Low-Density Spray-Dried Detergent via Steam Puffing
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Solution Overview
Problem
There is a need to reduce the bulk density of low builder laundry detergent compositions to allow consumers to use the same volume as conventional high builder detergents, while maintaining excellent solubility in cold water temperatures, which is not effectively addressed by existing formulations.
Innovation Solution
A spray-drying process that involves preparing an aqueous slurry at specific temperatures and spraying it into a spray-drying tower under controlled conditions to promote steam puffing, resulting in a low-density, highly water-soluble spray-dried detergent powder with reduced zeolite and phosphate content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If zeolite and phosphate builders are removed to create low builder detergent compositions, then solubility in cold water is improved, but bulk density becomes too low causing consumers to use excessive volume
Solution Approach 1:
The patent changes the physical and chemical parameters of the detergent composition by replacing traditional zeolite and phosphate builders with alternative builder systems that have different solubility and density characteristics. This allows the formulation to achieve both low bulk density for improved solubility and controlled volume for consumer dosing requirements
Solution Approach 2:
The patent uses composite material systems combining multiple detergent ingredients including surfactants, alternative builders, enzymes, and fillers in specific ratios. This composite approach allows optimization of both solubility and bulk density properties that cannot be achieved with single ingredients alone
2Quantity of substance
If conventional high builder laundry detergents are used, then bulk density is high allowing small dosing volume, but solubility in cold water is poor requiring higher washing temperatures
Solution Approach 1:
The patent fundamentally changes the builder system parameters from traditional high-density zeolite and phosphate compounds to alternative builders with lower density and higher solubility. This parameter change enables cold water solubility while maintaining adequate bulk density for practical dosing
Solution Approach 2:
The patent replaces durable, high-density builder materials (zeolite, phosphate) with alternative materials that dissolve more readily in cold water. These alternative builders are designed to be consumed during the washing process, providing effective cleaning without requiring high washing temperatures
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 produces a low-density spray-dried detergent powder that maintains excellent solubility in cold water, enabling lower washing temperatures and reducing environmental and economic costs, while allowing consumers to maintain their usual dosing volume.
Implementation Method 1
The spray-drying process comprises the step of spray-drying an aqueous slurry comprising a large amount of water. The conditions of the spray-drying process promote steam puffing
Implementation Method 2
The conditions of the spray-drying process promote steam puffing; which in turn leads to the formation of spray-dried detergent powder having a very low bulk density
Data Source
AI summary
The present invention relates to a spray-drying process for the preparation of a spray-dried detergent powder having a bulk density of 426 g/l or less, wherein the spray-dried detergent powder comprises an anionic detersive surfactant and from 0 wt % to 10 wt % zeolite builder and from 0 wt % to 10 wt % phosphate builder, and wherein the process comprises the step of: (a) preparing an aqueous slurry suitable for spray-drying comprising from 30 wt % to 60 wt % water and from 40 wt % to 70 wt % non-aqueous material, wherein the non-aqueous material comprises an inorganic component and an organic component, wherein the weight ratio of the inorganic component to organic component is in the range of from 0.3:1 to 5:1; and (b) spraying the slurry into a spray-drying tower, wherein the temperature of the slurry as it enters the spray-drying tower is in the range of from 65° C. to 140° C., and wherein the outlet air temperature of the spray-drying tower is in the range of from 70° C. to 120° C.