Granular Detergent Polymer Distribution via Spray Drying
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Solution Overview
Problem
Granular laundry detergent compositions with polymers often form large granules due to uneven polymer distribution, leading to slow dissolution and poor cleaning performance, which is undesirable for consumers.
Innovation Solution
A process involving forming an aqueous detergent slurry, spray drying it to create particles, and then adding a polymer emulsion comprising a polyethylene glycol polymer and a surfactant to the particles, ensuring even distribution and preventing large granule formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polymer is sprayed onto detergent granules at the end of the manufacture process, then polymer can be added to provide benefits such as soil release and anti-redeposition, but large granules are formed due to uneven distribution of the polymer
Solution Approach 1:
The polymer is incorporated into the detergent granules during the granulation process rather than being added afterward. This preliminary action ensures uniform distribution of the polymer throughout the granule formation process, preventing the formation of large granules while maintaining the desired cleaning performance benefits
Solution Approach 2:
The polymer addition step is merged with the granulation process. By combining these two operations, the polymer is distributed evenly as the granules are being formed, eliminating the problem of uneven polymer distribution that occurs when polymer is sprayed onto already-formed granules
2Reliability
If polymer is sprayed onto detergent granules, then polymer benefits are achieved, but dissolution speed decreases due to large granule formation
Solution Approach 1:
The polymer is incorporated during granulation before the final granule size is achieved. This ensures that the polymer is uniformly distributed throughout the granule structure from the beginning, resulting in smaller, more uniform granules that dissolve faster while still providing the necessary cleaning performance
3Ease of manufacture
If polymer is added at the end of the manufacture process, then the process is simple, but granule appearance is poor due to large granule formation
Solution Approach 1:
The polymer addition is merged with the granulation process into a single integrated operation. This combines two steps into one, maintaining process efficiency while achieving uniform granule size and good appearance, as the polymer is distributed evenly during granule formation rather than requiring a separate spraying step
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 results in a granular detergent composition with smaller, more evenly sized granules that dissolve efficiently, improving cleaning performance and consumer acceptance.
Implementation Method 1
spray drying said aqueous detergent slurry to form a plurality of spray-dried detergent particles
Implementation Method 2
forming an emulsion comprising a polymer and a surfactant; and adding the emulsion from step c) to at least a portion of said plurality of spray-dried detergent particles
Data Source
AI summary
A process of making a granular detergent composition comprising the steps of: a) forming an aqueous detergent slurry; b) spray drying said aqueous detergent slurry to form a plurality of spray-dried detergent particles; c) forming an emulsion comprising a polymer; and d) adding the emulsion from step c) to at least a portion of said plurality of spray-dried detergent particles.