Spray-Drying Process Pipe Volume Reduction for Detergent Changeover

Solution Overview

Problem

The existing spray-drying process for laundry detergent base powder production is inefficient due to excessive unwanted material production and time delays during formulation changes, caused by the need to flush out previous ingredients from the equipment.

Innovation Solution

Introducing detergent ingredients later in the process, specifically dosing them into the pipe after the drop tank, and carefully controlling the pipe volume and dosing point to minimize flushing, thereby reducing changeover time and improving efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If detergent ingredients are dosed early in the process (in the drop tank), then complete mixing is achieved, but excessive flushing is required during formulation changes

Engineering Contradiction:

Improvemixing completenessVSAvoidflushing volume

Core Design Contradiction:

Stability of the object's compositionVSLoss of substance

Solution Approach 1:

The dosing process is segmented into two stages: common ingredients are dosed in the drop tank for complete mixing, while variable detergent ingredients are dosed later in the pipe after the drop tank. This segmentation allows the system to maintain complete mixing for base ingredients while minimizing flushing requirements for formulation changes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The pipe volume is carefully controlled to be less than 20% of the drop tank volume, creating a preliminary constraint on the system. This preliminary design decision ensures that when formulation changes occur, the volume of material that needs to be flushed is minimized, as the pipe contains only a small portion of the total ingredient volume.

Inventive Principle:

Principle #10Preliminary action

2Stability of the object's composition

If detergent ingredients are dosed early in the process (in the drop tank), then thorough mixing is achieved, but changeover time increases

Engineering Contradiction:

Improvemixing completenessVSAvoidchangeover time

Core Design Contradiction:

Stability of the object's compositionVSLoss of time

Solution Approach 1:

The dosing process is segmented into two stages: common ingredients are dosed in the drop tank for complete mixing, while variable detergent ingredients are dosed later in the pipe after the drop tank. This segmentation allows the system to maintain complete mixing for base ingredients while minimizing flushing requirements for formulation changes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The pipe volume is carefully controlled to be less than 20% of the drop tank volume, creating a preliminary constraint on the system. This preliminary design decision ensures that when formulation changes occur, the volume of material that needs to be flushed is minimized, as the pipe contains only a small portion of the total ingredient volume.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If pipe volume is increased, then dosing flexibility is improved, but flushing volume increases

Engineering Contradiction:

Improvedosing flexibilityVSAvoidflushing volume

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The pipe volume is carefully controlled to be less than 20% of the drop tank volume, creating a preliminary constraint on the system. This preliminary design decision ensures that when formulation changes occur, the volume of material that needs to be flushed is minimized, as the pipe contains only a small portion of the total ingredient volume.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system changes the parameter of pipe volume from being a large component to being a small component (less than 20% of drop tank volume). This parameter change maintains dosing flexibility for variable ingredients while dramatically reducing the flushing volume required during formulation changes.

Inventive Principle:

Principle #35Parameter changes

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 significantly reduces changeover time and enhances the overall efficiency and production capacity of the spray-drying process by minimizing flushing and unwanted material production.

Implementation Method 1

spraying the mixture through the spray nozzle into a spray-drying tower

Methodology Applied

Scientific EffectSpray: Fluid Spray

Implementation Method 2

spray-drying the mixture to form a spray-dried powder

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentEP2341124B1A spray-drying process

Publication Date: 2017.07.26 PROCTER & GAMBLE CO

AI summary

The present invention relates to a process for preparing a spray-dried detergent powder comprising: (i) detersive surfactant; and (ii) other detergent ingredients; wherein the process comprises the steps of: (a) dosing an aqueous detergent slurry into a drop tank; (b) transferring the aqueous detergent slurry from the drop tank to a pipe, and transferring the aqueous detergent slurry along the pipe through at least one pump to a spray nozzle; (c) contacting a detergent ingredient to the aqueous detergent slurry in the pipe to form a mixture; (d) spraying the mixture through the spray nozzle into a spray-drying tower; and (e) spray-drying the mixture to form a spray-dried powder, wherein the ratio of (i) the volume of the pipe of step (b) in litres to (ii) the volume of the drop tank of step (a) in litres is less than 1:1.