Light Density Silicate Salt in Solid Laundry Detergent
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Solution Overview
Problem
The challenge lies in producing chemically compacted solid laundry detergent compositions without zeolite using traditional batch processes, as previous attempts have been unsuccessful in incorporating low density silicate salts with small particle sizes effectively.
Innovation Solution
Incorporating a light density silicate salt with a bulk density of less than 400g/l and a weight average particle size of less than 300 micrometers into the detergent composition, along with a batch process that involves mixing and spray-drying to achieve a bulk density of 600g/l or less and a cake strength of 5N to 20N, while minimizing zeolite content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If zeolite is removed to chemically compact the formulation, then phosphate and zeolite usage is reduced for environmental benefits, but the detergent composition becomes difficult to produce using traditional batch processes
Solution Approach 1:
Light density silicate salt acts as an intermediary material that enables traditional batch process production of chemically compacted detergent formulations. The silicate salt facilitates uniform mixing and processability without requiring advanced continuous processing equipment, thus resolving the contradiction between environmental benefits of zeolite removal and ease of manufacture using traditional processes
Solution Approach 2:
The invention changes the particle size parameter of silicate salt to less than 300 micrometers and bulk density to less than 400g/l, which fundamentally alters the processing characteristics. These parameter changes enable the chemically compacted formulation to be produced using traditional batch processes, resolving the manufacturing difficulty while maintaining environmental benefits
2Ease of manufacture
If light density silicate salt with small particle size is incorporated into chemically compacted formulations, then traditional batch processes can be used for production, but the formulation becomes more difficult to make without proper particle size control
Solution Approach 1:
The invention specifies precise parameter ranges for silicate salt: bulk density less than 400g/l and weight average particle size less than 300 micrometers. These controlled parameters ensure that the material can be processed using traditional batch processes while maintaining manufacturability, resolving the contradiction between ease of manufacture and manufacturing precision
3Object-affected harmful factors
If chemically compacted formulations are produced without zeolite, then phosphate and zeolite content is minimized for environmental reasons, but the formulations require advanced continuous processing equipment
Solution Approach 1:
Light density silicate salt serves as a mediating material that bridges the gap between environmentally friendly chemically compacted formulations and traditional batch processing equipment. By incorporating this specific silicate salt, the formulation can be produced using simple batch mixers rather than complex continuous processing equipment, thus resolving the contradiction between reducing harmful factors and avoiding device complexity
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 enables the production of solid laundry detergent compositions with improved flow properties and reduced water-insoluble residues, allowing for efficient production using traditional batch processes and minimizing environmental impact by reducing phosphate and zeolite usage.
Implementation Method 1
a batch process that involves mixing and spray-drying to achieve a bulk density of 600g/l or less
Data Source
AI summary
The present invention relates to a solid laundry detergent composition comprising: (a) from 1wt% to 40 wt% light density silicate salt having a bulk density of less than 400g/l and a weight average particle size of less than 300 micrometers; (b) from 5wt% to 60wt% detersive surfactant; (c) from 0wt% to 50wt % carbonate salt; (d) from 0wt% to 40wt% sulphate salt; (e) from 0wt% to 10wt% phosphate builder; (f) from 0wt% to 5wt%% zeolite builder; and (g) from 0wt% to 15wt% water; wherein the composition has a bulk density of 600g/l or less.