibited more pronounced voids and cracking in the solid compared to the Test Composition.

[0196] lire performance of the two compositions used over 6 months at varying water conditions resulted in majority of accounts preferring the Test Composition over the Control, predominantly as a result of the reduction of rewashing or hand polishing of glasses and ware required when the Test Composition was used. There were also observed benefits of enhanced soil removal including from challenging soils (e.g. cheese, eggs, butter). Similarly, the Test Compositions resulted in visible improvements in cleaning of coffee cups, glassware, machines and a decrease in delime frequency. Visual images of the observed differences were also recorded.

[0197] It is to be understood that while the invention has been described in conjunction with the detailed description thereof, the foregoing description is intended to illustrate, and not limit the scope of the invention, which is defined by the scope of the appended claims. Other embodiments, advantages, and modifications are within the scope of the following claims. Any reference to accompanying drawings which form a part hereof, are shown, by way of illustration only. It is understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present disclosure.

[0198] The features disclosed m the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately, or in any combination of such features, be utilized for realizing the invention in diverse forms thereof.

Claims

PATENT APPLICATION Docket No. E12168WOU1- P14776WO00 CLAIMS What is claimed is:

1. A cast solid composition comprising: a) a concentrated caustic source; b) one or more granular raw materials, and c) a wetting agent comprising a short chain (C10 or less) linear or branched alkylpolyglucoside surfactant, wherein the composition is a cast solid and has an overall caustic to water weight ratio of 60 / 40 to 80 / 20, and the wetting agent provides fast wetting and dispersing or dissolving of the granular raw materials during the cast processing, resulting in non- cracked post chilling solid integrity.

2. The composition of claim 1, wherein the wetting agent is a low foam wetting surfactant.

3. The composition of any one of claims 1-2, wherein the wetting agent is a C6 alkylpolyglucoside or an C8 ethylhexyl alkylpolyglucoside.

4. The composition of any one of claims 1-3, wherein the composition comprises at least about 2 wt-% of the wetting agent.

5. The composition of any one of claims 1-54 wherein the granular raw material comprises at least about 15 wt-% of the cast solid and / or the granular raw material is an aminocarboxylate.

6. The composition of claim 5, wherein the aminocarboxylate comprises methyl glycine diacetic acid (MGDA).

7. The composition of any one of claims 1-6, further comprising a water conditioning polymer and / or chelant, a detersive surfactant, and / or a processing and / or solidification agent.PATENT APPLICATION Docket No. E12168WOU1- P14776WO00 8. The composition of claim 7, wherein the processing and / or solidification agent comprises an alkali metal sulfate or bisulfate and / or polyol, preferably glycerin.

9. The composition of any one of claims 1-8, wherein the composition is free of urea.

10. The composition of any one of claims 1-9, wherein the concentrated caustic source is an alkali metal hydroxide monohydrate and / or an alkali metal alkoxide.

11. The composition of any one of claims 1-10, wherein the composition is formed by combining from about 30 wt-% to about 80 wt-% of the concentrated caustic source, from about 10 wt-% to about 30 wt-% of the granular raw materials, from about 0.5 wt-% to about 10 wt-% of the wetting agent, and optionally further comprising from about 0.5 wt- % to about 10 wt-% of the water scavenger.

12. A method of forming stable cast solid compositions comprising: combining a molten concentrated caustic source and a wetting agent to form a solution, wherein the wetting agent comprises a short chain (C10 or less) linear or branched alkylpolyglucoside; and thereafter adding one or more granular raw materials to disperse or dissolve within the solution, wherein the composition is a cast solid and has an overall caustic to water ratio of about 60 / 40 to about 80 / 20, and does not crack during post chilling of the cast solid.

13. The method of claim 12, wherein the method further comprises adding to the solution one or more of water conditioning polymers, chelants, detersive surfactants, processing aids and / or solidification agents.

14. The method of any one of claims 12-13, wherein the cast solid has a solid integrity as measured by lack of cracking in the solid for at least 24 hours post chilling of the cast solid.PATENT APPLICATION Docket No. E12168WOU1- P14776WO00 15. The method of any one of claims 12-14, wherein the one or more granular raw materials is the last material added in the method of forming the stable cast solid compositions.

16. The method of any one of claims 12-15, wherein the one or more granular raw materials are added to the molten solution and mixed for at least about 30 minutes.

17. The method of any one of claims 12-16, wherein the wetting agent is a low foam wetting surfactant, preferably a C6 alkylpolyglucoside or a C8 ethylhexyl alkylpolyglucoside.

18. The method of any one of claims 12-17, wherein the composition comprises at least about 2 wt-% of the wetting agent.

19. The method of any one of claims 12-18, wherein the granular raw material comprises at least about 15 wt-% of the cast solid.

20. The method of any one of claims 12-19, wherein the granular raw material is an aminocarboxylate.

21. A method of use comprising: generating a use solution of the cast solid composition according to any one of claims 1-11; and contacting an article or surface in need of cleaning.

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