Extruded Soap Bar with High Water Content Structuring
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Solution Overview
Problem
Existing soap bar compositions with high water content face challenges in extrusion and stamping due to low Total Fatty Matter (TFM) content, leading to stickiness and compromised bar integrity, while attempts to reduce TFM often result in unsuitable materials for personal washing or inefficient structuring.
Innovation Solution
A soap bar composition with 40 to 60 wt% TFM, 21 to 40 wt% water, and a structuring system comprising a mixture of sodium silicate and an acrylic/acrylate polymer, where the polymer is included during the saponification step, enabling easy extrusion and stamping without compromising sensorial properties like lather and wear rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If water content is increased to reduce TFM content for sustainability, then environmental sustainability is improved, but extrusion and stamping become difficult due to stickiness
Solution Approach 1:
The patent introduces a structuring system comprising aluminium stearate and sodium stearate as intermediary substances that mediate between the high water content soap matrix and the extrusion process. These structuring agents form a network that prevents stickiness while allowing water content to reach 25-40%, enabling both sustainability goals and manufacturability
Solution Approach 2:
The patent changes the chemical composition parameters by incorporating specific structuring agents (aluminium stearate 1-5 wt% and sodium stearate 1-5 wt%) that fundamentally alter the rheological properties of the soap mass, enabling it to maintain structural integrity at high water contents during extrusion and stamping operations
2Quantity of substance
If TFM content is reduced to increase water content, then water content is improved, but bar integrity and sensorial properties are compromised
Solution Approach 1:
The patent creates a composite soap structure combining water-soluble soaps (providing cleaning), water-insoluble soaps (providing structure), and structuring agents (aluminium stearate and sodium stearate). This composite approach allows the bar to maintain integrity with 25-40% water content, as the structuring agents form a reinforcing network within the soap matrix
Solution Approach 2:
The patent applies local quality by distributing structuring agents specifically to provide structural support where needed, while maintaining high water content in the bulk matrix for sustainability. The structuring agents create localized rigid regions that prevent bar disintegration while allowing the overall composition to be environmentally friendly
3Shape
If aluminium phosphate is used to structure low TFM bars, then bar structuring is improved, but skin friendliness deteriorates
Solution Approach 1:
The patent replaces the harmful but effective aluminium phosphate with a biodegradable alternative system using aluminium stearate and sodium stearate. While these alternatives may be less potent structuring agents, they provide sufficient bar integrity for personal wash applications while being skin-friendly and environmentally degradable, aligning with the sustainable personal care ethos
4Shape
If natural aluminosilicate clays are used to structure bars, then bar structuring is achieved, but structuring efficiency is insufficient at low amounts
Solution Approach 1:
The patent changes the chemical nature of the structuring agents from natural clays to metal soap combinations (aluminium stearate and sodium stearate). This chemical parameter change dramatically improves structuring efficiency, allowing effective bar formation at lower concentrations (1-5 wt% each) compared to clay systems, while also improving skin compatibility
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 composition achieves stable water retention and desired hardness, ensuring easy extrudability and stampability while maintaining high lather and low mush properties, even with reduced sodium silicate amounts, thus addressing the limitations of previous approaches.
Implementation Method 1
0.1 to 10 wt% of a structuring system comprising a mixture of sodium silicate and an acrylic/ acrylate polymer
Implementation Method 2
21 to 40 wt% water... achieves stable water retention
Data Source
AI summary
The present invention relates to an extruded soap bar composition. It more particularly relates to a soap bar composition which comprises low amount of soap where high amount of water can be incorporated. This is achieved by including selective amount of a mixture of sodium or calcium silicate and an acrylic/acrylate polymer, wherein the soap bar comprises 0.01 to 0.7 wt% of the polymer. The soap bars of the invention are easy to extrude and has acceptable product hardness.