Detergent Concentrate Mixing Sequence for Homogeneous Low-Energy Production

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Solution Overview

Problem

Existing methods for producing concentrated liquid cleaning agent compositions, such as hand dishwashing liquids, are complex, costly, and require high-shear mixers with recirculation lines, which are energy-intensive and require significant infrastructure, limiting process flexibility.

Innovation Solution

A simplified manufacturing process that eliminates the need for high-shear mixers with recirculation lines by using a specific dosing sequence and process parameters, such as controlled dosing speed and stirring time, to ensure homogeneity and solubility of surfactants, particularly fatty alcohol ether sulfates.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a high-shear mixer with recirculation line is used to produce concentrated cleaning agent compositions, then homogeneous mixing and dissolution of surfactants is achieved, but device complexity, energy consumption, and infrastructure requirements increase

Engineering Contradiction:

Improvehomogeneity of cleaning agent compositionVSAvoidcomplexity of mixing equipment

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the complex recirculation line system from the mixing equipment, using a simple single-vessel mixing approach where all components are combined and mixed in one container without requiring recirculation piping, thereby achieving homogeneity without the associated complexity

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent segments the mixing process into a specific sequential dosing order: first dissolving surfactants in water, then adding co-surfactants and auxiliaries in stages, which allows homogeneous mixing to be achieved through process segmentation rather than complex mechanical recirculation

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If a high-shear mixer with recirculation line is used, then surfactant dissolution and homogenization is effective, but energy consumption increases

Engineering Contradiction:

Improvehomogeneity of cleaning agent compositionVSAvoidenergy consumption of mixing equipment

Core Design Contradiction:

Stability of the object's compositionVSUse of energy by moving object

Solution Approach 1:

The patent employs periodic intermittent stirring instead of continuous high-shear mixing, allowing the mixture to settle and redistribute between stirring cycles, which achieves homogeneity with significantly reduced energy input compared to continuous high-speed mixing

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The patent changes the mixing parameters by using low-speed intermittent stirring combined with a specific dosing sequence, transforming the energy-intensive high-shear mixing process into a low-energy process that achieves the same homogenization effect through temporal and sequential parameter optimization

Inventive Principle:

Principle #35Parameter changes

3Productivity

If continuous mixing plant is used for production, then manufacturing efficiency is improved, but infrastructure requirements and investment costs increase

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidflexibility of production setup

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent creates a universal mixing protocol that can be implemented in various settings from small batch production to large-scale manufacturing using the same basic equipment and dosing sequence, making the process adaptable to different production scales and facility types without requiring specialized continuous mixing infrastructure

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent replaces expensive permanent continuous mixing infrastructure with simple, inexpensive batch mixing equipment that can be easily deployed and dismantled, allowing flexible production capacity adjustment without significant capital investment in fixed infrastructure

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The process is more cost-effective, sustainable, and flexible, producing homogeneous liquid cleaning agent compositions efficiently while reducing energy consumption and infrastructure requirements.

Implementation Method 1

stirring the mixture from step a)

Methodology Applied

Scientific EffectStirring: Stirring

Data Source

PatentEP4686751A1Process for the preparation of a detergent concentrate

Publication Date: 2026.02.04 HENKEL KGAA

AI summary

The invention relates to a method for producing a liquid cleaning agent composition, in particular a concentrated liquid cleaning agent composition, preferably a concentrated liquid hand dishwashing detergent composition, wherein the composition comprises at least a first and at least a second surfactant, comprising the steps a) providing a mixture of (i) water, (ii) optionally a preservative, (iii) optionally a third surfactant from the group of amine oxides, (iv) an organic solvent, (v) a salt, (vi) the first surfactant from the group of betaines and (vii) citric acid; b) stirring the mixture from step a); c) adding the second surfactant from the group of fatty alcohol ether sulfates; d) stirring the mixture from step c); and e) optionally adding (ix) dye and/or (x) perfume and/or (xi) citric acid and/or (xii) enzymes.