Granule Bulk Density via High-Temp Spray Drying
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Solution Overview
Problem
Existing processes for producing powders or granules containing chelating agents, such as MGDA and GLDA, result in low bulk density, which limits the active ingredient content in compacted forms like single unit doses (SUDs) for automatic dishwashing (ADW) formulations.
Innovation Solution
A process involving the mixing of chelating agents (MGDA or GLDA alkali metal salts), alkali metal silicate, and a (co)polymer containing carboxylic acid groups, followed by spray-drying or spray granulation using a gas with an inlet temperature of at least 125°C, to produce powders or granules with increased bulk density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If spray-drying or spray granulation is performed using a gas with an inlet temperature of at least 125°C, then bulk density is increased, but process complexity increases
Solution Approach 1:
The patent applies parameter changes by specifying a minimum inlet temperature of 125°C for the drying gas, which is a critical parameter modification that enables the formation of dense granules. This temperature threshold triggers a phase change in the liquid slurry components, causing rapid evaporation and granule formation that increases bulk density while maintaining process simplicity through a single temperature parameter specification.
2Object-affected harmful factors
If chelating agents are used in phosphate-free formulations, then environmental compatibility is improved, but bulk density decreases
Solution Approach 1:
The patent employs composite materials by combining chelating agents (MGDA, GLDA, or IDS) with alkali metal silicates and carboxylic acid-containing polymers in specific weight ratios. This composite formulation creates a synergistic effect where the silicate and polymer components provide structural support that increases bulk density while the chelating agent maintains environmental compatibility through phosphate-free chemistry.
Solution Approach 2:
The patent applies parameter changes by controlling the weight ratio of chelating agent to the combined weight of silicate and polymer within 20:1 to 100:1. This parameter optimization ensures that the chelating agent concentration is sufficient for environmental compatibility while the higher proportion of silicate and polymer provides the necessary bulk density for compacted formulations.
3Productivity
If higher active ingredient content is achieved in SUDs, then productivity is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by optimizing the weight ratio of chelating agent to silicate-polymer combination within 20:1 to 100:1. This parameter control enables higher active ingredient content in the final granules, which directly increases productivity in SUD formulations. The process maintains simplicity by using a single mixing and spray-drying operation without requiring complex multi-step manufacturing procedures.
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 achieves powders or granules with a high bulk density, allowing for a higher active ingredient content per volume unit, which is particularly beneficial for compacted forms like SUDs for ADW formulations.
Implementation Method 1
removing most of said water by spray-drying or spray granulation using a gas with an inlet temperature of at least 125° C.
Data Source
AI summary
Process making a powder or granule containing(A) at least one chelating agent selected from alkali metal salts of methyl glycine diacetic acid (MGDA) and of glutamic acid diacetate (GLDA) and of iminodisuccinic acid (IDS),(B) at least one alkali metal silicate, and(C) at least one (co)polymer containing carboxylic acid group, partially neutralized with alkali,in a weight ratio of (A):[(B)+(C)] of from 20:1 up to 100:1,wherein said powder or granule contains at least 75% by weight of chelating agent (A), said process comprising the steps of(a) mixing the at least one chelating agent (A) and the at least one alkali metal silicate (B) and the at least one (co)polymer (C) in the presence of water,(b) removing most of said water by spray-drying or spray granulation using a gas with an inlet temperature of at least 125° C.