CA2329243A1

CA2329243A1 - Water-dispersible non-particulate detergent product from low-density particulate detergent particles

Info

Publication number: CA2329243A1
Application number: CA002329243A
Authority: CA
Inventors: Thomas Edward Stone; Adrian John Waynforth Angell; Les Charles Zorb
Original assignee: Individual
Current assignee: Procter and Gamble Co
Priority date: 1998-04-27
Filing date: 1999-04-21
Publication date: 1999-11-04
Also published as: ES2217743T3; JP2002513074A; DE69915276T2; ATE260968T1; CN1307631A; BR9909960A; EP1076686B1; AU3049899A; EP1076686A1; DE69915276D1; WO1999055821A1; AR015027A1

Abstract

A process for producing a water-dispersible non-particulate detergent product from low density particulate detergents includes the step of providing a low density particulate detergent composition having an intra-particle porosity in a range of from about 10 % to about 90 % by volume. The process further includes the step of adding a liquid to the low density particulate detergent composition in an amount sufficient to reduce the intra-particle porosity by at least about 10 %. The process then includes the step of compacting the low density particulate detergent composition having reduced intra-particle porosity by applying a pressure in an amount sufficient to form the water-dispersible non-particulate detergent product having a density of at least about 1000 g/l. This process enables the manufacture of a rapidly dispersing non-particulate detergent product that sinks in water.

Description

WATER-DISPERSIBLE NON-PARTICULATE DETERGENT PRODUCT FROM LOW-DENSITY
PARTICULATE DE-TERGENT PARTICLES
TECHNICAL FIELD
The present invention relates to detergent compositions in non-particulate form. More particularly, the invention relates to a process for making a non-particulate detergent product, such as a tablet, block, or bar which sinks in water, readily disintegrates in water and is rapidly dispersible in water, by using a low density particulate detergent composition having a particulate bulk density less than 800 g/1 as a starting material.
BACKGROUND OF THE INVENTION
Non-particulate detergents are an attractive alternative to granular or particulate forms of detergents from the standpoint of simplifying the dosing of such detergents for automatic laundry or dishwashing machines. Non-particulate detergents are usually supplied in the form of bars, tablets or briquettes and they not only prevent spillage of the detergent composition but also eliminate the need for the consumer to estimate the correct dosage of the detergent composition per wash.
Non-particulate detergents minimize the contact by the consumer with the detergent.
An important factor for successful performance of a non-particulate detergent is its ability to disintegrate and dissolve in the washing machine in a controlled manner according to a desired dissolution profile during the program cycle of the machine. Another important performance factor is that the non-particulate detergent should be hard enough to facilitate easy handling of the detergent prior to use, so that it does not inadvertently lose its structure, crumble, or deteriorate, both during the packaging, transport and storage and during handling by the end consumer prior to actual use.
Additionally, a very desirable feature of a non-particulate detergent, such as for example, a tablet, is its ability to sink in water and rapidly disperse in water to WO 99/55821 PG"T/IB99/00708 form a wash solution. In order to sink in water, a detergent tablet must have a density greater than 1000 g/1 and in order to disperse in water, a detergent tablet must be able to break up in water. However, when laundry tablets are made from 35 low bulk density detergents, such as those made by spray dried processes, wherein the detergent powder has a bulk density less than about 650 g/1, the problem frequently encountered is that the force required to compact the detergent powder into tablets having a density of at least 1000 g/1 is so high that the detergent tablets do not readily disperse in water. This problem is further escalated by the fact that 40 detergent powders made from spray dried processes tend to be more porous and sticky. Thus when these detergent powders are pressed into tablets having a density of at least 1000 g/1, the powder particles stick together and consequently the tablet does not readily break up and dissolve in water. Conversely, if the tablets made from low bulk density detergent powders are compacted using a lower force, they 45 generally disperse in water but at a slower rate because they have a density less than 1000 g/1 and thus tend to float in water before fully dispersing in water.
The above problem is usually not encountered when making detergent tablets from a detergent powder made by agglomeration processes because detergent powders made by agglomeration processes usually have a bulk density in a range of 50 about 700 g/1 to about 850 g/1 and consequently, the force required to compress the powder into a tablet having a density of at least 1000 g/1 is not so high.
Thus detergent tablets made by compacting detergent powders made from agglomeration process usually sink in water. However, agglomeration process detergents or "agglomerates", which inherently have higher density than spray dried process 55 detergents or "spray dried granules", generally exhibit slower dissolution rates in water, as compared to spray dried granules.
Thus the production of detergent tablets is a complex matter. It involves more than the mere selection of components or the compression of a particular detergent composition into a tablet. The tablet must be capable of withstanding the 60 shocks of packaging, handling and distribution without crumbling. In other words the tablet must be strong. But the tablet must also have a satisfactory rate of disintegration when immersed in water. The tablets known so far have generally shown too long a disintegration time, in favor of their strength, or they have had a very low strength, in favor of their shorter disintegration time.
65 It is highly desirable to have a laundry detergent tablet with a core which is formed by compressing a particulate material which has a detersive surfactant and a builder and wherein the particulate material has a bulk density less than 850 g/1 so that the detergent tablet formed by compressing such a particulate material not only sinks in water but also rapidly disintegrates and readily dissolves in water.
70 This kind of a tablet performance has heretofore not been available and this level of performance requires not only careful selection of the type of detergent that makes up the core, but also a carefully selected density range of the particulate detergent to improve the dissolution of the detergent. To achieve a particulate detergent bulk density within an optimal range, it is desirable to exploit not only the 75 benefits of using mixtures of spray dried granules and agglomerates but also processing the detergent particles in a manner so as to reduce their inherent porosity and bring that particle porosity within an optimally desired range, prior to the step of compacting that detergent particles into a non-particulate form. It is thus necessary to carefully tailor the particle porosity of the particulate detergent prior to 80 compaction. The present invention overcomes the problems as set forth above.
BACKGROUND ART
The prior art is replete with methods of forming tablets and coating tablets.
One approach has been to use acetate salt to improve the dissolution rate of detergents compressed in the form of tablets. EP-A-0002293, published on 13'"
June 85 1979, discloses detergent tablets containing hydrated salt. The preferred hydrate salt is a mixture of sodium acetate trihydrate and sodium metaborate tetrahydrate.
Another approach known in the art is to use effervescent aids to improve tablet disintegration. CA-A-2040307 discloses lundry detergent tablets comprising anionic surfactants mixed with sodium carbonate and citric acid.
90 As far as coated tablets are concerned, GB-A-0 989 683, published on 22nd April 1965, discloses a process for preparing a particulate detergent from surfactants and inorganic salts; spraying on water-soluble silicate; and pressing the detergent particles into a solid form-retaining tablet. Finally a readily water-soluble organic film-forming polymer (for example, polyvinyl alcohol) provides a coating to make 95 the detergent tablet resistant to abrasion and accidental breakage.
European publication, EP-A-0 002 293, published on 13th June 1979, discloses a tablet coating comprising hydrated salt such as acetate, metaborate, orthophosphate, tartrate, and sulphate. Another Euaopean publication, EP-A-0 144, published on 12th June 1996, also discloses laundry detergent tablets with 100 water-soluble coatings which may be organic polymers including acrylic/maleic co-polymer, polyethylene glycol, PVPVA, and sugar.
U.S. Patent No. 5,658,874, issued on Aug. 19, 1997 to Alan P. Davies et al.
and assigned to Lever Brothers Company, discloses a process for making tablets of a detergent composition comprising detergent active compound, detergency builder 1 OS and other ingredients, in which at least some particles of .the composition are individually coated with a material that functions as a binder and a disintegrant capable, when the tablet is immersed in water, for disrupting the structure of the tablet. However, this patent discloses the use of high molecular weight binders that generally lead to tablets that are more porous.

The invention meets the needs above by providing a process for producing a water-dispersible, non-particulate detergent product. Specifically, in one aspect of the present invention, the process includes the step of providing a low density particulate detergent composition having an infra-particle porosity in a range of from 115 about 10% to about 90% by volume. The process further includes the step of adding a liquid to the low density particulate detergent composition in an amount sufficient to reduce the infra-particle porosity by at least about 10%. The process then includes the step of compacting the low density particulate detergent composition having reduced infra-particle porosity by applying a pressure in an amount sufficient to 120 form the water-dispersible non-particulate detergent product having a density of at least about 1000 g/1.
In another aspect of the present invention, a rapidly water-dispersible non-particulate detergent product is disclosed. The product is formed by a process comprising the steps of providing low density detergent particles having an intra-125 particle porosity in a range of from about 5% to about 90% by volume, adding a liquid to the low density detergent particles in an amount sufficient to reduce the infra-particle porosity by at least about 10%, and compacting the low density detergent particles having the reduced infra-particle porosity, by applying a pressure in an amount sufficient to form the water-dispersible, non-particulate detergent 130 product having a density of at least about 1000 g/1.
In still another aspect of the present invention, a method of laundering soiled clothes includes the step of immersing said soiled clothes in an aqueous medium containing an effective amount of a non-particulate detergent product made by a process as set forth above.
135 In yet another aspect of the present invention, a process for producing a water-dispersible, non-particulate detergent product from a low density detergent composition is disclosed. The process includes the steps of providing spray dried detergent granules having a bulk density less than about 650 g/1. The process further include the step of providing agglomerated detergent particles having a bulk density 140 in a range of from about 700 g/1 to about 900 g/l. The process still further includes the steps of mixing the spray dried detergent granules and the agglomerated detergent particles to form a low density detergent composition, wherein the spray dried detergent granules are present in a range of from about 40% to about 80%
by weight of the low density detergent composition and the agglomerated detergent 145 particles are present in a range of from about 20% to about 60% by weight of the low density detergent composition. The process also includes the step of adding a liquid to the low density detergent composition in an amount sufficient to reduce said infra-particle porosity by at least about 10%, and compacting the low density detergent composition having the aforementioned reduced infra-particle porosity, by 150 applying a pressure in an amount sufficient to form the water-dispersible, non particulate detergent product having a density of at least about 1000 g/l.
In still another aspect of the present invention, a method of laundering fabric materials in a washing machine is provided. The method includes the steps of 155 providing a flexible porous bag adapted for receiving a non-particulate detergent WO 99/55821 PCT/iB99/00708 product, providing a non-particulate detergent product made according to the process described above, placing the non-particulate detergent product within the flexible porous bag, and placing the flexible porous bag containing the detergent product in the washing machine with the fabric materials to be washed. The flexible porous 160 bag is adapted for permitting entry of an aqueous washing medium through the bag, thereby dissolving the non-particulate detergent product placed therein, into the aqueous washing medium, and releasing a resultant wash solution from inside of the bag to outside of the bag and into the aqueous wash medium during a wash cycle.
DETAILED DESCRIPTION OF THE INVENTION
165 Process In the preferred embodiment of the present invention, the process includes the step of providing a low density particulate detergent composition having an infra-particle porosity desirably, in a range of from about 10% to about 90% by volume. Preferably, the porosity is in a range of from about 15% to about 170 70% by volume and most preferably, the porosity is in a range of from about 20% to about 65% by volume. This porosity is measured by a Mercury Porosimeter, which technique is well known to those skilled in the art and need not be described in any detail here.
The particulate detergent composition 175 The term "particulate" as used herein means forms such as powders, granules, particles, flakes and other similar particulate forms that are capable of being compacted into a more dense non-particulate form.
In particular for laundry tablets, detergent particles having ingredients such as builder and surfactant can be spray-dried in a conventional manner and then 180 compacted at a suitable pressure. The surfactants and builders normally provide a substantial part of the cleaning power of the tablet. The term "builder" is intended to mean all materials which tend to remove calcium ion from solution, either by ion exchange, complexation, sequestration or precipitation.
The particulate material used for making the detergent tablet provided in this 185 invention can be made by any particulation or granulation process. An example of such a process is spray drying (in a co-current or counter current spray drying tower) 5$21 PCT/IB99/00708 which typically gives "spray-dried" detergent granules having low bulk densities of 600g/1 or lower. Particulate materials of higher density can be prepared by granulation and densification in a high shear batch mixer/granulator or by a 190 continuous granulation and densification process (e.g. using Lodige~ CB
andlor Lodige~ KM mixers). Other suitable processes include fluid bed processes, compaction processes (e.g. roll compaction), extrusion, as well as any particulate material made by any chemical process like flocculation, crystallization sentering, etc. The individual particles can also be in any other form, such as for example, 195 particle, granule, sphere or grain.
The particulate materials may be mixed together by any conventional means, for example, a concrete mixer, Nauta mixer, ribbon mixer or any other.
Alternatively the mixing process may be carried out continuously by metering each component by weight on to a moving belt, and blending them in one or more 200 drums) or mixer(s). A liquid spray-on to the mix of particulate materials (e.g. non-ionic surfactants) may be carried out. Other liquid ingredients may also be sprayed on to the mix of particulate materials either separately or premixed. For example perfume and slurries of optical brighteners may be sprayed. A finely divided flow aid (dusting agent such as zeolites, carbonates, silicas) can be added to the 205 particulate materials after spraying the non-ionic, preferably towards the end of the process, to make the mix less sticky.
The detergent particles can be made by an agglomerate process comprising the steps of i) admixing one or more detergent surfactants, a perborate component and an 210 acid source and optionally other detergent ingredients to form a mixture;
and ii) agglomerating the mixture to form agglomerated particles or "agglomerates".
Typically, such an agglomeration process involves mixing an effective amount of powder, including the acid source, with a high active surfactant paste in 215 one or more agglomerators such as a pan agglomerator, a Z-blade mixer or more preferably in-line mixers, preferably two, such as those manufactured by Schugi (Holland) BV, 29 Chroomstraat 8211 AS, Lelystad, Netherlands, and Gebruder Lodige Maschinenbau GmbH, D-4790 Paderborn 1, Elsenerstrasse 7-9, Postfach 2050, Germany. Preferably a high shear mixer is used, such as a Lodige CB
(Trade 220 Name). Most preferably, a high shear mixer is used in combination with a low shear mixer, such as a Lodige CB (Trade Name) and a Lodige KM (Trade name) or Schugi KM (Trade Name). Optionally, only one or more low shear mixer are used.
Preferably, the agglomerates are thereafter dried and/ or cooled.
Another agglomeration process involves mixing of various components of 225 the final agglomorate in different stages, using an fluidized bed. For example, a preferred particulate detergent in accordance with the present invention can be agglomerated by addition, preferably by spraying on, of nonionic, anionic surfactants and optionally a wax, or mixtures thereof, to the acid source in powdered form and other optional ingredients. Then, additional components, including the 230 perborate bleach and optinally the alkali source or part thereof, can be added and agglomerated in one or more stages, thus forming the final agglomerate particle.
The agglomerates may take the form of flakes, prills, marumes, noodles, ribbons, but preferably take the form of granules. A preferred way to process the particles is by agglomerating powders (e.g. aluminosilicate, carbonate) with high 235 active surfactant pastes and to control the particle size of the resulting agglomerates within specified limits. Typical particle sizes are from 0.10 mm to 5.0 mm in diameter, preferably from 0.25 mm to 3.0 mm in diameter, most preferably from 0.40 mm to 1.00 mm in diameter. Typically, the "agglomerates" have a bulk density desirably ,of at least 700 g/1 and preferably, in a range of from about 700 g/1 to about 240 900 g/l.
A high active surfactant paste comprising a mix of, typically, from 50% by weight to 95% by weight, preferably 70% by weight to 85% by weight of surfactant, and optionally it can contain an appropriate acid source. The paste may be pumped into the agglomerator at a temperature high enough to maintain a pumpable 245 viscosity, but low enough to avoid degradation of the anionic surfactants used. An operating temperature of the paste of 50°C to 80°C is typical.
Such pastes and methods for making and processing such pastes is for example described in WO
93/03128. In an especially preferred embodiment of the present invention, the detergent particles made by agglomeration process have a bulk density of greater 250 than about 600 g/1 and the detergent is in the form of powder or a granulate.
In the preferred embodiment of the present invention, the particulate detergent composition is a mixture of spray dried process and agglomeration process detergents, such that the final bulk density of the detergent composition is in a range of desirably, no greater than about 900 g/1, more desirably, in a range of from about 255 600 g/1 to about 850 g/1, and preferably, in a range of from about 625 g/1 to about 725 g/1. These ranges of bulk density are desirable because if the bulk density of the particulate detergent from which the tablet is to be compressed is greater than about 900 g/l, then the solubility of the detergent tablet will be detrimentally affected. A
bulk density less than about 600 g/1 is undesirable because at values less than about 260 600 g/l, the amount of pressure required to form a detergent tablet having a density of at least 1000 g/1 is so high that the tablet will not break up easily in water and will not dissolve rapidly.
To achieve the desired bulk densities as. set forth above, the particulate detergent composition contains selected amounts of spray dried granules and 265 detergent agglomerates in an optimum proportion. In this regard, the composition comprises desirably from about 40% to about 80%, preferably from about 40% to about 60%, and more preferably from about 45% to about 55%, by weight, of spray dried. Desirably, the composition includes from about 20% to about 60%, preferably from about 40% to about 60%, and more preferably from about 45% to 270 about 55%, by weight, of agglomerates.
Addition of Liquid to reduce porosity of detergent particles In the preferred embodiment of the present invention, the process further includes the step of adding a liquid to the low density particulate detergent composition in an amount sufficient to reduce the infra-particle porosity by at least 275 about 10%. It is desirable to reduce the infra-particle porosity by at least about 10%, and preferably by at least 20%, because if the porosity reduction is less than about 10%, no appreciable dispersibility of the detergent tablet is expected.
Without being bound to a specific theory, it is theorized that the porosity reduction of the spray dried granules and agglomerates, and the resultant increase in particle density, WO 99/55821 PCT/iB99/00708 280 causes the agglomerates to harden while the spray dried granules remain relatively softer. When a pressure is applied to compact the detergent particle mixture into a tablet, for example, there is believed to me some mechanical interlocking between the hard agglomerated and the softer spray dried granules. The spray dried granules are believed to "flow" into the interstitial spaces between the particles, thereby 285 increasing the mechanical bonding between the particles upon the application of pressure. This results in the formation of a detergent tablet that is not only strong and can resist breakage, but also can disintegrate rapidly in water because the detergent particles do not "stick" together. Due to the mixture of spray dried granules and agglomerates in the composition, the dissolution rate of the detergent 290 tablet is also increased because of the faster solubility of spray dried particles in water.
Any liquid for reducing porosity can be used to carry out the invention, however non-Tonics are preferred as they also provide detergency benefits.
Suitable nonionic surfactants include compounds produced by the condensation of alkylene 295 oxide groups (hydrophilic in nature) with an organic hydrophobic compound, which may be aliphatic or alkyl aromatic in nature. The length of the polyoxyalkylene group which is condensed with any particular hydrophobic group can be readily adjusted to yield a water-soluble compound having the desired degree of balance between hydrophilic and hydrophobic elements. Other examples are nonionic 300 surfactants such as the polyethylene oxide condensates of alkyl phenols, e.g., the condensation products of alkyl phenols having an alkyl group containing from about 6 to 16 carbon atoms, in either a straight chain or branched chain configuration, with from about 4 to 25 moles of ethylene oxide per mole of alkyl phenol. Still other nonionics are the water-soluble condensation products of aliphatic alcohols 305 containing from 8 to 22 carbon atoms, in either straight chain or branched configuration, with an average of up to 25 moles of ethylene oxide per more of alcohol.
Polyhydroxy fatty acid amides may be produced by reacting a fatty acid ester and an N-alkyl polyhydroxy amine. The preferred amine for use in the present 310 invention is N-(Rl)--CH2(CH20H)4--CH2--OH, where R1 is typically a alkyl, e.g.

methyl group; and the preferred ester is a C 12-C20 fatty acid methyl ester.
Methods of manufacturing polyhydroxy fatty acid amides have been described in WO 92 6073, published on 16th Apr., 1992. This application describes the preparation of polyhydroxy fatty acid amides in the presence of solvents. In a highly preferred 31 ~ embodiment of the invention N-methyl glucamine is reacted with a C 12-C20 methyl ester. It also says that the formulator of granular detergent compositions may find it convenient to run the amidation reaction in the presence of solvents which comprise alkoxylated, especially ethoxylated (EO 3-8) C12-C14 alcohols (page 15, lines 27). This can directly yield nonionic surfactant systems which are preferred in the 320 present invention, such as those comprising N-methyl glucosamide and C 12-alcohols with an average of 3 ethoxylate groups per molecule. Nonionic surfactant systems, and granular detergents made from such systems have been described in WO 92 6160, published on 16th Apr., 1992. This application describes (example 15) a granular detergent composition prepared by fme dispersion mixing in an Eirich 325 RV02 mixer which comprises N-methyl glucosamide (10%), nonionic surfactant ( 10%). Both of these patent applications describe nonionic surfactant systems together with suitable manufacturing processes for their synthesis, which have been found to be suitable for use in the present invention.
Other nonionic surfactants which may be used as components of the 330 surfactant systems herein include ethoxylated nonionic surfactants, glycerol ethers, glucosamides, glycerol amides, glycerol esters, fatty acids, fatty acid esters, fatty amides, alkyl polyglucosides, alkyl polyglycol ethers, polyethylene glycols, ethoxylated alkyl phenols and mixtures thereof.
In the preferred embodiment, the liquid used is one of ionic surfactants, 335 anionic surfactants, water and polyethylene glycol, and mixtures thereof.
Preferably, the liquid is a nonionic surfactant, and more preferably, it is polyethylene glycol (PEG). Most preferably, the PEG has a molecular weight of less than about 1000 and in the best mode, the molecular weight of PEG is 200. In the preferred embodiment, PEG is added to the detergent composition in a range of from about 340 0.1 % to about 10% by weight and preferably about 5% by weight. In the preferred embodiment, the addition of PEG having a molecular weight of about 200 results in a porosity reduction in a range of 5% to 200%.
D~ r~~ent Material The starting dry detergent material of the present process preferably comprises 345 materials selected from the group consisting of carbonates, sulfates, carbonate/sulfate complexes, tripolyphosphates, tetrasodium pyrophosphate, citrates, aluminosilicates, cellulose-based materials and organic synthetic polymeric absorbent gelling materials.
More preferably, the dry detergent material is selected from the group consisting of aluminosilicates, carbonates, sulfates, carbonate/sulfate complexes, and mixtures 350 thereof. Most preferably, the dry detergent material comprise a detergent aluminosilicate builder which are referenced as aluminosilicate ion exchange materials and sodium carbonate.
The aluminosilicate ion exchange materials used herein as a detergent builder preferably have both a high calcium ion exchange capacity and a high exchange rate.
355 Without intending to be limited by theory, it is believed that such high calcium ion exchange rate and capacity are a function of several interrelated factors which derive from the method by which the aluminosilicate ion exchange material is produced. In that regard, the aluminosilicate ion exchange materials used herein are preferably produced in accordance with Corkill et al, U.S. Patent No. 4,605,509 (Procter &
360 Gamble), the disclosure of which is incorporated herein by reference.
Preferably, the aluminosilicate ion exchange material is in "sodium" form since the potassium and hydrogen forms of the instant aluminosilicate do not exhibit the as high of an exchange rate and capacity as provided by the sodium form.
Additionally, the aluminosilicate ion exchange material preferably is in over dried form so as to 365 facilitate production of crisp detergent agglomerates as described herein.
The aluminosilicate ion exchange materials used herein preferably have particle size diameters which optimize their effectiveness as detergent builders. The term "particle size diameter" as used herein represents the average particle size diameter of a given aluminosilicate ion exchange material as determined by conventional analytical 370 techniques, such as microscopic determination and scanning electron microscope (SEM). The preferred particle size diameter of the aluminosilicate is from about 0.1 micron to about 10 microns, more preferably from about 0.5 microns to about 9 microns. Most preferably, the particle size diameter is from about 1 microns to about 8 microns.
375 Preferably, the aluminosilicate ion exchange material has the formula Naz[(A102)z.(Si02)y]xH20 wherein z and y are integers of at least 6, the molar ratio of z to y is from about 1 to about 5 and x is from about 10 to about 264. More preferably, the aluminosilicate has the formula 380 Nal2[(A102)12.(Si02)12]xH20 wherein x is from about 20 to about 30, preferably about 27. These preferred aluminosilicates are available commercially, for example under designations Zeolite A, Zeolite B and Zeolite X. Alternatively, naturally-occurring or synthetically derived aluminosilicate ion exchange materials suitable for use herein can be made as described 385 in Krummel et al, U.S. Patent No. 3,985,669, the disclosure of which is incorporated herein by reference.
The aluminosilicates used herein are further characterized by their ion exchange capacity which is at least about 200 mg equivalent of CaC03 hardness/gram, calculated on an anhydrous basis, and which is preferably in a range from about 300 to 352 mg 390 equivalent of CaC03 hardness/gram. Additionally, the instant aluminosilicate ion exchange materials are still further characterized by their calcium ion exchange rate which is at least about 2 grains Ca++/gallon/minute/-gram/gallon, and more preferably in a range from about 2 grains Ca~/gallon/minute/-gram/gallon to about 6 grains Ca++/gallon/minute/-gram/gallon.
395 Additionally, those builder materials discussed previously as an optional coating agent can be used herein. These particular builder materials have the formula (Mx)i Cay (C03)z wherein x and i are integers from 1 to 15, y is an integer from 1 to 10, z is an integer from 2 to 25, Mi are cations, at least one of which is a water-soluble, and the equation Ei - 1-15(xi multiplied by the valence of Mi) + 2y = 2z is satisfied such that 400 the formula has a neutral or "balanced" charge. Additional details and examples of these builder materials have been set forth previously and are incorporated herein by reference. Preferably, these builder materials are selected from the group consisting of Na2Ca(C03)2, K2Ca(C03)2, Na2Ca2(C03)3, NaKCa(C03)2, NaKCa2(C03)3, K2Ca2(C03)3, and combinations thereof.
405 Adjunct Deter; e~t~redients The starting dry detergent material in the present process can include additional detergent ingredients and/or, any number of additional ingredients can be incorporated in the detergent composition during subsequent steps of the present process.
These adjunct ingredients include other detergency builders, bleaches, bleach activators, suds 410 boosters or suds suppressers, anti-tarnish and anticorrosion agents, soil suspending agents, soil release agents, germicides, pH adjusting agents, non-builder alkalinity sources, chelating agents, smectite clays, enzymes, enzyme-stabilizing agents and perfumes. See U.S. Patent 3,936,537, issued February 3, 1976 to Baskerville, Jr. et al., incorporated herein by reference.
415 Other builders can be generally selected from the various water-soluble, alkali metal, ammonium or substituted ammonium phosphates, polyphosphates, phosphonates, polyphosphonates, carbonates, borates, polyhydroxy sulfonates, polyacetates, carboxylates, and polycarboxylates. Preferred are the alkali metal, especially sodium, salts of the above. Preferred for use herein are the phosphates, 420 carbonates, C 10-1$ fatty acids, polycarboxylates, and mixtures thereof.
More preferred are sodium tripolyphosphate, tetrasodium pyrophosphate, citrate, tartrate mono- and di-succinates, and mixtures thereof (see below).
In comparison with amorphous sodium silicates, crystalline layered sodium silicates exhibit a clearly increased calcium and magnesium ion exchange capacity. In 425 addition, the layered sodium silicates prefer magnesium ions over calcium ions, a feature necessary to insure that substantially all of the "hardness" is removed from the wash water. These crystalline layered sodium silicates, however, are generally more expensive than amorphous silicates as well as other builders. Accordingly, in order to provide an economically feasible laundry detergent, the proportion of crystalline 430 layered sodium silicates used must be determined judiciously.
The crystalline layered sodium silicates suitable for use herein preferably have the formula NaMSix02x+1 ~YH20 wherein M is sodium or hydrogen, x is from about 1.9 to about 4 and y is from about 0 435 to about 20. More preferably, the crystalline layered sodium silicate has the formula NaMSi205.yH20 wherein M is sodium or hydrogen, and y is from about 0 to about 20. These and other crystalline layered sodium silicates are discussed in Corkill et al, U.S.
Patent No.
4,605,509, previously incorporated herein by reference.
440 Specific examples of inorganic phosphate builders are sodium and potassium tripolyphosphate, pyrophosphate, polymeric metaphosphate having a degree of polymerization of from about 6 to 21, and orthophosphates. Examples of polyphosphonate builders are the sodium and potassium salts of ethylene diphosphonic acid, the sodium and potassium salts of ethane 1-hydroxy-1, 445 1-diphosphonic acid and the sodium and potassium salts of ethane, 1,1,2-triphosphonic acid. Other phosphorus builder compounds are disclosed in U.S. Patents 3,159,581; 3,213,030; 3,422,021; 3,422,137; 3,400,176 and 3,400,148, all of which are incorporated herein by reference.
Examples of nonphosphorus, inorganic builders are tetraborate decahydrate 450 and silicates having a weight ratio of Si02 to alkali metal oxide of from about 0.5 to about 4.0, preferably from about 1.0 to about 2.4. Water-soluble, nonphosphorus organic builders useful herein include the various alkali metal, ammonium and substituted ammonium polyacetates, carboxylates, polycarboxylates and polyhydroxy sulfonates. Examples of polyacetate and polycarboxylate builders are 455 the sodium, potassium, lithium, ammonium and substituted ammonium salts of ethylene diamine tetraacetic acid, nitrilotriacetic acid, oxydisuccinic acid, mellitic acid, benzene polycarboxyiic acids, and citric acid.
Polymeric polycarboxylate builders are set forth in U.S. Patent 3,308,067, Diehl, issued March 7, 1967, the disclosure of which is incorporated herein by 460 reference. Such materials include the water-soluble salts of homo- and copolymers of aliphatic carboxylic acids such as malefic acid, itaconic acid, mesaconic acid, fumaric acid, aconitic acid, citraconic acid and methylene malonic acid. Some of these materials are useful as the water-soluble anionic polymer as hereinafter described, but only if in intimate admixture with the non-soap anionic surfactant.
465 Other suitable polycarboxylates for use herein are the polyacetal carboxylates described in U.S. Patent 4,144,226, issued March 13, 1979 to Crutchfield et al, and U.S. Patent 4,246,495, issued March 27, 1979 to Crutchfield et al, both of which are incorporated herein by reference. These polyacetal carboxylates can be prepared by bringing together under polymerization conditions an ester of glyoxylic acid and a 470 polymerization initiator. The resulting polyacetal carboxylate ester is then attached to chemically stable end groups to stabilize the polyacetal carboxylate against rapid depolymerization in alkaline solution, converted to the corresponding salt, and added to a detergent composition. Particularly preferred polycarboxylate builders are the ether carboxylate builder compositions comprising a combination of tartrate 475 rnonosuccinate and tartrate disuccinate described in U.S. Patent 4,663,071, Bush et al., issued May 5, 1987, the disclosure of which is incorporated herein by reference.
Bleaching agents and activators are described in U.S. Patent 4,412,934, Chung et al., issued November l, 1983, and in U.S. Patent 4,483,781, Hartman, issued November 20, 1984, both of which are incorporated herein by reference.
Chelating 480 agents are also described in U.S. Patent 4,663,071, Bush et al., from Column 17, line 54 through Column 18, line 68, incorporated herein by reference. Suds modifiers are also optional ingredients and are described in U.S. Patents 3,933,672, issued January 20, 1976 to Bartoletta et al., and 4,136,045, issued January 23, 1979 to Gault et al., both incorporated herein by reference.
485 Suitable smectite clays for use herein are described in U.S. Patent 4,762,645, Tucker et ai, issued August 9, 1988, Column 6, line 3 through Column 7, line 24, incorporated herein by reference. Suitable additional detergency builders for use herein are enumerated in the Baskerville patent, Column 13, line 54 through Column 16, line 16, and in U.S. Patent 4,663,071, Bush et al, issued May 5, 1987, both incorporated 490 herein by reference.
The non-particulate deter~entproduct The detergent tablets can be prepared simply by mixing the solid ingredients together and compressing the mixture in a conventional tablet press as used, for example, in the pharmaceutical industry.
495 The detergent tablets provided can be made in any size or shape. Prior to compaction, the detergent particles may be surface treated with a flow aid according to the present invention. The detergent tablets provided may be manufactured by using any compacting process, such as tabletting, briquetting, or extrusion, preferably tabletting. Suitable equipment includes a standard single stroke or a S00 rotary press (such as Courtoy~, Korch~, Manesty~, or Bonals~). As used herein, the term "non-particulate detergent product" includes physical shapes such as tablets, blocks, bars and the like.
Coating for non-particulate detergent product In one embodiment, the tablets are coated with a coating in order to provide 505 mechanical strength and shock and chip resistance to the compressed tablet core.
The tablets are coated with a coating that is substantially insoluble in water so that the tablet does not absorb moisture, or absorbs moisture at only a very slow rate.
The coating is strong so that moderate mechanical shocks to which the tablets are subjected during handling, packing and shipping result in no more than very low 510 levels of breakage or attrition. Further, the coating is preferably brittle so that the tablet breaks up when subjected to stronger mechanical shock. Furthermore it is advantageous if the coating material is dissolved under alkaline conditions, or is readily emulsified by surfactants. This avoids the deposition of undissolved particles or lumps of coating material on the laundry load. This may be important when the 515 coating material is completely insoluble (for example less than 1 g/1) in water.
As defined herein "substantially insoluble" means having a very low solubility in water. This should be understood to mean having a solubility in water at 25°C of less than 20 g/L, preferably less than 5 g/I, and more preferably less than 1 g/1. Water solubility is measured following the test protocol of ASTM E1148-87 520 entitled, "Standard Test Method for Measurements of Aqueous Solubility".
Suitable coating materials are fatty acids, adipic acid and C8-CI3 dicarboxylic acids, fatty alcohols, diols, esters and ethers. Preferred fatty acids are those having a carbon chain length of from C 12 to C22 and most preferably from C 18 to C22. Preferred dicarboxylic acids are adipic acid (C6), suberic acid (C8), 525 azelaic acid (C9), sebacic acid (C 10), undecanedioic acid (C 11 ), dodecanedioic acid (C 12) and tridecanedioic acid (C 13 ). Preferred fatty alcohols are those having a carbon chain length of from C 12 to C22 and most preferably from C 14 to C 18.
Preferred diols are 1,2-octadecanediol and 1,2-hexadecanediol. Preferred esters are tristearin, tripalmitin, methylbehenate, ethylstearate. Preferred ethers are 530 diethyleneglycol mono hexadecylether, diethyleneglycol mono octadecylether, diethyleneglycol mono tetradecylether, phenylether, ethyl naphtyl ether, 2 methoxynaphtalene, beta naphtyl methyl ether and glycerol monooctadecylether.
Other preferred coating materials include dimethyl 2,2 propanol, 2 hexadecanol, 2 octadecanone, 2 hexadecanone, 2, 15 hexadecanedione and 2 hydroxybenzyl 535 alcohol. The coating is a hydrophobic material having a melting point preferably of from 40 °C to 180 °C.
In the preferred embodiment, the coating can be applied in a number of ways.
Two preferred coating methods are a) coating with a molten material and b) coating with a solution of the material. In a), the coating material is applied at a temperature 540 above its melting point, and solidifies on the tablet. In b), the coating is applied as a solution, the solvent being. dried to leave a coherent coating. The substantially insoluble material can be applied to the tablet by, for example, spraying or dipping.
Normally when the molten material is sprayed on to the tablet, it will rapidly solidify to form a coherent coating. When tablets are dipped into the molten material and 545 then removed, the rapid cooling again causes rapid solidification of the coating material. Clearly substantially insoluble materials having a melting point below 40 °C are not sufficiently solid at ambient temperatures and it has been found that materials having a melting point above about 180 °C are not practicable to use.
Preferably, the materials melt in the range from 60 °C to 160 °C, more preferably 550 from 70 °C to 120 °C.
By "melting point" is meant the temperature at which the material when heated slowly in, for example, a capillary tube becomes a clear liquid. For most purposes, the coating forms from 1% to 10%, preferably from 1.5% to 5%, of the tablet weight.
555 Addition of flow aids In one embodiment, the process includes adding a flow aid to the particulate detergent composition in a range of from about 0.1% to about 25% by weight of the particulate detergent composition before compaction.
As used herein, the term "flow aids" means any material capable of being 560 deposited on to the surface of detergent particles so as to reduce the stickiness of the detergent particles and allow them to flow freely. Flow aids could include porous carrier particles selected from the group consisting of amorphous silicates, crystalline nonlayer silicates, layer silicates, calcium carbonates, calcium/sodium carbonate double salts, sodium carbonates, clays, zeolites, sodalites, alkali metal 565 phosphates, macroporous zeolites, chitin microbeads, carboxyalkylcelluloses, carboxyalkylstarches, cyclodextrins, porous starches and mixtures thereof.
The preferred flow aids are zeolite A, zeolite X, zeolite Y, zeolite P, zeolite MAP and mixtures thereof. The term "zeolite" used herein refers to a crystalline aluminosilicate material. The structural formula of a zeolite is based on the crystal 570 unit cell, the smallest unit of structure represented by Mmln[(A102)m(Si02)y]~xH20 where n is the valence of the canon M, x is the number of water molecules per unit cell, m and y are the total number of tetrahedra per unit cell, and y/m is 1 to 100.
Most preferably, y/m is 1 to 5. The cation M can be Group IA and Group IIA
575 elements, such as sodium, potassium, magnesium, and calcium.
In the preferred embodiment of the present invention, the flow aid is added in an amount in a range, desirably, from about 0.1% to about 25% by weight of the particulate detergent, more desirably from aboutl % to about 15% by weight, preferably from about 1 % to about I 0% by weight, and most preferably in an 580 amount of about 5% by weight. It is undesirable to add more than 25% by weight of the flow aid because too excessive a force would be needed to make the detergent particles to stick together and stay in a particulate form. Flow aid addition in an amount less than about 0.1 % by weight is also undesirable because little or no reduction in the stickiness of the detergent particles would occur, which 585 upon compression into a particulate form would cause the resultant detergent tablet to not disintegrate readily when placed in water in a washing machine.
In one embodiment, the flow aids have a perfume adsorbed on their surface before being deposited on the detergent particles. Preferably, the flow aids are zeolites preferably containing less than about 20% desorbable water, more 590 preferably less than about 8% desorbable water, and most preferably less than about S% desorbable water. Such materials may be obtained by first activating/dehydrating by heating to about 1 SO to 350 C, optionally with reduced pressure (from about 0.001 to about 20 Torr). After activation, the perfume is slowly and thoroughly mixed with the activated zeolite and, optionally, heated to 595 about 60°C for up to about 2 hours to accelerate absorption equilibrium within the zeolite particles. The perfume/zeolite mixture is then cooled to room temperature and is in the form of a free-flowing powder. The term "perfume" is used to indicate any odoriferous material which is subsequently released into the aqueous bath and/or onto fabrics contacted therewith. The perfume will most often be 600 liquid at ambient temperatures. A wide variety of chemicals are known for perfume uses, including materials such as aldehydes, ketones and esters. More commonly, naturally occurring plant and animal oils and exudates comprising complex mixtures of various chemical components are known for use as perfumes.
The perfumes herein can be relatively simple in their compositions or can 605 comprise highly sophisticated complex mixtures of natural and synthetic chemical components, all chosen to provide any desired odor. Typical perfumes can comprise, for example, woody/earthy bases containing exotic materials such as sandalwood, civet and patchouli oil. The perfumes can be of a light floral fragrance, e.g., rose extract, violet extract, and lilac. The perfumes can also be 610 formulated to provide desirable fruity odors, e.g., lime, lemon, and orange. Any chemically compatible material which exudes a pleasant or otherwise desirable odor can be used in the perfumed compositions herein. Perfumes also include pro-fragrances such as acetal pro-fragrances, ketal pro-fragrances, ester pro-fragrances (e.g., digeranyl succinate), hydrolyzable inorganic-organic pro-fragrances, and 615 mixtures thereof. These pro-fragrances may release the perfume material as a result of simple hydrolysis, or may be pH-change-triggered pro-fragrances (e.g., pH drop) or may be enzymatically releasable pro-fragrances.
In the preferred embodiment, the amount of perfume adsorbed on the carrier material, such as zeolite for example, is preferably in the range of about 0.1 % to 620 about 50% by weight, more preferably in the range of about 0.5% to about 25% by weight, and most preferably in the range of about 1 % to about 15% by weight of zeolite powder.
Comnaction of particulate deter~~ent to form non-particulate deterg-ent product In the preferred embodiment, the process still further includes the step of 625 compacting the particulate detergent composition having at least 10%
reduced porosity by applying a pressure in an amount sufficient to form the water-dispersible, non-particulate detergent product having a density of at least about 1000 g/l. It is desirable to form a detergent tablet that has a density of at least about 1000 g/1 so that the tablet will sink in water. If the density of the detergent 630 tablet is less than about 1000 g/1, the tablet will float when placed in the water in a washing machine and this will detrimentally reduce the dissolution rate of the tablet in the water. It is desirable to apply at least that much pressure as is sufficient to compress the particulate detergent material to form a tablet having a density of at least about 1000 g/l. Too little a pressure will result in a compressed 635 tablet with a density less than about 1000 g/1.
EXAMPLE A
Detergent tablets are formed from detergent particles having at least 10%
reduced porosity before such particles are compressed into a tablet form, according to the following composition:
640 Table A.1 In~eredients % by weig-ht Detergent particles 95.00 polyethylene glycol (MW=200) 5.00 645 Total 100.00 The detergent particles have the following composition:

Table A.2 Particulate deter eg nt Ingredients % by weight C ,z_,6 linear alkylbenzene sulfonate 8.80 650 C ,4_,5 alkyl sulfate/C ,4_,5 alkyl 8.31 ethoxy sulfate C ,2_,3 alkyl ethoxylate 1.76 polyacrylate (MW=4500) 2.40 polyethylene glycol (MW=4000) 0.96 sodium sulfate 8.40 655 aluminosilicate 21.28 sodium carbonate 16.80 protease enzyme 0.32 sodium perborate monohydrate 2.08 lipase enzyme 0.17 660 cellulase enzyme 0.08 NOBS extrudate 4.80 citric acid monohydrate 2.25 sodium bicarbonate 2.75 sodium acetate 15.00 665 free water 1.60 other minor ingredients (perfume etc.) 2.24 Total 100.00 670 The detergent tablet formed is coated with a coating according to the following composition:
Table A.3 In redient % by wei ht Detergent tablet having PEG 91.10 675 Coating:
dodecanedioc acid 8.00 carboxymethyl cellulose 0.90 Total 100.00 680 Optionally, a flow aid (zeolite) is also added to the particulate detergent composition in about 5% by weight of the detergent and mixed by one of various methods, such as agitation for example.
The tablets are formed by compressing the tablet ingredients in a cylindrical die having a diameter of 55 mm using a laboratory press having a trade name 685 Carver Model 3912, to form a tablet having a height of 20 mm. The formed tablets were then coated with the protective coating by dipping the tablet into a molten bath of the coating for about 3 seconds. The molten coating bath is maintained at a temperature of about 145 degrees centigrade.
The term "NOBS extrudate" as used herein, is an acronym for the chemical 690 sodium nonanoyloxybenzene sulfonate, commercially available from Eastman Chemicals, Inc. The carboxymethyl cellulose used in the above example is commercially available from Metsa-Serla and sold under the trade name, Nymcel ZSB-16.
Test for determining dispersibility in water 695 The following method is used to measure the rate of dispersion (ROD) of a detergent tablet expressed as percentage residue remaining after "t" minutes, where "t" is 3, 5 and 10 minutes. The equipment used includes a 5000 ml glass beaker, a stopwatch with alarm, an electrical stirrer with variable speed IKA RW 20 DZM
or equivalent, a cage made of perforated metal gauze (diameter 52 mm, height 40 mm 700 having 16 apertures each of about 2.5 mm square) and a weigh scale with accuracy of 0.1 grams.
The method includes the following steps: The beaker is filled with 4000 ml (+/-50 ml) of distilled water at 20 °C (+/- 1 °C ). The cage tester is mounted in the electrical stirrer. A tablet with a known weight is placed in the cage and the cage is 705 connected to the stirrer. The cage is submerged in the water with the cage suspended about half way down the beaker and the stirrer is started at a fixed speed of 80 rpm. The stopwatch is started. The stirrer is stopped after 3 minutes.
The cage is lifted out of the water and the tablet residue remaining in the cage is weighed. The % residue is calculated with the following equation:

residue = Tablet weight after "t" minutes x 100 Initial tablet weight The remaining tablet is placed back in the cage and the process is repeated for an additional 2 and 5 minutes to give yield data for tablet dispersion after 3, 5 and 10 715 minutes.
As used herein, the term "dispersibility in water" is defined as a measure of the % residue, as calculated above, after 3 minutes. In other words, for example, a detergent tablet which has 5% by weight less residue than another detergent tablet would be deemed to have 5% greater dispersibility in water.
720 It is unexpectedly and surprisingly discovered that the non-particulate detergent product, e.g., a detergent tablet, has at least about S% greater dispersability in water as compared to another non-particulate detergent product having a density of at least about 1000 g/1 but not having nonionic liquid added to the detergent composition according to this invention.
725 In another embodiment of the present invention, a method of laundering fabric materials in a washing machine includes the steps of providing a flexible porous bag adapted for receiving a non-particulate detergent product, providing a non-particulate detergent product, placing the non-particulate detergent product within the flexible porous bag, and placing the flexible porous bag containing the 730 detergent product in the washing machine with the fabric materials to be washed.
The flexible porous bag is permeable to water and to the washing medium and is thus adapted for permitting entry of an aqueous washing medium through the bag, thereby dissolving the non-particulate detergent product placed therein, into the aqueous washing medium, and releasing a resultant wash solution from inside of the 735 bag to outside of the bag and into the aqueous wash medium during a wash cycle.
The flexible porous bag is made of a material capable of retaining the non-particulate detergent product without allowing it to pass through until the detergent product has dissolved in the washing medium. The bag is also made of a material capable of withstanding the temperatures of washing laundry in a washing machine.
740 The process of the invention may be applied not only to non-particulate detergents but also to any non-particulate product which is active during washing, such as, for example; bleaching agents, such as agents releasing chlorine or active oxygen (peroxygen compounds), bleaching catalysts, bleaching activators, bactericides, foam regulators, whiteners, agents preventing the re-deposition of soil, enzymes, 745 softeners, agents capable of removing grease stains or other constituents having no direct effect on the soiling but capable of taking part in the laundry washing process.
The flexible bag may be made from any material which offers a sufficient resistance to water, such as a woven or non-woven material produced from natural or synthetic fibers. For example, the bag is formed of pure cotton either in the form of 750 a fabric with a mesh opening of less than about 0.5 mm or in the form of a non-woven article with openings having a size in a range of from about 0.5 mm to about 0.8 mm.
Accordingly, having thus described the invention in detail, it will be obvious to those skilled in the art that various changes may be made without departing from 755 the scope of the invention and the invention is not to be considered limited to what is described in the specification.

Claims

WHAT IS CLAIMED IS:

1. A process for producing a water-dispersible, non-particulate detergent product from low density detergent particles, characterized by the steps of:
(a) providing low density detergent particles having an intra-particle porosity in a range of from 5% to 90% by volume;
(b) adding a liquid to said low density detergent particles in an amount sufficient to reduce said intra-particle porosity by at least 10%; and (c) compacting said low density detergent particles having said reduced intra-particle porosity, by applying a pressure in an amount sufficient to form said water-dispersible, non-particulate detergent product having a density of at least 1000 g/l.

2. The process of claim 1 wherein said low density detergent particles of step (a) have an intra-particle porosity in a range of from 10% to 80% by volume.

3. The process of any of claims 1-2 wherein said low density detergent particles of step (a) have a bulk density no less than 400 g/l.

4. The process of any of claims 1-3 wherein said low density detergent particles of step (a) have a bulk density in a range of from 400g/l to 850g/l.

5. The process of any of claims 1-4 wherein said liquid is a nonionic surfactant and is added to said low density detergent particles in an amount sufficient to reduce said intra-particle porosity by at least 20%.

6. The process of any of claims 1-5 wherein said liquid is added in an amount in a range of from 0.1 % to 10% by weight of said low density detergent particles.

7. The process of any of claims 1-6 wherein said liquid is selected from the group consisting of nonionic surfactants, anionic surfactants, water, polyethylene glycol, and mixtures thereof.

8. The process of any of claims 1-7 wherein said liquid is a nonionic surfactant.

9. The process of any of claims 1-8 wherein said liquid is polyethylene glycol having a molecular weight less than 1000.

10. The process of any of claims 1-9 wherein said water-dispersible, non-particulate detergent product has at least 5% greater dispersability in water as compared to a non-particulate detergent product having a density of at least 1000 g/l but not having said liquid added to said low density particulate detergent composition per step (b).

11. A rapidly water-dispersible non-particulate detergent product formed by a process characterized by the steps of:
(a) providing low density detergent particles having an intra-particle porosity in a range of from 5% to 90% by volume;
(b) adding a liquid to said low density detergent particles in an amount sufficient to reduce said intra-particle porosity by at least 10%; and (c) compacting said low density detergent particles having said reduced intra-particle porosity, by applying a pressure in an amount sufficient to form said water-dispersible, non-particulate detergent product having a density of at least 1000 g/l.

12. A method of laundering soiled clothes characterized by the step of immersing said soiled clothes in an aqueous medium containing an effective amount of a non-particulate detergent product made by a process according to any of claims 1-11.

13. A process for producing a water-dispersible, non-particulate detergent product from a low density detergent composition, characterized by the steps of:
(a) providing spray dried detergent granules having a bulk density less than 650 g/l;

(b) providing agglomerated detergent particles having a bulk density in a range of from 700 g/l to 900 g/l;
(c) mixing said spray dried detergent granules and said agglomerated detergent particles to form a low density detergent composition, wherein said spray dried detergent granules are present in a range of from 40% to 80% by weight of said low density detergent composition and said agglomerated detergent particles are present in a range of from 20% to 60% by weight of said low density detergent composition;
(d) adding a liquid to said low density detergent composition in an amount sufficient to reduce said intra-particle porosity by at least 10%; and (e) compacting said low density detergent composition having said reduced intra-particle porosity, by applying a pressure in an amount sufficient to form said water-dispersible, non-particulate detergent product having a density of at least 1000 g/l.

14. A method of laundering fabric materials in a washing machine, characterized by the steps of:
providing a flexible porous bag adapted for receiving a non-particulate detergent product;
providing a non-particulate detergent product made by a process according to any of claims 1-13;
placing said non-particulate detergent product within said flexible porous bag;
placing said flexible porous bag containing said detergent product in said washing machine with said fabric materials to be washed; and said flexible porous bag being adapted for permitting entry of an aqueous washing medium through said bag, thereby dissolving said non-particulate detergent product placed therein, into said aqueous washing medium, and releasing a resultant wash solution from inside of said bag to outside of said bag into said aqueous wash medium during a wash cycle.