Inline Rheology Modifier Addition for Dentifrice Viscosity Control
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Solution Overview
Problem
Current methods for producing dentifrices face challenges with high viscosity due to the addition of rheology modifiers, leading to increased processing time, reduced production capacity, and significant cleaning times required between batches, as the thickened premix adheres to tank surfaces and complicates deaeration.
Innovation Solution
The method involves forming a premix with lower viscosity in the mix tank, adding rheology modifiers inline during high energy dispersion, and using an inline deaeration device positioned to minimize pressure drop, allowing for efficient deaeration and packaging before the viscosity increases, thus reducing processing time and cleaning requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If rheology modifiers are added directly to the mix tank, then the final product achieves desired viscosity, but processing time increases significantly and production capacity decreases
Solution Approach 1:
The patent applies preliminary action by adding rheology modifiers to the mix tank before the high energy dispersion step, allowing the viscosity to be established early in the process. This enables the bulk of the thickening to occur during the high energy dispersion phase rather than requiring extended mixing time after all ingredients are combined, thereby maintaining productivity while achieving the desired final viscosity.
Solution Approach 2:
The patent utilizes parameter changes by controlling the timing of rheology modifier addition relative to the high energy dispersion step. By adjusting when the rheology modifiers are introduced (before versus after the high energy dispersion), the process optimizes both viscosity development and processing time, resolving the contradiction between achieving stable composition and maintaining high productivity.
2Stability of the object's composition
If rheology modifiers are added during the mixing process, then the final product achieves desired viscosity, but the premix thickens and adheres to tank surfaces requiring extensive cleaning time
Solution Approach 1:
The patent applies preliminary action by establishing the rheology modifier addition at an early stage in the mixing process, before the premix becomes excessively thick. This timing ensures that the viscosity development occurs when the mixture is still relatively fluid, preventing excessive adhesion to tank surfaces and minimizing subsequent cleaning requirements while still achieving the desired final viscosity.
Solution Approach 2:
The patent employs the skipping principle by rapidly progressing through the mixing sequence to complete the rheology modifier addition and high energy dispersion step before significant adhesion can occur. This rushed-through approach minimizes the time the thickened premix remains in contact with tank surfaces, thereby reducing cleaning time and lost production time.
3Stability of the object's composition
If rheology modifiers are added during mixing, then the final product achieves desired viscosity, but deaeration becomes more difficult and processing time increases
Solution Approach 1:
The patent applies preliminary action by completing the rheology modifier addition and high energy dispersion step before initiating the deaeration phase. This sequencing ensures that the viscosity is established early, allowing the deaeration process to proceed more efficiently once the mixture is thickened, rather than attempting to deaerate a continuously thickening mixture, thereby reducing overall deaeration time.
Solution Approach 2:
The patent utilizes parameter changes by optimizing the timing of rheology modifier addition relative to the deaeration step. By controlling when the rheology modifiers are introduced (before versus after the high energy dispersion but before deaeration), the process achieves the desired viscosity development while maintaining favorable conditions for efficient deaeration, resolving the contradiction between viscosity stability and deaeration efficiency.
4Manufacturing precision
If high energy mixing is used to combine components, then homogenous product composition is achieved, but processing time increases and production capacity decreases
Solution Approach 1:
The patent applies preliminary action by performing the rheology modifier addition and high energy dispersion step early in the mixing sequence, before all ingredients are fully combined. This allows the high energy dispersion to work more efficiently on a smaller portion of the total mixture volume, achieving homogeneity faster and reducing overall processing time while maintaining productivity.
Solution Approach 2:
The patent utilizes parameter changes by adjusting the timing and intensity of high energy dispersion relative to the addition of rheology modifiers. By controlling these parameters, the process achieves the desired homogeneity with reduced energy input and shorter processing time, thereby resolving the contradiction between manufacturing precision and productivity.
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
This approach reduces downtime due to inter-batch cleaning, enhances deaeration efficiency, and increases production throughput by maintaining lower viscosity during processing, allowing for faster and more efficient production of dentifrices.
Implementation Method 1
The ingredients are typically combined together in the mix tank by recirculating the ingredients through a high shear mixing device to create a final homogenous product composition
Implementation Method 2
Vacuum is then applied to the mix tank to deaerate the dentifrice to the desired finished density
Data Source
AI summary
Methods of making personal care compositions, such as dentifrices, involving the addition of rheology modifiers at a later stage in the personal care composition formation process.