Superfatted low TFM soap composition

Abstract

The present invention provides a solid soap composition comprising 45 to 70 wt% total fatty matter; 0.5 to 6 wt% electrolyte; 0.1 to 5 wt% polymeric polyol; 15 to 35 wt% water; 0.1 to 5 wt% of acrylate-based linear chain homopolymer or linear chain copolymer; and 1 to 5 wt% free fatty acid.

Description

[0001] P0000240WQ CPL

[0002] 1

[0003] SUPERFATTED LOW TFM SOAP COMPOSITION

[0004] Field of the invention

[0005] The present invention is in the field of superfatted soap bars, especially superfatted 5 solid soap compositions having low TFM in the form of a bar.

[0006] Background of the invention

[0007] Superfatted soaps are true soap bars that contain extra oil. The extra oil within these bars has not been saponified.

[0008] In the formulation of soap-based toilet bar compositions it has been desirable to include free fatty acids in the composition. Such compositions are referred to as “superfatted” soaps. The free fatty acid contributes substantially to the lathering performance of the composition, and also provides a mildness benefit in that it produces a lower pH 15 product than is obtained with fully neutralized soap, and it has an emollient effect on the skin. Thus, superfatting improves the soap's moisturizing abilities and makes it less irritating to the skin.

[0009] Soaps employing superfatting agents of many kinds are known in the art and are 20 commercially available. Such superfatting agents can include lanolin, higher fatty alcohols, mineral oils, and higher fatty acids. The use of free fatty acids as a superfatting agent is also known in the art. The presence of free fatty acids (such as lauric, palmitic, stearic, oleic, and others) in the soap product improves the volume and quality of lather, causing it to be more stable with smaller air bubbles to give a lather characterized as richer and creamier, and is also alleged to tend to soften skin. Thus, the incorporation of free fatty acids into a soap bar is desirable in that it helps eliminate free alkali, lowers the pH and may make the soap milder. It is also indicated to improve the lathering characteristics of the bar.

[0010] 30 Soap in bar form has long been in use for cleansing purposes. Those skilled in the art use the term soap to designate the reaction product of a carboxylic acid with a base, typically a metal hydroxide or carbonate. The resulting salt has both a polar hydrophilic end and a non-polar lipophilic end which facilitates the removal of oils and other nonpolar materials from the skin or other surface in the presence of water.P0000240WQ CPL

[0011] 2

[0012] Regular soap can have a tendency to defat the skin owing to its slightly alkaline character. This can be a problem, particularly to people with dry skin. The incorporation of a superfatting agent containing a free fatty acid into a soap bar imparts 5 enhanced tactile properties to the composition by eliminating the effect of free alkali on the user's skin. The presence of free fatty acid also affects the bubble size of the lather formed by the soap bar, thus imparting a perception of a richer, creamier lather.

[0013] Incorporating higher moisture in soap bar is desirable to reduce the TFM. Bringing higher moisture in a conventional soap bar leads to softening of the bar and brings huge processing challenges. The challenges get enhanced in extrudable process bars. There have been attempts to incorporate higher moisture through water structuring approach, but still the gap remains for superfatted bars. Incorporation of higher moisture in superfatted bars even in the presence of conventional structuring systems 15 could not sustain the bar hardness, and hence these bars are non-extrudable.

[0014] Therefore, there is a need for low TFM supperfatted soap compositions which can be used to obtain extrudable soap bars.

[0015] 20 Summary of the invention

[0016] In a first aspect the present invention provides a solid soap composition comprising 45 to 70 wt% total fatty matter; 0.5 to 6 wt% electrolyte; 0.1 to 5 wt% polymeric polyol; 15 to 35wt% water; 0.1 to 5 wt% of acrylate- based linear chain homopolymer or linear chain copolymer; and 1 to 5 wt% free fatty acid.

[0017] A second aspect of the present invention provides a process for preparing a soap composition of the first aspect, comprising the steps of:

[0018] i) saponifying a fatty saponifiable matter with an alkali to produce a saponified mass, while monitoring the extent of saponification, wherein 0.1 to 6 wt% of an 30 electrolyte is added during the saponification process;

[0019] ii) adding polymeric polyol, acrylate-based linear chain homopolymer or linear chain copolymer;

[0020] iii) extruding said saponified mass into solid soap composition according to the first aspect;P0000240WQ CPL

[0021] 3

[0022] wherein water is added at either of the steps (i) or (ii).

[0023] As used herein the term “comprising” encompasses the terms “consisting essentially of” and “consisting of”. Where the term “comprising” is used, the listed steps or options 5 need not be exhaustive. Unless otherwise specified, numerical ranges expressed in the format “from x to y” are understood to include x and y. In specifying any range of values or amounts, any particular upper value or amount can be associated with any particular lower value or amount. Except in the examples and comparative experiments, or where otherwise explicitly indicated, all numbers are to be understood as modified by the word “about”. All percentages and ratios contained herein are calculated by weight unless otherwise indicated. As used herein, the indefinite article “a” or “an” and its corresponding definite article “the” means at least one, or one or more, unless specified otherwise. The various features of the present invention referred to in individual sections above apply, as appropriate, to other sections mutatis 15 mutandis. Consequently, features specified in one section may be combined with features specified in other sections as appropriate. Any section headings are added only for convenience and are not intended to limit the disclosure in any way. The invention is not limited to the embodiments illustrated in the drawings. Accordingly, it should be understood that where features mentioned in the claims are followed by 20 reference numerals, such numerals are included solely for the purpose of enhancing the intelligibility of the claims and are in no way limiting to the scope of the claims.

[0024] Various components of the composition are described in greater detail below.

[0025] Detailed description of the invention

[0026] The solid soap composition of the present invention comprises 45 to 70 wt% total fatty matter; 0.5 to 6 wt% electrolyte; 0.1 to 5 wt% polymeric polyol; 15 to 35 wt% water; 0.1 to 5 wt% of acrylate-based linear chain homopolymer or linear chain copolymer; and 1 to 5 wt% free fatty acid.

[0027] 30

[0028] The expression total fatty matter is used very widely in the field of soaps and detergents. The term - abbreviated to “TFM” - is used to denote the wt% of fatty acid and triglyceride residues present in the soap composition without taking into account the accompanying cations. For a soap having 18 carbon atoms, an accompanyingP0000240WQ CPL

[0029] 4

[0030] sodium cation will generally amount to about 8 wt%. Other cations may be employed as desired, for example zinc, potassium, magnesium, alkyl ammonium and aluminium.

[0031] It is preferred that the composition of the invention comprises 45 to 70 wt% TFM, more 5 preferably 40 to 65 wt% TFM and most preferably 38 to 60 wt% TFM by weight of the soap composition.

[0032] The term soap means salts of fatty acids in which the accompanying cation may be an alkali metal, alkaline earth metal or ammonium ion, preferably an alkali metal. Preferably, the cation is sodium or potassium. The soap may be saturated or unsaturated, depending on the nature of the corresponding fatty acid and / or oil used for saponification.

[0033] It is preferred that the fat blend comprises 10 to 20 parts by weight lauric fatty acid, 35 15 to 50 parts by weight saturated non-lauric fatty acids and 20 to 45 parts by weight unsaturated non-lauric fatty acids, where the sum total of all fatty acids is 100 parts by weight.

[0034] Lauric fatty acid comprises C12, i.e. lauric acid, and may contain minor amounts (of up 20 to 5 wt%) of shorter or longer- chain fatty acids, e.g., C10 to C14. Preferably the lauric fatty acid is derived from coconut or palm kernel oil.

[0035] Saturated non-lauric fatty acids means those fatty acids that are of carbon chain length higher than C14 and which are saturated. It is preferred that saturated non-lauric fatty acids comprise at least one of palmitic, myristic, or stearic acid. Such fatty acids may comprise up to 2 to 3 wt% of other longer or shorter chain fatty acids, e.g. C20.

[0036] Unsaturated non-lauric fatty acids means those fatty acids that are unsaturated and of carbon chain length higher than C12. It is preferred that unsaturated non-lauric fatty 30 acids comprise one or more of oleic, linoleic, palmitoleic, or linolenic acid. Such fatty acids may comprise up to 2 to 3 wt% of other longer or shorter chain fatty acids, e.g. C20 or C8. It is preferred that unsaturated non-lauric fatty acids are procured from at least one of tallow, lard, soya bean, sunflower, rice bran, linseed, olive, rapeseed,P0000240WQ CPL

[0037] 5

[0038] ground nut, or fish oil. A variety of other alternative sources such as bioengineered oils may be employed.

[0039] Commercially available blends which may be used, with appropriate modifications or 5 additional oils / fats, include 80 / 20, 85 / 15 blends, where the lager number represents parts by weight of non-lauric fatty acids the smaller number represents the parts by weight of the lauric fatty acid.

[0040] The composition of the present invention is preferably used as or used to prepare a shaped solid, for example a bar. The cleaning soap composition is preferably used as or used to prepare a wash off product that generally has sufficient amount of surfactants included therein that it is used for cleansing the desired topical surface (e.g. the whole body, the hair and scalp or the face). It is applied on the topical surface and left thereon only for a few seconds or minutes and washed off thereafter with copious 15 amounts of water.

[0041] The soap composition may additionally comprise synthetic surfactants selected from one or more of anionic, non-ionic, cationic or zwitterionic surfactants, preferably from anionic surfactants. These synthetic surfactants, as per the present invention, are 20 included in less than 8wt%, preferably less than 4wt%, more preferably less than 1 wt% and sometimes absent from the composition. By “absent” it is meant that there is no deliberately added synthetic surfactant in the soap composition of the present invention.

[0042] The soap composition of the invention is capable of stably retaining high levels of water in the range of 15 to 35 wt.% as compared to a conventional soap composition. Thus, water is preferably present in an amount of at least 15 wt.%, further preferably at least 18 wt.%, still more preferably at least 20 wt.% furthermore preferably at least 23 wt.%, but on the other hand the amount of water in the soap composition is preferably not 30 more than 45 wt.%, still preferably not more than 40 wt.%, most preferably not more than 38 wt.%. In highly preferred aspects, the amount of water in the soap composition ranges from 15 to 45%, more preferably 18 to 40% by weight of the composition.P0000240WQ CPL

[0043] 6

[0044] By incorporating polymeric polyols and acrylate- based polymers in appropriate amounts, the present inventors have found that it is possible to structure greater than 20% water in a soap bar matrix without losing bar hardness. This can be achieved both with and without the presence of a high amount of super fat (>2%). The bars 5 according to the present invention were also found to be slippery and did not show cracking.

[0045] Free fatty acids are often desired in a soap composition to get certain consumer desired characteristics such as slipperiness, less sogginess and mush, creamy lather, better perfume delivery, and overall for a premium feel. However, incorporation of free fatty acids comes with the limitation of reduced moisture content of the soap bar, as the moisture has to be reduced to get the desired soap bar hardness. When the present inventors attempted to incorporate high amount of water such as 20 wt% in a conventional superfatted soap bar, the resultant composition was not ploddible and 15 therefore couldn’t be structured into a soap bar. When the superfatted soap bars were structured with water as high as 20wt% in a composition according to the present invention, it was surprisingly observed that a soap bar with good hardness of 3 KgF, having 3.8 wt% free fatty acid content could be structured even with water content of 22 wt%.

[0046] 20

[0047] It is preferred that in the composition of the invention the acrylate-based linear chain homopolymer or linear chain copolymer is not hydrophobically modified.

[0048] It is preferred that in the composition of the invention the composition comprises 0.1 to 5 wt% salt of an acid having a pKa in the range of 2 to 6.

[0049] It is preferred that in the composition of the invention the polymeric polyol has a molecular weight in the range of 85 to 8000 g / mol.

[0050] 30 It is preferred that in the composition of the invention the polymeric polyol is selected from the group of polyethylene glycol and polypropylene glycol.

[0051] It is preferred that in the composition of the invention the electrolyte is selected from sodium chloride, sodium sulphate, sodium citrate, or a mixture thereof.P0000240WQ CPL

[0052] 7

[0053] It is preferred that in the composition of the invention the electrolyte comprises sodium chloride or sodium sulphate, or a mixture thereof in an amount of 0.5 to 1.5 wt% of total weight of the composition.

[0054] 5

[0055] It is preferred that in the composition of the invention the iodine value of the composition is 30-45 g / lodine per 100 g of saponified fatty matter.

[0056] It is preferred that in the composition of the invention the composition has a pH in the range from 9 to 13 when measured in a 4% solution with distilled water at 25°C.

[0057] Total fatty matter

[0058] The term total fatty matter is used very widely in the field of soaps and detergents. The term Total Fatty Matter, abbreviated to “TFM”, is used to denote the percentage by 15 weight of fatty acid and triglyceride residues present in the personal wash composition without taking into account the accompanying cations. For a soap having 18 carbon atoms, an accompanying sodium cation will generally amount to about 8 percent by weight. Other cations may be employed as desired, for example zinc, potassium, magnesium, alkyl ammonium and aluminium.

[0059] 20

[0060] When the soap composition of the present invention is for personal washing applications it comprises TFM in an amount of 45 to 70 wt%, preferably 47 to 70 wt%, more preferably 50 to 68 wt%, and most preferably 52 to 65 wt% by weight of the soap composition.

[0061] The term soap means salt of fatty acid. Preferably, the soap is a soap of Cs to C24 fatty acids.

[0062] The cation may be an alkali metal, alkaline earth metal or ammonium ion, preferably 30 alkali metals. Preferably, the cation is selected from sodium or potassium, more preferably sodium. The soap may be saturated or unsaturated. Saturated soaps are preferred over unsaturated soaps for stability. The oil or fatty acids may be of vegetable or animal origin.P0000240WQ CPL

[0063] 8

[0064] The soap may be obtained by saponification of oils, fats or fatty acids. The fats or oils generally used to make soap compositions may be selected from tallow, tallow stearins, palm oil, palm stearins, soya bean oil, fish oil, castor oil, rice bran oil, sunflower oil, coconut oil, babassu oil, and palm kernel oil. The fatty acids may be from 5 coconut, rice bran, groundnut, tallow, palm, palm kernel, cotton seed, or soyabean.

[0065] The fatty acid soaps may also be synthetically prepared (e.g. by the oxidation of petroleum or by the hydrogenation of carbon monoxide by the Fischer-Tropsch process). Resin acids, such as those present in tall oil, may also be used. Naphthenic acids may also be used.

[0066] The soap compositions of the present invention preferably include low molecular weight soaps (Cs to C14 soaps) which are generally water soluble, and may be included in an amount of 2 to 20% by weight of the composition. It is preferred that the soap 15 composition includes 15 to 55 wt% of the soap of a C16 to C24 fatty acid, which are generally water insoluble soaps. Unsaturated fatty acid soaps, preferably at 15 to 42 wt%, may also be included in the total soap content of the composition. Unsaturated soaps are preferably oleic acid soaps.

[0067] 20 Water

[0068] The soap compositions of the present invention can hold high amount of moisture or water content. The soap compositions of the present invention comprise 15 to 35 wt% of water, preferably 20 to 30 wt%, more preferably 22 to 28 wt% and most preferably 25 to 40 wt% of water by weight of the soap composition.

[0069]

[0070] The composition comprises a polymeric polyol or mixture of polymeric polyols. Polymeric polyol is a term used herein to designate a polymer of a compound having multiple hydroxyl groups (at least two, preferably at least three) which is highly water 30 soluble. Many types of polymeric polyols are available including: modified carbohydrates such as hydrolyzed starch, dextrin and maltodextrin, and polymeric synthetic polymeric polyols such as polyalkylene glycols, for example polyoxyethylene glycol (PEG) and polyoxypropylene glycol (PPG). Especially preferred polymeric polyols are glycerol, sorbitol and their mixtures.P0000240WQ CPL

[0071] 9

[0072] The amount of polymeric polyol in the composition ranges from 0.1 to 5 wt%, more preferably from 0.1 to 4.8 wt%, further preferably from 2% to 4.5 wt%, and most preferably from 2.2 to 4.0 wt% based on the weight of the soap composition.

[0073] 5

[0074] Preferred cleansing bars comprise 0.1% to 5wt% polymeric polyols based on the weight of the composition. Preferred polymeric polyols include one or more of glycerol, sorbitol, propylene glycol, or polyethylene glycol. Typically a mixture is used. More preferred bars comprise polymeric polyol in an amount of 0.1 to 4.8 wt%, further preferably in an amount of 2% to 4.5 wt%, and most preferably in an amount of 2.2 to 4.0 wt% based on the weight of the soap composition. Polyhydric alcohols (polymeric polyols), such as propylene glycol, may serve as diluents to thin out the otherwise thick mixture of caustic soda and fatty acids.

[0075] 15 Other polyols, such as glycerol, perform as a humectant and moisturizer. A mixture of polymeric polyols is usually used. When included, polyethylene glycol used in the invention preferably has a molecular weight of from 200 to 1500 Da.

[0076] When the polymeric polyol comprises propylene glycol, it is present in an amount of 20 from 0.1% to 5 wt%, more preferably in an amount of from 0.1 to 4.8 wt%, further preferably in an amount of 2% to 4.5 wt%, and most preferably in an amount of from 2.2 to 4.0 wt% based on the weight of the soap composition.

[0077] When the polymeric polyol comprises polyethylene glycol, it is present in an amount of from 0.1% to 5 wt%, more preferably in an amount of from 0.1 to 4.8 wt%, further preferably in an amount of from 2% to 4.5 wt%, and most preferably in an amount of from 2.2 to 4.0 wt% based on the weight of the soap composition.

[0078] Salt of an acid having a pKa in the range of 2 to 6

[0079] 30 The soap composition of the present invention preferably comprises a salt of an acid having a pKa in the range of 2 to 6, preferably in an amount of 0.1 to 5wt%, more preferably in an amount of 0.5 to 4.8 wt% and most preferably in an amount of 1 to 4.5 wt% by weight of the soap composition, wherein the salt of the acid having a pKa in the range of 2 to 6 is different from the electrolyte.P0000240WQ CPL

[0080] 10

[0081] It is preferred that the acid having a pKa in the range of 2 to 6 is selected from the group comprising organic acid, polyacrylic acid, and dicarboxylic acid.

[0082] 5 It is preferred that when the acid is an organic acid, it is selected from the group comprising (but not limited to) citric acid, acetic acid, lactic acid, oxalic acid, tartaric acid, ascorbic acid, maleic acid, and maleic anhydrate.

[0083] It is preferred that when the acid is a dicarboxylic acid, it is selected from the group comprising and not limited to adipic acids.

[0084] Acrylate-based polymer

[0085] For the compositions of the present invention, polymers of the acrylate class are especially preferred. The soap composition of the present invention comprises 15 acrylate-based linear chain homopolymer or linear chain copolymer. It is preferred that the polymer is not hydrophobically modified. It is preferred that the polymer is not branched or crosslinked.

[0086] Commercially available polymer of these classes which may be used include 20 Sokalan® PA, Sokalan® CP polymers from BASF or Acusol 445G- polymer from Dow.

[0087] The polymer is included in an amount of from 0.1 to 5 wt%, preferably from 0.8 to 4 wt% by weight of the soap composition.

[0088] Free fatty Acids

[0089] Free fatty acids are desired in a soap bar as they give consumer desirable benefits, such as higher fragrance retention, better foam, less soggy and mushiness, and slipperiness. By free fatty acids is meant a carboxylic acid comprising a hydrocarbon chain and a terminal carboxyl group bonded to an H.

[0090] 30 The composition of the present invention has free fatty acids in an amount of 1 to 5wt%, more preferably in an amount of 1.2 to 4.8 wt%, and most preferably in an amount of 1.5 to 4.5 wt% by weight of the soap composition. It is preferred that the composition of the present invention have at least 1 wt% of free fatty acids, as this is required for the achieving the desired sensorial attributes of the invention. The freeP0000240WQ CPL

[0091] 11

[0092] fatty acids for the purpose of the invention can be produced either in-situ or may be added.

[0093] Typically, PKO-based (C8-C14) are added in sigma mixer while PO-based (C16-18) 5 are added in soap making or formed in-situ by acids.

[0094] Suitable fatty acids are C8 to C22 fatty acids. Preferred fatty acids are C12 to C18, and are preferably predominantly saturated, straight-chain fatty acids. However, some unsaturated fatty acids can also be employed. Preferably lauric acid, hysteric acids, stearic acids such as 10 or 12 HSA may be added as free fatty acids.

[0095] The soap composition generally comprises electrolyte. Electrolytes as per this invention include compounds that substantially dissociate into ions in water.

[0096] 15 Electrolytes as per this invention are not an ionic surfactant. Suitable electrolytes for inclusion in the soap making process are alkali metal salts. Preferred alkali metal salts include sodium sulfate, sodium chloride, sodium acetate, sodium citrate, potassium chloride, potassium sulfate, sodium carbonate, and other mono or di or tri salts of alkaline earth metals. More preferred electrolytes are sodium chloride, sodium sulfate, 20 sodium citrate, potassium chloride, and an especially preferred electrolyte is sodium chloride, sodium sulphate, sodium citrate, or a combination thereof. For the avoidance of doubt, it is clarified that the electrolyte is a non-soap material. Electrolyte is preferably included at an amount of 0.5 to 6%, more preferably 0.8 to 6%, even more preferably 1 to 5%, furthermore preferably 1.2 to 4.8%, and most preferably 1.5 to 4.5% by weight of the composition. It is preferred that the electrolyte is included in the soap composition during the step of saponification to form the soap.

[0097] Inclusion of small amount of an electrolyte (other than soap) can influence the liquid and solid phase ratio. Increasing the electrolyte content lowers the solubility of soap 30 thereby increasing the solid phase amount; on the other hand lowering the electrolyte levels make the bars softer.

[0098] It is most preferred that sodium sulphate and sodium chloride are used as electrolytes for the composition of the present invention.P0000240WQ CPL

[0099] 12

[0100] It is preferred that when sodium sulphate is present it is in an amount of 0.5 to 6%, more preferably 0.8 to 6%, even more preferably 1 to 5%, furthermore preferably 1.2 to 4.8%, and most preferably 1.5 to 4.5% by weight of the composition. It is preferred that 5 sodium sulphate is present in an amount of at least 0.5 wt%, more preferably at least 0.7 wt%, and most preferably at least 1 wt%; and it is preferred that sodium sulphate is present in an amount of not more than 6 wt%, more preferably not more than 5.8 wt%, furthermore preferably not more than 5.5 wt% and most preferably not more than 5 wt% of the total weight of composition of the present invention.

[0101] It is preferred that when sodium chloride is present it is present in an amount of 0.5 to 6%, more preferably 0.8 to 6%, even more preferably 1 to 5%, furthermore preferably 1.2 to 4.8%, and most preferably 1.5 to 4.5% by weight of the composition. It is preferred that sodium chloride is present in an amount of at least 0.5 wt%, more 15 preferably at least 0.7 wt%, and most preferably at least 1 wt% ; and it is preferred that sodium chloride is present in an amount of not more than 6 wt%, more preferably not more than 5.8 wt%, furthermore preferably not more than 5.5 wt% and most preferably not more than 5 wt% of the total weight of composition of the present invention.

[0102] 20 Non-soap surfactant

[0103] In addition to the soap of fatty acids, preferred bars may include a non-soap surfactant, which acts as a co-surfactant and which is selected from anionic, non-ionic, zwitterionic, amphoteric and cationic surfactants. Preferred bars include 0.0001 to 15 wt% co-surfactants based on the weight of the composition. More preferred bars include 2 to 10 wt% co-surfactant and most preferred compositions include 2.5 to 6 wt% co-surfactant based on the weight of the composition.

[0104] Suitable anionic surfactants include water soluble salts of organic sulphuric reaction products having in their molecular structure an alkyl radical containing from 8 to 22 30 carbon atoms, and a radical chosen from sulphonic acid or sulphuric acid ester radicals, and mixtures thereof.

[0105] Examples of suitable anionic surfactants are sodium and potassium alcohol sulphates, especially those obtained by sulphating the higher alcohols produced by reducing theP0000240WQ CPL

[0106] 13

[0107] glycerides of tallow or coconut oil; sodium and potassium alkyl benzene sulphonates such as those in which the alkyl group contains from 9 to 15 carbon atoms; sodium alkyl glyceryl ether sulphates, especially those ethers of the higher alcohols derived from tallow and coconut oil; sodium coconut oil fatty acid monoglyceride sulphates; 5 sodium and potassium salts of sulphuric acid esters of the reaction product of one mole of a higher fatty alcohol and from 1 to 6 moles of ethylene oxide; sodium and potassium salts of alkyl phenol ethylene oxide ether sulphate with from 1 to 8 units of ethylene oxide molecule and in which the alkyl radicals contain from 4 to 14 carbon atoms; the reaction product of fatty acids esterified with isethionic acid and neutralized with sodium hydroxide where, for example, the fatty acids are derived from coconut oil and mixtures thereof. The preferred water-soluble synthetic anionic surfactants are the alkali metal (such as sodium and potassium) and alkaline earth metal (such as calcium and magnesium) salts of higher alkyl benzene sulphonates, and mixtures with olefin sulphonates and higher alkyl sulphates, and the higher fatty acid monoglyceride 15 sulphates.

[0108] Suitable nonionic surfactants can be broadly described as compounds produced by the condensation of alkylene oxide groups, which are hydrophilic in nature, with an organic hydrophobic compound which may be aliphatic or alkyl aromatic in nature.

[0109] 20

[0110] The length of the hydrophilic or polyoxyalkylene radical which is condensed with any particular hydrophobic group can be readily adjusted to yield a water-soluble compound having the desired degree of balance between hydrophilic and hydrophobic elements. Particular examples include the condensation product of aliphatic alcohols having from 8 to 22 carbon atoms in either straight or branched chain configuration with ethylene oxide, such as a coconut oil ethylene oxide condensate having from 2 to 15 moles of ethylene oxide per mole of coconut alcohol; condensates of alkylphenols whose alkyl group contains from 6 to 12 carbon atoms with 5 to 25 moles of ethylene oxide per mole of alkylphenol; condensates of the reaction product of ethylenediamine 30 and propylene oxide with ethylene oxide, the condensate containing from 40 to 80 percent of polyoxyethylene radicals by weight and having a molecular weight of from 5,000 to 11,000; tertiary amine oxides of structure R3NO, where one group R is an alkyl group of 8 to 18 carbon atoms and the others are each methyl, ethyl or hydroxyethyl groups, for instance dimethyldodecylamine oxide; tertiary phosphineP0000240WQ CPL

[0111] 14

[0112] oxides of structure R3PO, where one group R is an alkyl group of from 10 to 18 carbon atoms, and the others are each alkyl or hydroxyalkyl groups of 1 to 3 carbon atoms, for instance dimethyldodecylphosphine oxide; and dialkyl sulphoxides of structure R2SO where the group R is an alkyl group of from 10 to 18 carbon atoms and the other is 5 methyl or ethyl, for instance methyltetradecyl sulphoxide; fatty acid alkylolamides;

[0113] alkylene oxide condensates of fatty acid alkylolamides and alkyl mercaptans.

[0114] Suitable cationic surfactants that can be incorporated are alkyl substituted quarternary ammonium halide salts, e.g. bis (hydrogenated tallow) dimethylammonium chlorides, cetyltrimethyl ammonium bromide, benzalkonium chlorides and dodecylmethylpolyoxyethylene ammonium chloride and amine and imidazoline salts for e.g. primary, secondary and tertiary amine hydrochlorides and imidazoline hydrochlorides.

[0115] 15 Suitable amphoteric surfactants are derivatives of aliphatic secondary and tertiary amines containing an alkyl group of 8 to 18 carbon atoms and an aliphatic radical substituted by an anionic water-solubilising group, for instance sodium 3- dodecylamino-propionate, sodium 3-dodecylaminopropane sulphonate and sodium N- 2-hydroxydodecyl-N- methyltaurate.

[0116] 20

[0117] Suitable zwitterionic surfactants are derivatives of aliphatic quaternary ammonium, sulphonium and phosphonium compounds having an aliphatic radical of from 8 to 18 carbon atoms and an aliphatic radical substituted by an anionic water-solubilising group, for instance 3-(N-N-dimethyl-N- hexadecylammonium) propane-1 -sulphonate betaine, 3-(dodecylmethyl sulphonium) propane-1 -sulphonate betaine and 3- (cetylmethylphosphonium) ethane sulphonate betaine.

[0118] Further examples of suitable detergent-active compounds are compounds commonly used as surface-active agents given in the well-known textbooks “Surface Active 30 Agents”, Volume I by Schwartz and Perry and “Surface Active Agents and Detergents”, Volume II by Schwartz, Perry and Berch.P0000240WQ CPL

[0119] 15

[0120] Other preferred ingredients

[0121] In addition to the ingredients described earlier, preferred cleansing bars may include other ingredients.

[0122] 5 A preferred bar may include up to 30 wt% benefit agents. Preferred benefit agents are moisturizers, emollients, sunscreens, and anti-ageing compounds. The agents may be added at an appropriate step during the process of making the bars. Some benefit agents may be introduced as macro domains.

[0123] Examples of moisturizers and humectants include cetyl alcohol, CARBOPOL® 934, ethoxylated castor oil, paraffin oils, lanolin and its derivatives. Silicone compounds such as silicone surfactants like DC ®3225C (Dow Corning) and / or silicone emollients, silicone oil (DC-200® ex. Dow Corning) may also be included. Sunscreens such as 4- tertiary butyl-4'- methoxy dibenzoylmethane (available under the trade name 15 PARSOL® 1789 from Givaudan) or 2-ethyl hexyl methoxy cinnamate (available under the trade name PARSOL ®MCX from Givaudan) or other UV-A and UV-B sunscreens may also be added. Lipids such as cholesterol, ceramides, and pseudoceramides, and exfoliant particles such as polyethylene beads, walnut shells, apricot seeds, flower petals and seeds may also be present. Structurants such as maltodextrin or starch 20 may be used to structure the bars. Preferred bars may also include essential oils such as bergamot and citrus or insoluble extracts of avocado, grape, grapeseed, myrrh, cucumber, watercress, calendula, elder flower, geranium, linden blossom, amaranth, seaweed, gingko, ginseng and other plant extracts. Further optional ingredients include chelating agents such as ethylene diamine tetra acetic acid, preservatives (e.g. GLYDANT®), antioxidants, and natural and synthetic perfumes. Cationic polymers may be included as conditioners. These include POLYQUATERNIUM ® , MERQUAT ® polymers, and JAGUAR ® polymers. The composition can also optionally include other ingredients conventionally used in soap such as lather boosters, hemectants such as glycerine, moisturisers, colourants and opacifiers.

[0124] 30

[0125] Other adjunct materials may include germicides and preservatives. These ingredients normally will be in amounts less than 2 wt%, usually less than 0.5 wt%. Other optional ingredients like anti-oxidants, perfumes, polymers, chelating agents, colourants, deodorants, dyes, emollients, moisturizers, enzymes, foam boosters, germicides,P0000240WQ CPL

[0126] 16

[0127] antimicrobials, lathering agents, pearlescers, skin conditioners, stabilisers, superfatting agents, sunscreens may be added in suitable amounts in the process of the invention. Preferably, the ingredients are added after the saponification step and before filtering. Sodium metabisulphite, ethylene diamine tetra acetic acid (EDTA), borax and ethylene 5 hydroxy diphosphonic acid (EH DP) are preferably added to the formulation.

[0128] It is preferred that the cleansing bar has no or essentially no opacifiers. By opacifiers is meant compounds which limit the quantity of light passing through the solid composition. When opacifiers are present, the solid composition is generally opaque, i.e. “opacification”. Examples of opacifiers include titanium dioxide, zinc oxide and the like.

[0129] Optional ingredients in soap compositions

[0130] The various optional ingredients that make up the final soap composition are as 15 described below:

[0131] The total level of the adjuvant materials used in the bar composition generally is in an amount not higher than 50%, preferably 1 to 50%, more preferably 3 to 45% by wt. of the soap composition.

[0132] 20

[0133] The adjuvant system may optionally include insoluble particles comprising one or a combination of materials. By insoluble particles is meant materials that are present in solid particulate form and suitable for personal washing. Preferably, there are mineral (e.g. inorganic) or organic particles.

[0134] The insoluble particles should not be perceived as scratchy or granular and thus should have a particle size less than 300 microns, more preferably less than 100 microns and most preferably less than 50 microns.

[0135] 30 Preferred inorganic particulate material may be inorganic fillers, including but not limited to: talc, clay, and calcium carbonate. Talc is a magnesium silicate mineral material, with a sheet silicate structure and a composition of Mg3Si4(OH)22 and may be available in the hydrated form. It has a plate-like morphology, and is essentially oleophilic / hydrophobic, i.e. it is wetted by oil rather than water.P0000240WQ CPL

[0136] 17

[0137] Calcium carbonate or chalk exists in three crystal forms: calcite, aragonite and vaterite. The natural morphology of calcite is rhombohedral or cuboidal, acicular or dendritic for aragonite and spheroidal for vaterite.

[0138] 5

[0139] Examples of other optional insoluble inorganic particulate materials include aluminates, silicates, phosphates, insoluble sulfates, borates and clays (e.g., kaolin, china clay) and their combinations.

[0140] Organic particulate materials include: insoluble polysaccharides such as highly crosslinked or insolubilized starch (e.g. by reaction with a hydrophobe such as Octyl succinate) and cellulose; synthetic polymers such as various polymer lattices and suspension polymers; insoluble soaps and mixtures thereof.

[0141] 15 It is preferred that the compositions of the invention comprise polymers.

[0142] Bar compositions preferably comprise 0.1 to 25% by wt. of bar composition, preferably 5 to 15 by wt. of these mineral or organic particles.

[0143] 20 An opacifier may be optionally present in the personal care composition. When opacifiers are present, the cleansing bar is generally opaque. Examples of opacifiers include titanium dioxide, zinc oxide, and the like. A particularly preferred opacifier that can be employed when an opaque soap composition is desired is ethylene glycol mono- or di-stearate, for example in the form of a 20% solution in sodium lauryl ether sulphate. An alternative opacifying agent is zinc stearate.

[0144] The product can take the form of a water-clear, i.e. transparent soap, in which case it will not contain an opacifier.

[0145] 30 The pH of preferred soaps bars of the invention is from 8 to 11, more preferably 9.5 to 11.

[0146] A preferred bar may additionally include up to 30 wt% benefit agents. Preferred benefit agents include moisturizers, emollients, sunscreens and anti-ageing compounds. TheP0000240WQ CPL

[0147] 18

[0148] agents may be added at an appropriate step during the process of making the bars. Some benefit agents may be introduced as macro domains.

[0149] Other optional ingredients like anti-oxidants, perfumes, polymers, chelating agents, 5 colourants, deodorants, dyes, enzymes, foam boosters, germicides, anti-microbials, lathering agents, pearlescers, skin conditioners, stabilizers or superfatting agents, may be added in suitable amounts in the process of the invention. Preferably, the ingredients are added after the saponification step. Sodium metabisulphite, ethylene diamine tetra acetic acid (EDTA), borax or ethylene hydroxy diphosphonic acid (EHDP) are preferably added to the formulation.

[0150] The composition of the invention could be used to deliver antimicrobial benefits. Antimicrobial agents that are preferably included to deliver this benefit include oligodynamic metals or compounds thereof. Preferred metals are silver, copper, zinc, 15 gold or aluminium. Silver is particularly preferred. In the ionic form it may exist as a salt or any compound in any applicable oxidation state. Preferred silver compounds are silver oxide, silver nitrate, silver acetate, silver sulfate, silver benzoate, silver salicylate, silver carbonate, silver citrate, or silver phosphate, with silver oxide, silver sulfate and silver citrate being of particular interest in one or more embodiments. In at 20 least one preferred embodiment the silver compound is silver oxide. Oligodynamic metal or a compound thereof is preferably included in an amount of 0.0001 to 2%, preferably 0.001 to 1% by weight of the composition. Alternately an essential oil antimicrobial active may be included in the composition of the invention. Preferred essential oil actives which may be included are terpineol, thymol, carvacol, (E) -2(prop- 1-enyl) phenol, 2- propylphenol, 4- pentylphenol, 4-sec-butylphenol, 2-benzyl phenol, eugenol or combinations thereof. Furthermore, preferred essential oil actives are terpineol, thymol, carvacrol or thymol, most preferred being terpineol or thymol and ideally a combination of the two. Essential oil actives are preferably included in an amount of 0.001 to 1%, preferably 0.01 to 0.5% by weight of the composition.

[0151] 30

[0152] In soap compositions for laundering fabric, one or more of the above described optional ingredients may be included. However, in laundry bars, antimicrobial agents are generally not added. Laundry bars generally include chelating agents that are generally not included in soap compositions for personal cleansing. Chelating agentsP0000240WQ CPL

[0153] 19

[0154] may be selected from (but are not limited to): ethylene diamine tetra acetic acid (EDTA), ethylene hydroxy diphosphonic acid (EHDP) or mixtures thereof. The chelating agent is preferably present in an amount ranging from 0.01 wt.% to 1 wt.%. Non-phosphate chelating agents like methylglycinediacetic acid and salts thereof are 5 also preferred.

[0155] Process

[0156] In a second aspect, the present invention relates to a soap composition of the first aspect, comprising the steps of:

[0157] i) saponifying a fatty saponifiable matter with an alkali to produce a saponified mass, while monitoring the extent of saponification, wherein 0.1 to 6 wt% of an electrolyte is added during the saponification process;

[0158] ii) adding polymeric polyol, acrylate-based linear chain homopolymer or linear chain copolymer;

[0159] 15 iii) extruding said saponified mass into solid soap composition according to the first aspect;

[0160] wherein water is added at either of the steps (i) or (ii).

[0161] It is preferred that in the process of the present invention the polymeric polyol is added 20 in an amount of 0.1 to 5% by weight of the soap composition.

[0162] It is preferred that in the process of the present invention the acrylate-based polymer linear chain homopolymer or linear chain copolymer is added in an amount of 0.1 to 5% by weight of the soap composition.

[0163] It is preferred that in the process of the present invention a salt of an acid having a pKa in the range of 2 to 6 is added at step (ii).

[0164] It is preferred that in the process of the present invention the salt of an acid having a 30 pKa in the range of 2 to 6 is added in an amount of 0.1 to 5% by weight of the soap composition.

[0165] It is preferred that in the process of the present invention the composition comprises 45 to 70 wt% total fatty matter.P0000240WQ CPL

[0166] 20

[0167] The soap composition may be made into a bar by a press that first involves saponification of the fat charge with alkali followed by extruding the mixture in a conventional plodder. The plodded mass may then be optionally cut to a desired size 5 and stamped with a desirable indicia. An especially important benefit of the present invention is that, notwithstanding the high water content of the soap composition, compositions thus prepared by extrusion are found to be easy to stamp with a desirable indicia. By “easy to extrude” is meant that the hardness of the bar as it is extruded is high enough that it exits the extruder in a firm enough form that it can be called a rigid bar. The hardness of the bar is preferably higher than 1.2 kg, more preferably in the range of 1.2 to 5.0 kg (at 40°C). The hardness is preferably measured using the TA-XT Express apparatus available from Stable Micro Systems. The hardness is measured using this apparatus with a 30° conical probe - Part #P / 30c to a penetration of 15 mm. If the soap mass is too soft and is passed through the extruder 15 it will not extrude out of the extruder in a cohesive enough mass to be called a bar. By “easy to stamp” is meant that the soap composition is of such a consistency and low enough stickiness that it does not stick to the die that is used to stamp any desired indicia on the bar. The soap composition prepared by the process of the invention therefore preferably comprises an indicium stamped thereupon.

[0168] 20

[0169] The specific process that may be employed using the above described general process for soap composition manufacture comprises one of the following processes.

[0170] In another preferred aspect, the process to prepare the soap composition of the present invention comprises the steps of (a) preparing soap in a plough shear mixer or crutcher by reacting desired amount of fatty acid / oil with alkali at 90 to 110°C; (b) including sodium aluminosilicate gel in the plough shear mixer or crutcher to mix with the soap so formed in step (a) with said gel to prepare a mixture; (c) providing a pH quencher salt having pKa value between 4 to 6.8; (d) spray drying the mixture or 30 passing it through a triple roll mill; and (e) then passing it though a plodder to prepare the desired soap composition.

[0171] In yet another aspect, preferably, the process to prepare the soap composition of the present invention comprises the steps of (a) preparing the sodium alumino silicate is inP0000240WQ CPL

[0172] 21

[0173] situ in a plough shear mixer or crutcher by reacting the desired amount of sodium aluminate with sodium silicate; followed by (b) preparing soap in the same plough shear mixer or crutcher by reacting desired amount of fatty acid / oil with alkali at 90 to 110°C with constant agitation to prepare a mixture; (c) providing a pH quencher salt 5 having pKa value between 3.5 to 6.8; (d) spray drying the mixture or passing it through a triple roll mill; and (e) then passing it though a plodder to prepare the desired soap composition.

[0174] It is preferred that in the process of the present invention the TFM of soap composition is in the range of 45 to 70%.

[0175] Example 1- Soap Compositions

[0176] The soap compositions of the examples were prepared in accordance with the present 15 invention.

[0177] Final soap bar composition was prepared in two stages: a) High moisture noodle preparation with polymer, polymeric polyols and acids b) converting the noodle into finished soap bars.

[0178] 20

[0179] High moisture noodle (-23% moisture) was prepared in a plough shear mixer (PSM). The following steps were followed: Required quantity of fatty acids (from PKO) were neutralized by caustic soda in the presence of NaCI, Na2SC>4 and Glycerin at 90°C in a PSM. After complete neutralization of fatty acids, the following were added: process water, polymeric polyols (PEG-8), polymer (poly acrylic acids), acids (adipic acids), followed by 5 min of mixing. The soap composition was discharged and passed through a chilled drum (where chilled water at 9°C) and the semi-liquid soap mass converted into soap flakes.

[0180] 30 The following steps were followed to convert the premade high moisture noodle into soap bars. Required quantity of soap flake was added into a sigma mixer and mixed for 5 min. Then minors and color were dosed and mixed for a further 3 min. Required quantity of perfume was mixed with soap composition for 2 min. The mixture was passed through a triple roll mill and plodder to get the soap mass in the shape of billet.P0000240WQ CPL

[0181] 22

[0182] The hardness of the soap bars / billet was measured by a TA-XT meter and simultaneously the billet temperature was taken by inserting a temperature probe into it. The billets were then stamped in a pneumatic stamper and the bars were taken out 5 from the stamper cavity.

[0183] The hardness of the samples was measured using the procedure described below:

[0184] Hardness Testing Protocol

[0185] Principle

[0186] A 30° conical probe penetrates into a soap / syndet sample at a specified speed to a pre-determined depth. The resistance generated at the specific depth is recorded. There is no size or weight requirement of the tested sample except that the bar / billet be bigger than the penetration of the cone (15 mm) and have enough area. The recorded 15 resistance number is also related to the yield stress and the stress can be calculated as noted below. The hardness (and / or calculated yield stress) can be measured by a variety of different penetrometer methods. In this invention, as noted above, we use probe which penetrates to depth of 15 mm.

[0187] 20 Apparatus and Equipment

[0188] TA-XT Express (Stable Micro Systems)

[0189] 30° conical probe - Part #P / 30c (Stable Micro Systems)

[0190] Sampling Technique

[0191] This test can be applied to billets from a plodder, finished bars, or small pieces of soap / syndet (noodles, pellets, or bits). In the case of billets, pieces of a suitable size (9 cm) for the TA-XT can be cut out from a larger sample. In the case of pellets or bits which are too small to be mounted in the TA-XT, the compression fixture is used to form several noodles into a single pastille large enough to be tested.

[0192] 30P0000240WQ CPL

[0193] 23

[0194] Procedure

[0195] Setting up the TA-XT Express

[0196] These settings need to be inserted in the system only once. They are saved and loaded whenever the instrument is turned on again. This ensures settings are constant 5 and that all experimental results are readily reproducible.

[0197] Set test method- Press MENU

[0198] Select TEST SETTINGS (Press 1)

[0199] Select TEST TPE (Press 1)

[0200] Choose option 1 (CYCLE TEST) and press OK

[0201] Press MENU

[0202] Select TEST SETTINGS (Press 1)

[0203] Select PARAMETERS (Press 2)

[0204] 15 Select PRE TEST SPEED (Press 1)

[0205] Type 2 (mm s-1) and press OK

[0206] Select TRIGGER FORCE (Press 2)

[0207] Type 5 (g) and Press OK

[0208] Select TEST SPEED (Press 3)

[0209] 20 Type 1 (mm s-1) and press OK

[0210] Select RETURN SPEED (Press 4)

[0211] Type 10 (mm s-1) and press OK

[0212] Select DISTANCE (Press 5)

[0213] Type 15 (mm) for soap billets or 3 (mm) for soap pastilles and press OK

[0214] Select TIME (Press 6)

[0215] Type 1 (CYCLE)

[0216] Calibration

[0217] Screw the probe onto the probe carrier.

[0218] 30 Press MENU

[0219] Select OPTIONS (Press 3)

[0220] Select CALIBRATE FORCE (Press 1) - the instrument asks for the user to check whether the calibration platform is clear

[0221] Press OK to continue and wait until the instrument is ready.P0000240WQ CPL

[0222] 24

[0223] Place the 2kg calibration weight onto the calibration platform and press OK

[0224] Wait until the message “calibration completed” is displayed and remove the weight from the platform.

[0225] 5 Sample Measurements

[0226] Place the billet onto the test platform.

[0227] Place the probe close to the surface of the billet (without touching it) by pressing the UP or DOWN arrows.

[0228] Press RUN

[0229] Take the readings (g or kg) at the target distance (Fin).

[0230] After the run is performed, the probe returns to its original position.

[0231] Remove the sample from the platform and record its temperature.

[0232] Calculation & Expression of Results

[0233] 15 Output

[0234] The output from this test is the readout of the TA-XT as “force” (RT) in g or kg at the target penetration distance, combined with the sample temperature measurement. (In the subject invention, the force is measured in Kg at 40°C at 15 mm distance)

[0235] 20 The force reading can be converted to extensional stress, according to the equation given below.

[0236] The equation to convert the TX-XT readout to extensional stress is

[0237]

[0238] where: o = extensional stress

[0239] C = “constraint factor” (1.5 for 30° cone)

[0240] Gc= acceleration of gravity

[0241] A = projected area of cone = ^(<7 tan 16»)

[0242] d = penetration depth

[0243] 30 0 = cone angleP0000240WQ CPL

[0244] 25

[0245] For a 30° cone at 15 mm penetration, Equation 2 becomes

[0246] cr (Pa) = RT(g) x 128.8

[0247] This stress is equivalent to the static yield stress as measured by penetrometer.

[0248] 5 The extension rate is:

[0249] ■F

[0250]

[0251] where E = extension rate (s-1)

[0252] V = cone velocity

[0253] For a 30° cone moving at 1mm / s, E = 0.249 s-1

[0254] Temperature Correction

[0255] The hardness (yield stress) of skin cleansing bar formulations is temperature-sensitive. For meaningful comparisons, the reading at the target distance (RT) should be corrected to a standard reference temperature (normally 40°C), according to the 15 following equation:

[0256] R40 - Ry ■■ exp[c / .(T-40)]

[0257] where

[0258] 20 R40 = reading at the reference temperature (40°C)

[0259] RT = reading at the temperature T

[0260] a = coefficient for temperature correction

[0261] T = temperature at which the sample was analyzed.

[0262] The correction can be applied to the extensional stress.

[0263] The result is the temperature-corrected force or stress, but it is advisable to record the instrument reading and the sample temperature also.

[0264] 30 A hardness value of at least 1.2 kg (measured at 40°C), preferably at least 2.7 kg is acceptable.Table 1

[0265] E1

[0266] E2 E3 E4 E5 E6 E7 (Control)

[0267] Out of the scope Out of the scope Within the scope of the

[0268] of the present of the present present invention

[0269] invention invention TFM 71.30 69.17 61.34 61.34 63.1 61 61.76 IV 40 40 40 40 40 40 40 PEG-8

[0270] 0 0.00 1.00 1.00 1.00 1.00 1.0 (Polymeric polyols)

[0271] Electrolyte 0.7 2.0 2.0 2.0 2.0 2.0 2.0 Salt of Adipic Acid

[0272] 0.0 0.0 1.0 1.0 0.0 1.0 0.0 (Dibasic)

[0273] Glycerine 2 2.00 4.00 4.00 4.00 4.00 2.00 Polyacrylate

[0274] 0 0.00 0.45 1.0 0.45 0.0 0.00 (PA-15, BASF)

[0275] Stearic Acids (Free

[0276] — 4.00 — — 2.0 — 4.00 Fatty acids added)

[0277] Lauric acid 0.25-0.5

[0278] Talc 2.5 0 0 0 0 0 0 Water Content 16 14 22 24 21 22 22 Minors to 100 to 100 to 100 to 100 to 100 to 100 to 100 Processability

[0279] Yes Yes Yes Yes Yes No No (Ploddability)

[0280] Bar hardness @40°C

[0281] 4.1 3.1 3.0 2.9 2.7 N / A N / A (KgF)

[0282] Free Fatty Acids (%) 0.25-0.5 4.00 3.80 4.0 2.2 3.4 4.00

[0283]

[0284] Soap compositions E1 to E7 were prepared according to the given methodology. E1 is a 71.30 wt% TFM control soap composition without salt of adipic acid and without acrylate-based polymer having free fatty acid concentration of 0.25-0.5 wt%. E2 is a conventional superfatted soap bar composition having free fatty acid concentration of 4 wt%, without salt of adipic acid, polymeric polyol and without acrylate-based polymer. E7 is another conventional superfatted soap composition differing from E2 in that E2 has a moisture content of 14 wt%, whereas E7 has polymeric polymer and a high moisture content of 22 wt%. Composition E3 to E5 are according to the first aspect of the present invention. E3 and E4 have adipic acid and acrylate-based polymer with about 3.8 wt% and 4wt% free fatty acids generated in situ. E5 is a soap barP0000240WQ CPL

[0285] 27

[0286] composition in absence of adipic acid but having acrylate-based polymer and added free fatty acids. E6 did not have acrylate-based polymer and has in situ generated 3.4 wt% free fatty acids. E2, E5 and E7 compositions had added free fatty acids as stearic acid.

[0287] 5

[0288] The data given above demonstrate that a regular control soap bar E1 with low free fatty acid content has a good bar hardness of 4.1 kgF. The conventional superfatted soap bars commercially available E2 also have a good bar hardness of 3.1 KgF with free fatty acid content of 4wt%, however it only has a water content of 14 wt%. When 10 similar soap bars as that of commercially available ones were attempted with a high water content of 22 wt% and with polymeric polyol as in E7 with 4 wt% of free fatty acids, it was observed that the resultant soap composition was not even plodibble, and structuring a soap bar from such a composition was not possible.

[0289] When soap compositions E3 to E5 were prepared according to the present invention, it was surprisingly observed that a soap bar with good hardness and free fatty acid content could be structured with high water content of 21 to 24 wt%. When E3 of the invention was attempted to be altered by taking out the polyacrylic acid polymer, it was observed that the soap composition E6 was not ploddible could not be structured into a 20 soap bar.

[0290] The data in table indicates that superfatted soap compositions with high moisture content can be prepared according to the composition of the present invention which extrude well and have good hardness.

Claims

Claims1. A solid soap composition comprising:a. 45 to 70 wt% total fatty matter;b. 0.5 to 6 wt% electrolyte;c. 0.1 to 5 wt% polymeric polyol;d. 15 to 35 wt% water;e. 0.1 to 5 wt% of acrylate-based linear chain homopolymer or linear chain copolymer; andf. 1 to 5 wt% free fatty acid.

2. A solid soap composition according to claim 1, wherein the acrylate-based linear chain homopolymer or linear chain copolymer is not hydrophobically modified.

3. A solid soap composition according to claims 1 or 2, wherein the composition comprises 0.1 to 5wt% salt of an acid having a pKa in the range of 2 to 6, wherein the salt of the acid having a pKa in the range of 2 to 6 is different from the electrolyte.

4. A solid soap composition according to any one of the preceding claims 1 to 3, wherein the polymeric polyol has molecular weight in the range of 85 to 8000 g / mol.

5. A solid soap composition according to according to any one of the preceding claims 1 to 4, wherein the polymeric polyol is selected from the group of polyethylene glycol and polypropylene glycol.

6. A solid soap composition according to any one of the preceding claims 1 to 5, wherein the electrolyte is selected from sodium chloride, sodium sulphate, sodium citrate, or a mixture thereof.

7. A solid soap composition according to any one of the preceding claims 1 to 6, wherein the electrolyte comprises sodium chloride or sodium sulphate or a mixture thereof in an amount of 0.5 to 4 wt% by total weight of the composition.

8. A solid soap composition according to any of the preceding claims 1 to 7, wherein iodine value of the composition is 30-45 g / lodine per 100 g of said saponified fatty matter.

9. A solid composition according to any one of the preceding claims 1 to 8, wherein the composition has a pH in the range from 9 to 13 when measured in a 4% solution with distilled water at 25°C.

10. A process for preparing a solid soap composition according to anyone of the preceding claims from 1 to 9, the process comprising the steps of:i) saponifying a fatty saponifiable matter with an alkali to produce a saponified mass, while monitoring the extent of saponification, wherein 0.1 to 6 wt% of an electrolyte is added during the saponification process;ii) adding polymeric polyol, acrylate-based linear chain homopolymer, or linear chain copolymer;iii) extruding said saponified mass into solid soap composition according to any one of the preceding claims from 1 to 9;wherein water is added at either of the steps (i) or (ii).

11. A process according to claim 10, wherein the polymeric polyol is added in the range of 0.1 to 5% by weight of the solid soap composition.

12. A process according to claim 10 or 11, wherein the acrylate-based polymer is added in the range of 0.1 to 5% by weight of the solid soap composition.

13. A process according to any one of the preceding claims from 10 to 12, wherein the process further comprises addition of 0.1 to 5wt% of a salt of an acid having a pKa in the range of 2 to 6 at step (ii), wherein the salt of the acid having a pKa in the range of 2 to 6 is different from the electrolyte.

14. A process according to any one of the preceding claims 10 to 13, wherein the composition has 45 to 70wt% total fatty matter by weight of the solid soap composition.

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