Spray-Dried Laundry Detergent Particle Surface Drying Control
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Solution Overview
Problem
Detergent manufacturers face challenges in controlling bulk density and particle size distribution during the spray-drying process, which affects the dissolution, aesthetic appeal, and dosing ease of laundry detergent particles.
Innovation Solution
Introducing low levels of polyepoxy succinic acid polymer into the anionic detersive surfactant slurry during spray-drying, resulting in faster surface drying of spray-dried particles, thereby achieving lower bulk densities and narrower particle size distributions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional spray-drying is used without polyepoxy succinic acid polymer, then the process is simple, but the surface drying rate is slow resulting in high bulk density and wide particle size distribution
Solution Approach 1:
Polyepoxy succinic acid polymer is introduced as an intermediary substance that modifies the surface properties of the slurry droplet during spray-drying. The polymer acts as a mediator that accelerates moisture removal from the particle surface, enabling faster surface drying without complicating the overall spray-drying process setup
Solution Approach 2:
The invention changes the chemical composition parameter of the slurry by adding polyepoxy succinic acid polymer at low concentrations (0.1-3.5 wt%). This parameter change fundamentally alters the drying kinetics, transforming the surface drying rate from slow to fast, while the low concentration requirement keeps the modification minimal and cost-effective
2Manufacturing precision
If fast surface drying is achieved using polyepoxy succinic acid polymer, then bulk density is reduced and particle size distribution is narrowed, but the slurry formulation becomes more complex
Solution Approach 1:
By adjusting the concentration parameter of polyepoxy succinic acid polymer within the optimal range of 0.1-3.5 wt%, the invention achieves precise control over surface drying rate. This parameter optimization enables narrow particle size distribution and low bulk density while keeping the formulation simple and the additive concentration low
Solution Approach 2:
The polyepoxy succinic acid polymer replicates or enhances the desired surface drying effect that would otherwise require complex process control mechanisms. Instead of complicating the spray-drying equipment or process parameters, the polymer copy-cats the ideal drying behavior, simplifying the overall system while achieving precise particle size control
3Manufacturing precision
If fast surface drying is achieved, then internal moisture entrapment is reduced improving bulk density, but requires additional polymer additive
Solution Approach 1:
The invention applies partial action by using low concentrations of polyepoxy succinic acid polymer (0.1-3.5 wt%) to achieve the desired surface drying effect. This partial addition is sufficient to modify surface properties and accelerate moisture removal, preventing internal moisture entrapment and achieving low bulk density without requiring excessive polymer quantities
Solution Approach 2:
The polyepox}y succinic acid polymer serves as an intermediary that facilitates efficient moisture removal from the particle interior to surface pathway. By mediating the drying process at the surface, it prevents the formation of moisture-trapping structures, achieving good bulk density with minimal additive quantity
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 method produces spray-dried particles with improved dissolution, aesthetic appeal, and ease of dosing, while maintaining low bulk densities and narrow particle size distributions, enhancing the overall performance of laundry detergents.
Implementation Method 1
The rate of surface drying is measured as the time taken to reach a rate of moisture loss of zero, which occurs when the surface of the spray-dried particle is sufficiently dried to prevent internal moisture from escaping into the surrounding environment.
Data Source
AI summary
The present invention relates to a method of making a spray-dried laundry detergent particle, wherein the method comprises the steps: (a) forming an aqueous laundry detergent slurry, wherein the slurry comprises: (i) from 1wt% to 40wt% anionic detersive surfactant; (ii) from 0.1wt% to 3.5wt% polyepoxy succinic acid polymer; and (iii) from 10wt% to 80wt% water, and (b) spray drying the slurry formed in step (a) to form a spray-dried laundry detergent particle.