Spray-Dried Detergent Particle Anti-Caking via In-Situ Silicate Formation
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Solution Overview
Problem
Spray-dried detergent particles face challenges with caking and loss of free-flowing properties during extended storage, especially when using hygroscopic fillers like sodium chloride, and require improved stability in moisture-prone packaging conditions.
Innovation Solution
A process involving the formation of in-situ silicate and/or disilicate salts of alkaline earth metals by reacting alkali metal silicate with alkaline earth metal salts, combined with alkali metal silicate and carbonate builders, to create a spray-dried detergent particle that maintains free-flowing characteristics and anticaking properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hygroscopic fillers like sodium chloride are used to replace sodium sulphate, then cost is reduced, but the spray-dried particle tends to cake and loses free-flowing properties during storage
Solution Approach 1:
The patent uses a composite filler system combining hygroscopic sodium chloride with non-hygroscopic calcium carbonate in specific ratios (30-70 wt% NaCl and 70-30 wt% CaCO3). This composite approach allows cost reduction through NaCl while CaCO3 provides structural stability and prevents caking during storage, resolving the contradiction between manufacturing cost and storage reliability
Solution Approach 2:
The patent optimizes the proportion of hygroscopic to non-hygroscopic fillers as a key parameter, along with controlling surfactant concentration (40-60 wt%) and water content (5-15 wt%). By adjusting these parameters within specific ranges, the formulation achieves both cost-effectiveness and storage stability, preventing caking while using economical fillers
2Quantity of substance
If high concentration of anionic surfactants (at least 40 w.%) is used to concentrate the solid laundry detergent composition, then cleaning performance is improved, but the particle must maintain free-flowing properties over extended storage life which becomes more difficult
Solution Approach 1:
The patent maintains surfactant concentration within 40-60 wt% while controlling water content at 5-15 wt% and using optimized filler combinations. These parameter adjustments ensure high cleaning performance through concentrated surfactants while preventing caking and maintaining free-flowing properties during extended storage
Solution Approach 2:
The combination of hygroscopic and non-hygroscopic fillers creates a composite structure that accommodates high surfactant concentrations without compromising flow stability. The non-hygroscopic CaCO3 provides structural integrity that prevents caking even when high surfactant content is present
3Adaptability or versatility
If recyclable paper-based packaging is used to improve sustainability, then environmental friendliness is improved, but moisture barrier protection is reduced leading to increased caking tendency
Solution Approach 1:
The patent formulates the detergent particle with a balanced filler system containing non-hygroscopic calcium carbonate (70-30 wt%) that preemptively counteracts moisture absorption. This preliminary anti-action against hygroscopy protects the product even when packaged in moisture-permeable sustainable materials like paper, preventing caking before moisture ingress can occur
Solution Approach 2:
The use of calcium carbonate as a non-hygroscopic filler provides a protective matrix that mimics the moisture barrier function traditionally provided by plastic packaging. This alternative protective structure enables sustainable packaging while maintaining product stability
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 results in spray-dried detergent particles with extended shelf life and excellent powder properties, preventing caking and maintaining performance even in conditions with lower moisture barriers, such as paper-based packaging.
Implementation Method 1
contacting an alkaline earth metal salt with an alkali metal silicate salt in an aqueous mixture comprising a detersive surfactant, wherein the alkaline earth metal salt reacts with the alkali metal silicate salt to form in-situ silicate salt and/or disilicate salt of alkaline earth metal
Implementation Method 2
spray-drying said aqueous slurry to form said spray dried detergent particle
Data Source
AI summary
The present invention relates to a process for preparing a particulate, free flowing detergent particle by a slurry making and spray drying technique. It is thus an object of the present invention to provide a process for preparing a detergent solution for a spray-dried detergent particle which provides for incorporating a carbonate builder and silicate salt at optimum levels whilst provides good cleaning performance and good powder properties. The present inventors have surprisingly found that a spray-dried detergent particle exhibits extended shelf life and demonstrates excellent powder properties without getting caked during use, when the spray dried detergent particle is prepared by a process where an in-situ silicate and/or a disilicate a salt of an alkaline earth metal is formed by reacting an alkali metal silicate with an alkaline earth metal salt, and the spray dried detergent particle also includes an alkali metal silicate salt along with optimum detersive surfactant content, filler and carbonate builder, wherein the composition preferably has no phosphate builder and zeolite builder.