CA2037310A1 - Continuous process for preparing low density bar soap - Google Patents

Continuous process for preparing low density bar soap

Info

Publication number
CA2037310A1
CA2037310A1 CA 2037310 CA2037310A CA2037310A1 CA 2037310 A1 CA2037310 A1 CA 2037310A1 CA 2037310 CA2037310 CA 2037310 CA 2037310 A CA2037310 A CA 2037310A CA 2037310 A1 CA2037310 A1 CA 2037310A1
Authority
CA
Canada
Prior art keywords
soap
molten
neat
continuously
aerated
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
CA 2037310
Other languages
French (fr)
Inventor
Mary Middlebrook
Barry M. Weinstein
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Colgate Palmolive Co
Original Assignee
Colgate Palmolive Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Colgate Palmolive Co filed Critical Colgate Palmolive Co
Publication of CA2037310A1 publication Critical patent/CA2037310A1/en
Abandoned legal-status Critical Current

Links

Abstract

ABSTRACT
The invention relates to a continuous process for preparing low density aerated soap of toilet soap quality which comprises the steps of: a) preparing neat soap with a composition of 10 to 50% coconut oil and 50 to 90% tallow with moisture content between 28% and 35%, b) feeding the molten soap mass into a continuously operating high shear mixer, c) working the molten soap while air is continuously incorporated at a pressure of 90 psi, d) casting the soap into soap making frames, e) cooling, cutting, stamping and wrapping the bars.

Description

203~3111 ~
CONTINUOUS PROCESS FOR PREPARING
.~
LOW DENSITY BAR SOAP
FIELD OF THE INVENTION
,~
The invention relates to a continuous process for preparing low density bar soap with a specific gravity that can be controlled between 0.5 and 0.9. The invention is especially directed to a process for economically making a white soap of toilet har quality, without the use of opacifiers, whiteners or brighteners; for increasing the volume of the said soap bar; and for increasing the allow-able water content in the finished soap bar.

BACKGROUND OF THE INVENTION
_ _ _ _ ._ Various processes for preparing aerated soap bars by incorporation of air into the soap composition ha~e been known for some time. These methods ~ary from simple mechan-ical agitation of the soap in the cru~cher, to proc~sses that require special eguipment and in some cases special formulations to produce a commerrially acceptable product.
Typical prior art methods include:
l. Air is whipped into the molten soap while in the crutcher, for example by rever-~ing the rotation of the central stirri~g mechanism.
2. Incorporation of air into partially dried soap chips at 115F by means of a modified soap plodder, dis-closed in U~S. Patent 2,525~081 to Schulerud.
. 3. Mazzoni 'Float-o-matic' plodder. Commercially available.
4. Aeration by introducing gas and mixing by passage between two mutually displaceable surfaces, dis-closed in European Patent 9064~.

I ~3731~

S. Molten soap processed through heat exchanger, flash chamber, continuous crutcher with addition of air, then cooling/mixing de~ice, disclosed in U.S. Patent 2,295,594 to Mills.
Methods 1, 2, 3 and 4 do not produce a bar that has the uniformity of color, appearance or density required. I
Methods 3, 4 and 5 require spec~al equipment.
Other processes are disclosed in U.S. Patent 1,780,330 to Blair; 2,210,924 to Hood 2,398,776 to Bodman; 2,494,891 to Marshall; 4,311,604 to Hornig; and 4,680,132 to Clark et al~
SUMMARY OF THE INVENTION
It is an object of the process of the present invention to aerate bar soap in order to reduce bar density, for increased volume, and for floatability of the soap bar.
It is also an object of the process of the present invention ~o increase the allowable water content in bar soap.
Thirdly, it i8 an object of the invention to produce a commercially acceptable white soap bar by incorpo-ration of air in a finely divided and uniformly distributed form into the 80ap composition ir~ order to increase the light scattering effect of the composition.
Fourthly, it is a~ object of thP invention to produce soap bars with superior performance attributes compared to commercially available soap bars of sLmilar ~om~osition, by means of an economical con~inuous process that simpli~ies the usual 50ap processing procedure.
Also, it is an object of the process of the inve~tion to insorporate air into the soap composition in a finely controllable manner, so that density o~ the bar is eproducible betweeD 0.5 and 0 9 specific gravity, and J0 ~ ~373~

that the soap bar has consistent texture and color.
The process has several advantages over the prior art.
The process provides for the density of the bar of soap to be easily controllable, providing for soap densities of between 0.5 and 0.9 with high reproducibility.
The process improves homogeneity of the bar composition so that the soap texture is uniform. The process allows for air cell5 to be finely dispersed through- ¦
out the soap composition ~hus resulting in a soap with superior use characteristics and improved whiteness. Neat soap with usual water composition of between 28~ and 35~ can be continuously aerated by the present process so tha~ the finished soap bar contains water content in the same range.
The process shortens or eliminates the drying and plodding stages of soap processing, thus simplifying the soap making process for resulting lower energy consumption than is usual in the manufacture of soap. The process also allows for increased flexibility in utilization of soap making facil-ities.

DESCRIPTION OF TH~ DRAWINGS
. .

Figures 1 and 2 are diagrams showing the steps of two variations of the process.
DESCRIPTION OF T~E INVENTION
The first process of the invention is describPd with reference to Figure 1~ In the first step of ~he process sodium soap in the neat phase, of toilet soap quality, i~ prepared according to usual soapmaki~g proce-dures by the kettle method or by a continuou~ process, so the the neat soap has a composition of 10 to 50% coconut oil and 90 to 50~ tallow, with a moisture content of between 28% and 35%.
l - - 2~373~ ~

Preservatives and/or chelating agents, including but not limited to tetrasodium ethylenediamine tetraacetic acid, and etidronic acid, are mix~d into the molten nea~
soap in a crutcher maintained at a temperature of 180~ to 220F.
The molten soap mass is pumped into a water jacketed melt mixer, and cooled to a temperature above the melting point of the mixture. Antioxidants including but not limited to ditertiary butyl paracresol, are dissolved in the fragrance and added to the molten neat soap as it is pumped into the hopper of the Goodway aeration unit. The neat soap at this point contains preferably 30% moisture.
The mixer is operated continuously and air at a pressure of 90 lbs per square inch is incorporated into the soap mass with high shear mixing. The aerated soap is cast into soapmaking ~rames in known manner according to the rt.
The cooled soap is then cut and stamped with the desired logo, and conveyed to a packaging machine ~not shown).
The second process of the invention is described in reference to Figure 2.
Preservatives and/or chelating agents are mixed into the molten neat soap in a crutcher maintained at a temperature of 180F to 220F.
Antioxidants are dissolved in the fragrance and added inline to the molten neat soap as it is pumped into the hopper of a Goodway aeration unit.
The mixer is operated continuously and air at a pressure of 90 lbs per square inch is incorporated into the soap mass with high shear mixing. The hot aerated soap is then filled directly into soap molds, tray containers or other packaging. After the soap is cooled, the packaging is ~ ~037~a sealed and labelled.
When the process of ~he present invention is followed, the density of the product can be controlled by adjusting the air flow rate, the mixer head speed and the pump speed of the Goodway mixer. Bar soap of up to 30%
moisture is obtained compared to moisture content of 10 to 15% for regular toilet soaps~
Whiteners, brighteners or opacifiers such as titanium dioxide, which are no~mally added to improve the whiteness of toilet soap, are not required in the formu-lation, since the finely dispersed air cells within the solid soap cause a light scattering effect which increases the R-value (whiteness value) of the soap.
It is discernable both visually and by MacBeth colorimeter readings that the whitenes~ of the aerated soap bar is equivalent or greater than nonaerated toilet soap bars of comparable composition containing 0.5% titanium dioxide. ~R-v~lue 84.5 for aerated soap versus 79.2 for nonaerated soap with 0.5% titanium dioxide content.) Due to the nature of the high shear mixing in combinatio~ with dispersion of air cells in a finely divided form throughout the soap mass, the homogeneity of the product is greatly improved, resulting in a bar with commer-cially acceptable appearance in regard to color and surface texture.
It is obvious that the process of the present invention uses less energy ~han conventional bar soap under current manufacturing processes, and also allows for re-duction in formulation costs.
The process of the presen~ invention is also advantageous in that it elLminates the plodder and drier stages normally used for soap bar manufacture.

Il I

~ - 2~

The Goodway mixer is a commercially available mixer manufactured and sold by Goodway Industries, Inc. of Bohemia, N.Y~
The invention is illustrated by the followiny specific but non-limiting examples. .
Example 1 A total of 30 lbs of neat soap with composition 85% tallow and 15% coconut oil, with 31.5% moisture content was prepared, and the molten soap was moved continuously to the Goodway mixer, where air was incorporated into the soap with high shear mixing. The hot aerated soap was formed into blocks and cooled, bars cut and wrapped.
Exam ~
A total of 30 lbs of neat soap consist~n~ of a sodium soap containing 70% tallow and 30% coconut oil, with 30~ moisture content was prepared. A sufficient quantity of preservative was added to the molten soap. Soap fragrance was addea at 1% to 1.4~ and the soap was immedia$ely moved to the Goodway mixer where aix was incorporated into the molten soap with high shear mixing. The aerated soap moved continuously out of the mi~er and was c~st and allowed to cool. The cooled soap wa~ cut into bars and wrapped.
Example 3 A total of 30 lbs of neat soap with composi~ion 85% tallow and 15~ coconut oil, with 30% moisture content was prepared and the molten soap was aerated as in Examples 1 and 2. The hot aerated soap was filled directly into transparent packaging trays with debossed logo, cooled and sealed.
Bar soap produced according to the above described proc~sses was of toilet ~oap quality and ~he density was less t n that of water (i.e. the coap floated). The soap 373:L~

bar was very white and the volume was approximately 40%
greater than for a regular soap bar of the same weight.
Performance of the soap bars thus obtained was superior to toilet and laundry bar soaps of similar composi-tion, in regard to improved durability of the bar, rate of useup of the soap bar during use, improved maintainance of shape and texture over repeated use, and latherability.
Although the present invention has been described with respect to particular embodiments in the example thereof it will be understood by those skilled in the art that other variations and modifications of the invention can be made without departing from the essence and scope there-of, only such limitations should be applied as are indicated in the appended claims~

Claims (4)

1) A continuous process for preparing low density aerated soap of toilet soap quality which comprises the steps of:
a) preparing neat soap with a composition of 10 to 50% coconut oil and 50 to 90% tallow with moisture content between 28% and 35%7 b) feeding the molten soap mass into a continuously operating high shear mixer, c) working the molten soap while air is continuously incorporated at a pressure of 90 psi, d) casting the soap into soap making frames, e) cooling, cutting, stamping and wrapping the bars.
2) The process as in Claim 1 wherein preserva-tives, fragrance and other minors are added to the neat soap prior to aeration.
3) The process as in Claim 1 wherein a) preservatives are added to the neat soap b) the soap is cooled in a melt mixer above the melting point of soap c) antioxidants and fragrance are added to the soap mass d) which is fed continuously into the mixer/aerator e) while air is continuously incorporated into the soap, f) the aerated soap is cast into soap making frames g) then cooled, cut, stamped and wrapped.
4) A continuous process for preparing low density aerated soap of toilet soap quality which comprises the steps of:
a) preparing neat soap as in Claim 1, b) pumping the molten neat soap into the mixer/aerator c) while continuously adding preservatives, fragrance and other minors, d) working the soap as air is continuously incorporated at a pressure of 90 psi e) filling the aerated soap while molten into soap molds, preformed plastic trays, or other packages, f) sealing and labelling the packaging containers.
CA 2037310 1990-03-01 1991-02-28 Continuous process for preparing low density bar soap Abandoned CA2037310A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US48680390A 1990-03-01 1990-03-01
US486,803 1990-03-01

Publications (1)

Publication Number Publication Date
CA2037310A1 true CA2037310A1 (en) 1991-09-02

Family

ID=23933304

Family Applications (1)

Application Number Title Priority Date Filing Date
CA 2037310 Abandoned CA2037310A1 (en) 1990-03-01 1991-02-28 Continuous process for preparing low density bar soap

Country Status (14)

Country Link
JP (1) JPH04218599A (en)
CN (1) CN1057481A (en)
AR (1) AR245204A1 (en)
BG (1) BG60595B1 (en)
BR (1) BR9100796A (en)
CA (1) CA2037310A1 (en)
CZ (1) CZ280807B6 (en)
EG (1) EG19135A (en)
HU (1) HU210140B (en)
PL (1) PL166591B1 (en)
RO (1) RO106758B1 (en)
RU (1) RU2039084C1 (en)
YU (1) YU47164B (en)
ZA (1) ZA911267B (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2002024856A1 (en) * 2000-09-22 2002-03-28 Kao Corporation Method of manufacturing soap with air bubbles

Families Citing this family (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7517843B2 (en) 2000-09-22 2009-04-14 Kao Corporation Method for manufacturing soap products of a constant weight
ATE316569T1 (en) * 2000-09-22 2006-02-15 Kao Corp METHOD FOR PRODUCING SOAP WITH AIR INCLUDE
GB0317257D0 (en) * 2003-04-03 2003-08-27 Unilever Plc Improved detergent bar and process for manufacture
JP5632202B2 (en) * 2009-06-04 2014-11-26 花王株式会社 Frame kneaded soap composition
EA024376B1 (en) * 2011-03-16 2016-09-30 Юнилевер Нв Aerated soap bars
WO2013134109A2 (en) * 2012-03-04 2013-09-12 Traynor Daniel H Soap with dispersed articles producing light and/or sound
CN103013722B (en) * 2012-12-12 2015-01-21 合肥豪豪日化有限公司 High water content compound laundry bar soap and preparation method thereof
CN105861202B (en) * 2016-03-18 2018-09-11 杭州稞恩生物科技有限公司 A kind of floationg soap and preparation method thereof
CN109234085B (en) * 2018-08-16 2020-08-25 惠州兆婷化妆品有限公司 Floating soap and preparation method thereof

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2002024856A1 (en) * 2000-09-22 2002-03-28 Kao Corporation Method of manufacturing soap with air bubbles
US6809071B2 (en) 2000-09-22 2004-10-26 Kao Corporation Method of manufacturing soap with air bubbles

Also Published As

Publication number Publication date
RO106758B1 (en) 1993-06-30
PL289238A1 (en) 1991-11-04
BR9100796A (en) 1991-11-05
EG19135A (en) 1994-06-30
PL166591B1 (en) 1995-06-30
CN1057481A (en) 1992-01-01
HU910683D0 (en) 1991-09-30
RU2039084C1 (en) 1995-07-09
CZ280807B6 (en) 1996-04-17
HUT57825A (en) 1991-12-30
JPH04218599A (en) 1992-08-10
YU47164B (en) 1995-01-31
CS9100548A2 (en) 1991-09-15
AR245204A1 (en) 1993-12-30
BG60595B1 (en) 1995-09-29
HU210140B (en) 1995-02-28
ZA911267B (en) 1992-10-28
YU35091A (en) 1993-11-16

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