Solid Cleansing Bar Manufacturing via Liquid Isethionate Emulsion

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Solution Overview

Problem

The high cost and inefficiency in manufacturing cleansing bars compared to soap bars, due to the slow production processes and higher expenses associated with cleansing bars containing isethionate surfactants, which are typically more expensive than soap bars.

Innovation Solution

A method for producing a solid cleansing composition using at least 15%wt of a non-soap anionic surfactant with a melting point of at least 45°C, a carrier with a similar melting point, an emulsifier, and water, where the composition remains solid from 0°C to 40°C, and is formed by preparing an emulsion at elevated temperatures and cooling it to reduce water content, resulting in a homogeneous microstructure without soap or starch.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional cleansing bar manufacturing methods are used with isethionate surfactants, then the cleansing composition provides effective skin cleaning, but the production cost increases and manufacturing efficiency decreases

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidproduction cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The invention changes the physical state parameter of the surfactant from solid (traditional isethionates) to liquid form, enabling the use of continuous mixing and casting processes similar to soap manufacturing. This parameter change allows for faster production rates and reduced manufacturing costs while maintaining effective cleansing performance.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention makes the manufacturing process universal by using the same continuous production methodology for both soap and liquid surfactant-based cleansing bars. The process can handle different surfactant types (soap and liquid isethionates) through a single manufacturing line, improving both productivity and cost-effectiveness.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If soap is used as the primary ingredient, then the manufacturing cost is low and production is efficient, but the pH is too high (9-10) which is detrimental to skin health

Engineering Contradiction:

Improvemanufacturing costVSAvoidskin damage from high pH

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The invention introduces liquid isethionate surfactants as an intermediary substance that bridges the gap between soap's manufacturing advantages and skin-friendly pH requirements. These liquid surfactants can be processed like soap but produce a lower pH final product (closer to natural skin pH), eliminating the harmful high pH effect while retaining manufacturing efficiency.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Object-affected harmful factors

If cleansing bars with isethionate surfactants are produced using conventional methods, then the product provides gentle skin care, but the production rate is slow and costs are high

Engineering Contradiction:

Improveskin gentlenessVSAvoidproduction rate

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The invention replaces the traditional mechanical mixing and molding process for solid surfactants with a liquid-phase continuous casting system. The liquid surfactant allows for continuous mixing and pouring into molds, similar to soap production, dramatically increasing production rate while the surfactant composition maintains gentle skin care properties.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 method enables the production of solid cleansing compositions at higher rates and lower costs, using conventional soap-making equipment, while maintaining a pH closer to the natural skin pH, thus addressing the cost and efficiency issues of traditional cleansing bars.

Implementation Method 1

subjecting the emulsion to cooling and solidification, wherein its water content is reduced during the cooling and solidification to produce the solid cleansing composition

Methodology Applied

Scientific EffectCooling: Cooling

Implementation Method 2

subjecting the emulsion to cooling and solidification, wherein its water content is reduced during the cooling and solidification to produce the solid cleansing composition

Methodology Applied

Scientific EffectSolidification: Freezing

Data Source

PatentEP3837042B1Improvements in relation to the manufacture of personal cleansing compositions

Publication Date: 2023.01.04 THOS BENTLEY & SON LTD

AI summary

The invention relates to a method of making solid cleansing compositions which comprise a non-soap anionic surfactant, a carrier, an emulsifier and water. The method entails preparing an emulsion of the components at an elevated temperature using excess water and subjecting the emulsion to cooling and solidification, wherein the water content is reduced. The invention further relates to the emulsions and to the novel solid cleansing compositions formed therefrom.