Classifications

• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D9/00—Compositions of detergents based essentially on soap
  • C11D9/007—Soaps or soap mixtures with well defined chain length
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D10/00—Compositions of detergents, not provided for by one single preceding group
  • C11D10/04—Compositions of detergents, not provided for by one single preceding group based on mixtures of surface-active non-soap compounds and soap
  • C11D10/042—Compositions of detergents, not provided for by one single preceding group based on mixtures of surface-active non-soap compounds and soap based on anionic surface-active compounds and soap
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D17/00—Detergent materials or soaps characterised by their shape or physical properties
  • C11D17/0047—Detergents in the form of bars or tablets
  • C11D17/006—Detergents in the form of bars or tablets containing mainly surfactants, but no builders, e.g. syndet bar
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/02—Anionic compounds
  • C11D1/12—Sulfonic acids or sulfuric acid esters; Salts thereof
  • C11D1/29—Sulfates of polyoxyalkylene ethers
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/66—Non-ionic compounds
  • C11D1/72—Ethers of polyoxyalkylene glycols
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/66—Non-ionic compounds
  • C11D1/722—Ethers of polyoxyalkylene glycols having mixed oxyalkylene groups; Polyalkoxylated fatty alcohols or polyalkoxylated alkylaryl alcohols with mixed oxyalkylele groups
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/88—Ampholytes; Electroneutral compounds
  • C11D1/90—Betaines

Definitions

• the present invention relates to toilet soap bars, particularly to mild toilet soap bars comprising blends of soap with one or more coactives.
• soap bars have been manufactured from fats by conversion of triglyceride components of fats into fatty acids and the formation of these 'soaps' into bars.
• the longer chain fatty acid soaps particularly the less expensive C16 and C18 soaps (as obtained from tallow and palm oil) provide structure in the finished soap bars and prevent or retard disintegration of the soap bar on exposure to water.
• the more expensive, shorter chain, lauric fat-derived, ie. lauric acid and other soluble soaps (as obtained from coconut and palm kernel oil) contribute the lathering properties of the overall composition.
• a general problem in the formulation of bar soaps has been that of finding a balance between providing structure (as obtained from the cheaper component) and maintaining lathering properties (as obtained from the more costly component) at a practical overall cost.
• the coconut and palm kernel fats are particularly rich in the C10-C14 saturated fatty acids, particularly fatty acid residues derived from lauric acid itself.
• these fats containing saturated, relatively short chain fatty acids will be referred to hereinafter as the lauric fats.
• This definition includes the palm kernel, babassu or macauba oils as mentioned above.
• tallow and palm oil per se are an industrial source of non-lauric fats, especially those containing C16 and C18 fatty acid residues: both saturated and unsaturated residues being present in almost equal quantities.
• the C16 and C18 fatty acids, together with the longer chain fatty acid are referred to herein as nonlauric fats.
• iodine value A standard measure of the degree of saturation of a fatty acid residue, or more usually of a blend of fats or fatty acids, is the so-called iodine value.
• the iodine value of a fatty acid residue is determined by the ability of the residue to bind iodine expressed in MoleS. Iodine binds to unsaturated fatty acids in proportion to the extent of the unsaturation and does not bind to saturated fats. Consequently, saturated fats have low iodine values, mono unsaturated fats bind around 100 Mole % iodine and have iodine values ('IV') of around 100.
• soap bars contain from 90-50% fatty acid soaps obtained from tallow (ie. non-lauric fats) and 10-50% of fatty acid soaps obtained from coconut (ie. lauric fats).
• tallow ie. non-lauric fats
• coconut ie. lauric fats
• most commercial soap formulations comprise 80% tallow and 20% coconut oil.
• tallow is unacceptable other oils and fats, such as palm oil, replace tallow.
• compositions containing fatty acid soap are harshness, a property which is determined by a number of tests as will be elaborated upon hereafter.
• Known solutions to the problem of harshness include reduction of the level of soap present and replacement of the balance of the composition by so-called co-actives.
• a recognised problem engendered by the presence of co-actives is a loss of product structure in the resulting soap bars.
• GB 2182343-A (Procter & Gamble) discloses toilet soaps comprising a fatty acid soap, a synthetic surfactant co-active and a water soluble polymer.
• a fatty acid soap a synthetic surfactant co-active
• a water soluble polymer a water soluble polymer
• EP 363215 discloses the production of toilet soap bars from soap and an ethoxylated surfactant co-active.
• This soap composition needs to be dried to below a critical 5%wt moisture content in order to harden the material sufficiently for processing into bar form using conventional soap making/forming equipment.
• This drying step requires additional equipment in the form of batch drying trays to be used prior to soap finishing.
• EP 311343 (Procter & Gamble) discloses the combined use of a beta-crystalline phase, an ethoxylated non-ionic surfactant co-active and a water soluble polymer. As described above, these compositional modifications require modification of the soap processing line to provide for the energetic working needed to form the beta-crystalline phase.
• the present invention provides such a composition and subsists in the use of relatively more highly saturated long chain soaps, ie. relatively less unsaturated long chain soaps than in conventional soap compositions. It is believed that the removal of soluble non-lauric fatty acid soaps is particularly advantageous in improving the soap-structuring properties to an extent such that higher levels of co-actives than are conventionally used may be incorporated in the soap composition without the need for special processing.
• a first aspect of the present invention comprises the use, as a structuring agent, of insoluble non-lauric fatty acid soaps, having a low iodine value, in the preparation of a soap bar containing one or more synergistic mildness agents.
• lauric acid soaps promote lathering and are characterised by a fatty acid composition containing a high proportion, particularly 65-80% on fatty acid content, of C10-C14 saturated acids.
• suitable sources of lauric fatty acids include:- coconut oil/fatty acid, palm kernel oil/fatty acid, babassu oil/fatty acid, macauba oil/fatty acid and mixtures thereof.
• the fats and fatty acids derived from coconut are preferred due to availability.
• Suitable non-lauric soaps are those rich in saturated fatty acids having a chain length greater than C14.
• Sources of such fatty acids include animal fats/fatty acids, eg. tallow and lard and the fatty acid derived therefrom, and also vegetable derived oils, particularly fats/fatty acids rich in palmitic and stearic acid such as palm oils and fractions thereof.
• fatty acids are derived from oil-sources yielding fatty acids with a high degree of unsaturation, such as soya bean oil, sunflower oil, rice bran oil, linseed oil, rapeseed oils, ground nut oil, marine oils and the like
• the oil stocks are preferably hardened or fractionated to yield partially or fully hardened fatty acid mixtures and or stearines.
• the fats and fatty acids derived from tallow are preferred except where nut-oil or other vegetable substitutes are employed for cultural reasons.
• the preferred upper limit of the lauric acid soaps is about 60%, for reasons of economy.
• the iodine value of the non-lauric soaps ranges from 10 to 45, is more preferably 20 to 40, and most preferably in the range 25 to 40.
• the iodine value of the non-lauric soaps is measured at around 48 (similar to the quoted value for pure tallow), it can therefore be seen that the non-lauric fats of the compositions of the present invention are, in general, more saturated than those employed in conventional soap making.
• compositions according to the present invention the ratio of saturated to unsaturated fatty acids in the non-lauric soaps has been shifted in favour of the saturated fatty acids.
• This can be accomplished by the addition of saturates to the soap blend or the removal or unsaturates. It is particularly preferable that a relative increase in the level of saturates is accomplished by the removal of oleic soaps.
• the oleics are the soluble C18:1 (oleic) and C18:2 (linoleic) soaps in tallow and palm and removal of these increases the overall saturate content.
• the iodine value of the soap blend will be less than 35 taking into account both lauric and non-lauric components.
• the composition further comprises at least one synthetic anionic active at a level of not more than 20%wt, preferably at a level of not more than 10%wt, most preferably at a level of not more than 6%wt on the total active content of product.
• the overall soluble active inventory should be in the range 50-70%wt, based on a normalised total active content of 100%wt and classing saturated soaps with a carbon chain length of less than 16, unsaturated soaps, synthetic anionic actives and synergistic mildness actives within the soluble active component inventory.
• the synergistic mildness active is selected from the group consisting of non-ionic surfactants, amphoteric surfactants and mixtures thereof.
• the synergistic mildness active should be present at a level of at least 5%wt of the total active level.
• Particularly useful compositions comprise 5-25%wt, preferably 8-20%wt, more preferably 9-18%wt of synergistic mildness active on total actives.
• Suitable non-ionic surfactants include:- polyethoxylated alcohols, polyethoxylated alkyl phenols, alkyl polyglycosides, sorbitan esters, polysorbates, alkanolamides, poloxamers, and mixtures thereof.
• Preferred amongst the non-ionic surfactants are polyethoxylated alcohols, particularly tallow ethoxylates
• the preferred tallow ethoxylates have an average alkyl chain length of 10-20 carbons and an average ethoxylate content of 3-20 units.
• Suitable amphoteric surfactants include:- amine oxides, aminomides, betaines, amido betaines and sulphobetaines, and mixtures thereof. Cocoamidpropyl betaines and tegobetaines are particularly preferred due to their low potential nitrosamine-precursor content.
• the composition preferably comprises one or more synthetic anionic actives.
• Suitable synthetic anionic actives include:- alkyl sulphates, alkyl ether sulphates, alpha-olefin sulphonates, fatty isethionates, alkyl glyceryl ether sulphonates, mono-alkyl glyceryl sulphates, alkyl sarcosinates, alkyl taurides, alkyl sulphosuccinates, alkyl phosphates, and mixtures thereof.
• Preferred amongst the anionic actives are sodium lauryl ether sulphate (SLES), alpha-olefin sulphonates and sodium fatty isethionates.
• Sodium lauryl ether sulphate (SLES) is particularly preferred.
• compositions according to the present invention have a 'lathering ratio' greater than 0.56, preferably greater than 0.6, more preferably greater than 0.8.
• the lathering ratio is defined as the sum of the saturated soaps with carbon chain lengths less than 16 plus the synthetic anionic actives divided by the sum of the unsaturated soaps plus the synergistic mildness actives.
• the synergistic mildness actives can be either non-ionic surfactants, amphoteric surfactants and mixtures thereof.
• the ratio L/LL is about 0.45.
• the total water content of the soap bar should be in the range 8-20%wt of the soap bar, preferably 9-17%wt, more preferably 10-16%wt.
• the most preferred level of water in the final bar is a normal water content for soap bars (around 12%) hence conventional driers can be used to achieve this level.
• the salt content of the bars can vary. In practice the salt level will lie between 0 and 1.5%. Some or all of this salt can be residue from the saponification processes typically employed in soap making, as is known in the art. It is also known that the level of salt can have some slight influence on the eventual hardness of the product. This variation modifies the hardness of the soap bars and can be used to control the final hardness within production limits. It is preferred that the salt content lies between 0.2-0.8 wt%.
• compositions according to the present invention obey all the formulation rules given above: ie these blends comprise:
• a further aspect of the present invention provides a process for the manufacture of soap bars from neat soap which comprises the steps of:
• drying can precede the combination of ingredients or can follow the combination of ingredients.
• the combination of ingredients takes place during the drying process, ie. after the completion of a first drying stage, eg. after the heat exchangers but before the vacuum drying step.
• finishing step (c) comprises the conventional steps of milling, plodding and stamping.
• the fat charge was saponified as for conventional soap-making and washed/fitted to produce a neat soap at >70°C. This material was then dried via conventional flash vacuum drying equipment, with the synergistic mildness actives being injected into the process stream prior to passage of the process stream through heat exchangers.
• the optional synthetic anionic active(s) were injected into the process stream after the heat exchangers but prior to the drying chamber. Subsequent processing of the process stream was via conventional milling/plodding/stamping.
• the fat charge was saponified as for conventional soap and washed/fitted to produce a neat soap at >70°C as in the method of process example 1.
• This material is then dried via conventional flash drying equipment, with the synergistic mildness actives and optional synthetic anionic actives being injected at the same time either prior to or immediately after passage of the process stream through the heat exchangers. Subsequent processing of the process stream was via the conventional process operations of milling/plodding/stamping.
• the fat charge was saponified as for conventional soap and washed/fitted to produce a neat soap at >70°C as in example 1.
• the synergistic mildness agent(s) were added directly to this neat soap to produce a pumpable mix.
• the optional synthetic anionic active(s) were injected into this mix either before or after the heat exchangers and prior to a conventional drying step as in process example 1.
• soap bars were manufactured from the feedstocks listed below in product examples 1-13 as shown in Table 1 below. All ratios are given as ratios of wt% on total active. Process example 3 was found to be particularly advantageous in practice. In addition to the components mentioned below the process was conducted with conventional levels of further soap ingredients such as water, perfumes and colours.
• Example 1 is a control example in which conventional soap having a ratio of 80-parts conventional non-laurics to 20-parts laurics was employed.
• the iodine value of the nonlauric component of this blend was 48, a typical value for tallow. It can be seen that the Zein value of this composition was determined at 0.72. This result is to be expected of current toilet soap bars. Lower Zein values indicate milder products.
• Examples 2-10 relate to embodiments of the present invention in which hardened tallow (indicated as 'HT'), a non-ionic surfactant (indicated as 'Non') and coconut oil (indicated as 'CNO') were employed as the components of the fat charge.
• 'HT' hardened tallow
• 'Non' non-ionic surfactant
• 'CNO' coconut oil
• the iodine values of the non-lauric fats range from 1-28: this is indicative of the increased degree of saturation of the non-lauric fats.
• Zein value of the products prepared with these compositions ranged from 0.50 to 0.58, indicating a positive benefit as regards reduced harshness.
• the non-ionic surfactant used in the examples is Empilan KM20 unless otherwise indicated.
• sodium lauryl ethyl sulphate (indicated as 'SLES') a synthetic anionic, was incorporated into the composition by one of the methods discussed above.
• the addition level of SLES varied in the range 6-12% on total active.
• the presence of SLES or other synthetic anionics is optional in embodiments of the present invention. It can be seen that the Zein value of the products prepared with these compositions ranged from 0.44-0.45 indicating a further benefit as regards reduced harshness.
• the resulting soap bars had a hardness similar to that of conventional soap bars and had similar in-use properties with respect to wear-rate and mush formation.
• the soaps exhibited improved creaminess and a reduced Zien harshness.
• Examples 14-16 illustrate that soap bars according to the present invention can be manufactured with levels of solubles higher than those found in the control. It will be noted that the Iodine Value of these compositions (as defined below) is lower than that of the control and that the Zein value (see example 16) indicates a reduction in the harshness of the product as compared with the control.
• Examples 17-21 illustrate how soap bars containing SLES can be manufactured with higher levels of solubles than those found in the control.
• the Zein value indicates a reduction in the harshness of the product as compared with the control.
• Table 2 as presented below illustrates the present invention by means of comparative examples in which the soluble soap component inventory as defined above falls in the range 50-70% wt, ie. the preferred range of the present invention, but the lathering ratio as defined above are below the preferred lower limit of 0.56. In addition to the values tabulated in Table 1, lather volumes have been indicated.
• the non-ionic detergent employed was Empilan KM20.
• compositions having a low lathering ratio exhibit poor lathering performance, as demonstrated by the low lather volumes.
• Examples 14-17 are reproduced in the table with lather performance indicated. It can be seen that the embodiments of the invention have acceptable lather volumes, in all cases better than the control.
• Table 3 provides further examples of the present invention in which alternative mildness agents have been employed. In all cases it can be seen that the Zein harshness is improved as compared with a conventional soap bar (example 1).

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• Chemical & Material Sciences (AREA)
• Life Sciences & Earth Sciences (AREA)
• Engineering & Computer Science (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Oil, Petroleum & Natural Gas (AREA)
• Wood Science & Technology (AREA)
• Organic Chemistry (AREA)
• Detergent Compositions (AREA)
• Fats And Perfumes (AREA)
• Agricultural Chemicals And Associated Chemicals (AREA)
• Sanitary Thin Papers (AREA)

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Citations (4)

• 1992
  • 1992-10-08 NZ NZ244655A patent/NZ244655A/en unknown
  • 1992-10-08 CA CA002080154A patent/CA2080154C/fr not_active Expired - Lifetime
  • 1992-10-12 MY MYPI92001835A patent/MY108400A/en unknown
  • 1992-10-12 EP EP92309271A patent/EP0537964B1/fr not_active Expired - Lifetime
  • 1992-10-12 DE DE69223904T patent/DE69223904T2/de not_active Expired - Lifetime
  • 1992-10-12 ES ES92309271T patent/ES2110476T3/es not_active Expired - Lifetime
  • 1992-10-13 MX MX9205863A patent/MX9205863A/es unknown
  • 1992-10-13 BR BR929203964A patent/BR9203964A/pt not_active IP Right Cessation
  • 1992-10-14 JP JP4276308A patent/JPH0826358B2/ja not_active Expired - Lifetime
  • 1992-10-14 IN IN322BO1992 patent/IN176382B/en unknown
  • 1992-10-14 AU AU27008/92A patent/AU665032B2/en not_active Expired
  • 1992-10-16 TW TW081108221A patent/TW258665B/zh active

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