Structured Liquid Detergent Process Without Premix
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Solution Overview
Problem
Existing processes for structuring liquid detergent compositions require high water content and emulsifying agents, making them unsuitable for low water compositions and increasing costs and complexity, particularly for 'on-demand' processes and multi-compartment unit dose articles.
Innovation Solution
A process involving a first premix of surfactant and non-aqueous organic solvent with less than 30 wt% water, combined with a crystalline structurant at elevated temperatures, then cooled and mixed with a liquid composition to form a structured liquid composition without the need for a separate structuring premix or high water and emulsifying agents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a separate structuring premix is formed using conventional processes, then the liquid composition can be structured, but the process complexity increases and requires additional equipment and storage
Solution Approach 1:
The patent combines the structuring agent directly into the liquid composition formulation without requiring a separate structuring premix. The structuring agent is incorporated during the main composition mixing process, eliminating the need for separate premix preparation, storage tanks, and processing equipment.
Solution Approach 2:
The liquid composition formulation serves multiple functions simultaneously: it provides the base liquid matrix, contains the surfactant system, and incorporates the structuring agent to create the desired viscosity and shear resistance. This multi-functionality eliminates the need for separate structuring premix systems.
2Stability of the object's composition
If high water content is used in the structuring premix, then the structuring network can be formed, but the amount of other ingredients that can be added is limited
Solution Approach 1:
The patent changes the water content parameter from high (conventional premixes) to low (less than 30 wt%, preferably less than 10 wt%). This parameter change allows the structuring network to form effectively while leaving sufficient capacity in the formulation for other active ingredients, enzymes, and additives.
3Ease of manufacture
If high levels of emulsifying agents are added for emulsification, then the structuring premix can be formed, but the overall cost increases and performance of other ingredients is affected
Solution Approach 1:
The patent extracts or eliminates the need for high levels of separate emulsifying agents by incorporating the structuring agent directly into the liquid composition. The structuring agent itself provides the necessary emulsification and network formation without requiring additional emulsifier additives.
Solution Approach 2:
The structuring agent performs multiple functions: it forms the structuring network, provides viscosity enhancement, and acts as an emulsifying component. This multi-functionality eliminates the need for separate high-level emulsifying agent additions.
4Stability of the object's composition
If slow cooling rates are used to form threadlike networks, then the structuring network is effective, but continuous on-demand processes cannot be used
Solution Approach 1:
The patent changes the cooling rate parameter from slow (1-2 °C/min in conventional processes) to faster cooling rates that are compatible with continuous manufacturing. This parameter change enables on-demand structuring in continuous processes while still forming effective structuring networks through the direct incorporation method.
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 allows for the formation of stable, structured liquid compositions with improved shear resistance and viscosity, enabling the addition of more ingredients without affecting viscosity, and is suitable for low water compositions and unit dose articles, reducing costs and process complexity.
Implementation Method 1
combining the second premix with a liquid composition at a temperature of less than 40°C, to form the structured liquid composition
Implementation Method 2
providing a first premix comprising surfactant and non-aqueous organic solvent
Data Source
AI summary
The need for a process for making a structured liquid detergent composition which comprises a structurant without introducing high levels of water or emulsifying agents, or requiring a separate structuring premix to be formed, is met herein.