GB2562510A - Composition - Google Patents

Abstract

Process for the preparation of a soap material comprises the steps of: mixing a soap noodle; a frangible particulate comprising a benefit agent e.g. a dye; and optionally one or more other agents; and extruding the mixture through an extruder. The particulate may comprise a cellulosic shell and the soap may be shaped into a bar.

Description

(54) Title of the Invention: Composition

Abstract Title: Process for the preparation of a soap (57) Process for the preparation of a soap material comprises the steps of: mixing a soap noodle; a frangible particulate comprising a benefit agent e.g. a dye; and optionally one or more other agents; and extruding the mixture through an extruder. The particulate may comprise a cellulosic shell and the soap may be shaped into a bar.

COMPOSITION

TECHNICAL FIELD

The invention provides a process for the preparation of a soap material.

BACKGROUND OF THE INVENTION

Everyday personal cleaning is one of life necessities.

The cleaning process usually employs a soap material to aid soil removal. The soap material is commonly in the form of a solid bar. The bar shape aids holding of the soap and moving it around the user’s body.

The soap bars are usually made in an extrusion process. The extrusion process may include multiple stages such as a preliminary stage for the initial preparation of soap noodles and one or more secondary stages where the soap noodles are extruded for a second I further time. Certain components of the soap may go through all of the extrusion stages or be added and to one of the latter extrusion stages. The final extruded material may receive further treatment, such as moulding into bar shapes.

This kind of single extruder system lends itself to the production of homogenous soaps wherein all of the components are evenly distributed throughout the final soap.

With the use of a single extruder system (whether using one or more extrusion stages) it is difficult I impossible to produce a non-homogenous I variegated soap; certainly with any level of predictability I control over the overall soap composition.

Such soaps are desirable from a visual consideration and can be appealing to users.

It is of course possible to use a complex extrusion system with multiple extruders to achieve a non-homogenous soap. However, such a system has a high cost associated therewith; in terms of its initial set-up cost and then the running I maintenance costs.

It is an object of the present invention to obviate or mitigate the issues outlined above.

BRIEF SUMMARY OF THE INVENTION

According to a first aspect of the invention there is provided a process for the preparation of a soap material comprising the steps of:

mixing a soap noodle, a frangible particulate comprising a benefit agent and optionally one or more other agents; and extruding the mixture through an extruder.

It has been found that with the use of a frangible particulate a benefit agent can be distributed throughout the soap. The distribution is preferably in a non-homogenous I variegated fashion. Moreover, there is a high level of predictability I control over the overall soap composition

With the incorporation of the frangible particulate it has been found that a nonhomogenous soap may be produced in a simple I cost effective manner. The use of the frangible particulate avoids the need for multiple extruders and I or the need for multiple hoppers to be loaded with differing soap compositions.

DETAILED DESCRIPTION OF THE INVENTION

Most preferably the benefit agent comprises a dye. In this preferred embodiment by the incorporation of the benefit agent in the frangible particulate and by virtue of the subsequent extrusion process the present invention provides for non-uniform distribution of colour to provide variegated soap having at least two colours, white being considered a colour. Thus the soap preferably has a basic colour with speckles or streaks of at least one other colour. As the basic soap colour is generally white I cream, due the soap components, the dye is preferably selected to contrast with such a colour. Preferred dye colours includes red, blue and green.

Preferably the frangible particulate makes up from 0.01 to 20wt% of the overall mixture.

Generally the particulate comprises a shell, including a polymeric material. The shell contains the benefit agent within the particulate until the point of rupture. Preferred materials for the shell include cellulosic materials, especially CMC (carboxymethyl cellulose).

Preferably the particulate has a particle size in the range of 0.1 to 4mm. Most preferably the particulate has an average particle size (by mass) of about 3mm.

Generally the frangible particulate is contained in a liquor prior to addition to the soap noodle. Preferably the liquor is suitable for incorporation in a soap formulation. As such preferably the liquid comprises one or more of water or an oxygen / hydroxyl moiety containing solvent (such as an alcohol (such as a C2-6 alkyl mono-alcohol), a polyol (such as a glycol or glycerol) or glycol ether (such as polyethylene glycol)).

Preferably the extrusion process is continuous. The extrusion process may further comprising a cutting and / or a moulding step, such that the final soap is in the form of a shaped bar.

COMPOSITION

The soap base for use in preparing the solid soap composition of the present invention can be composed substantially entirely of sodium and / or potassium salts of fatty acids containing either 16 or 18 carbon atoms, or a mixture of the two. The fatty acids can be either saturated or unsaturated. Preferably, the soap base is composed entirely of the potassium salts of tallow fatty acids. The sodium and / or potassium soap used can be prepared by either saponification of the triglycerides of the fatty acids or by neutralization of the free fatty acids. If the triglycerides are saponified with sodium and I or potassium hydroxide, it is not necessary to remove the glycerine, although this is preferred since the glycerine is a valuable by-product. Preferably, the triglycerides are first split and the free fatty acids are recovered. The free fatty acids are then reacted with potassium hydroxide to produce the desired potassium salts of the fatty acids.

The overall composition may be translucent or opaque. The composition may have a translucent and an opaque portion.

For an opaque composition a wide variety of synthetic detergents can be satisfactorily employed in the solid soap composition of this invention. The general class of synthetic detergents most commonly used for use in the present soap composition can be defined as an anionic-type synthetic detergent having pronounced detergent power and including in its molecular structure an alkyl radical containing from 6 to 18 carbon atoms and a radical selected from the group consisting of sulfonic acid and sulfuric acid ester radicals. In addition, the anionic-type synthetic detergent for use in this invention is preferably normally solid, although paste or liquid type detergents can be employed.

The main types of detergents falling within the above class are: (I) the alkyl aryl sulfonates; (2) the alkyl sulfates; (3) the sulfonated fatty acid amides; and (4) the sulfonated monoglycerides.

The alkyl aryl sulfonates are preferred, but the other types of detergents listed can be employed. Either the sodium or potassium salts of the anionic-type detergents can be used. Specific examples of alkyl aryl sulfonates which can be employed are sodium or potassium dodecyl benzene sulfonate, sodium or potassium octadecylbenzene sulfonate, and sodium or potassium octyl naphthalene sulfonate. Specific examples of the alkyl sulfates which can be employed are the sodium and potassium salts of L dodecyl, hexadecyl-and octadecyl sulfates. Specific examples of suitable sulfonated fatty acid amides include the sodium and potassium salts of sulfonated amides of higher fatty acids such as the sodium or potassium salt of the oleic acid amide of methyl taurine. The sulfonated monoglycerides which can be employed are preferably either sodium or potassium salts of higher fatty acids of monoesters or lower molecular weight hydroxy alkyl sulfonates such as the oleic acid ester of the sodium salt of isethionic acid and the monococonut oil fatty acid ester of 1,2 hydroxy propane 3 sodium sulfonate. It will be understood that the specific synthetic detergents mentioned are only illustrative of those falling within the scope of this invention, and that other equivalent detergents can be substituted therefor.

Other ingredients can be incorporated in the opaque composition to improve the properties thereof; for example, a soil redeposition retarder such as carboxymethyl cellulose (C.M.C.). About 1% of C.M.C. on the basis of the total weight of the composition is usually sufficient for this purpose. Other relatively inert ingredients such as sodium sulfate-can be included without harmful effect. A number of synthetic detergents such as the alkyl aryl sulphonates, contain sodium sulfate in addition to the active detergent in their commercially available form. Such detergents can be incorporated directly in the soap composition.

Starch, talc or other fillers can also be incorporated in the composition if desired. Talc is a magnesium silicate mineral material, with a sheet silicate structure represented by the chemical formula Mg3Si40io(OH)2, and may be available in the hydrated form. Talc has a plate-like morphology, and is substantially oleophilic I hydrophobic. Examples of other optional insoluble inorganic particulate materials include alumino silicates, aluminates, silicates, phosphates, insoluble sulfates, borates and clays (e.g., kaolin, china clay) and their combinations. Organic particulate materials include: insoluble polysaccharides such as highly cross-linked or insolubilized starch (e.g., by reaction with a hydrophobe such as octyl succinate); synthetic or natural polymers such as various polymer lattices and suspension polymers and mixtures thereof.

Where present the level of inorganic particulate should be between 0.01 percent and 20 percent by weight of composition.

A mildness/moisturizing aid component could be also present. This can provide provides superior skin conditioning without negative tactile attributes such as greasy, sticky or tacky skin feel. Preferred mildness/moisturizing aids include silicones. The silicone materials useful in the present invention are generally non-volatile and may be either a polyalkyl siloxane, a polyaryl siloxane, a polyalkylaryl siloxane, a polysiloxane with amino functional substitutions, or a polyether siloxane copolymer. The siloxanes useful in the present invention may be endcapped with any number of moieties, including, for example, methyl, hydroxyl, ethylene oxide, propylene oxide, amino, and carboxyl. Mixtures of these materials may also be used and are preferred in certain executions. Additionally, volatile silicones may be used as part of the silicone mixture so long as the final mixture is non-volatile.

Where present the level of mildness/moisturizing aid should be between 0.01 percent and 10 percent by weight of composition.

Other performance chemicals and adjuncts may be needed. Adjunct materials including germicides, perfumes, colorants, and dyes I pigments such as titanium dioxide may also be present.

In the case of translucent formulas preferably a solvent is present. Preferred types of solvents include polyols. Many types of polyols are available including: relatively low molecular weight short chain polyhydroxy compounds such as glycerol and propylene glycol; sugars such as sorbitol, manitol, sucrose and glucose; modified carbohydrates such as hydrolyzed starch, dextrin and maltodextrin, and polymeric synthetic polyols such as polyalkylene glycols, for example polyoxyethylene glycol (PEG) and polyoxypropylene glycol (PPG). Preferred polyols are relatively low molecular weight compound which are either liquid or readily form stable highly concentrated aqueous solutions. These include low molecular weight polyols and sugars. Especially preferred polyols are propylene glycol, glycerol, sorbitol and their mixtures.

Where present the level of polyol should be between 0.5 percent and 20 percent by weight of composition.

Examples

Tables 1, 1a, 2 and 2a show formula cards of two formulations made using the frangible particulate. They both rendered a marbleized effect.

MANUFACTURING METHOD:

I. ACTIVE (TCC) SLURRY PRE-MIX

Conditions: Ambient temperature.

1. Add the formula quantity of Fragrance into a suitable mixing vessel.

2. Slowly add the formula quantity of TRICLOCARBAN (TCC) (or any suitable active) io to the mixing vessel.

3. Mix well to get uniform slurry.

Note: The pre-mix has to be used within one day. Mix the pre-mix before adding to main batch to ensure uniformity of TCC.

(The pre-mix step is added because our soaps are antibacterial but it is not a condition for the invention. The process is equally applicable to non-antibacterial soaps)

II. BATCH MAIN MIX

Procedure	Conditions/ Duration/Parameters
1. Check moisture content of soap noodles and adjust the quantity of soap noodles and water if needed.	N/A
2. Weigh and check the formula quantity of Soap noodles.	Ambient temperature.
3. Discharge the soap noodles into the sigma mixer. Mix until the noodles are crushed.	Ambient temperature. 3-5 Minutes or until it’s needed.
4. Add the formula quantity of Talc to the sigma mixer and start mixing.	Ambient temperature. 2 minutes.
5. Add the formula quantity of titanium dioxide and sodium olefin sulfonate (AOS powder) to the sigma mixer and start mixing.	Ambient temperature. 2 Minutes.
6. Add TCC slurry pre-mix followed by glycerin and silicone emulsion to main batch while mixing and ensure all the	Ambient temperature. 4 Minutes.

ingredients are well mixed with soap noodles. Note: Please, ensure simplex plodder is running to avoid any issue with soap getting stuck in the hopper.
7. Refining & Milling: Transfer the mixture into the simplex plodder and roll mill.	Screen Size for Simplex Plodder - 30 mesh. Gaps for Roll Mill: bottom to middle - 0.3 mm middle to top-0.15 mm
8. Duplex Vacuum Plodder: Transfer the mixture from roller mill to duplex vacuum plodder and simultaneously add crushable color beads. (The beads will be crushed in this stage releasing color in a random pattern, which provide the marbleized effect) Extrude the soap into slug.	Vacuum Setting: 450 to 550 mm Hg Cone temperature setting: 40-50°C Chilled water inlet temperature: 7-9°C Chilled water outlet temperature: 8-10°C
9. Cut slug in to billets	Billet temperature: 35-42°C
10. Stamp the billets according to the required shape	N/A
11. Perform QC routine analysis required for product release.	N/A
12. Upon QC approval, pack the soap bars into appropriate packaging.	N/A

Table 1

Raw Material	%w/w ranges
Soap Noodle 80:20	50-100
Talc -97%	0-20
Titanium Dioxide	0-1
Sodium C14-16 Olefin Sulfonate	0-5
Frangible particle with dye	0.001-20
Glycerine	0-2
Silicone SLM 551 (Silicone emulsion)	0-1
Fragrance	0-3
Deionized Water	0-5

Table 1a

Raw Material	%w/w
Soap Noodle	85.5500
Filler	8.5000
Pigment	0.3000
Synthetic surfactant	0.7500
Frangible particle with dye	1.0000
Glycerine	1.1000
Skin conditioning agent	0.5000
Fragrance	1.3000
Deionized Water	1.0000
	100.00

This contains a filler (talc) and it is an opaque formulation (the background is completely white).

Table 2

Raw material	%w/w ranges
Soap noodle (85:15)	50-100
Glycerin	0-12
DI water	0-3
Propylene Glycol	0-8
Active Premix	0-4
Lipospheres	0.001-20
Dye	0-1

100.00000

Active Premix
Raw material
Fragrance	0-3
Active	0-1

100.00000

Table 2a

Raw material	%w/w
Soap noodle	87.19999
Solvents	11
DI water	0.25000
Active Premix	1.05000
Lipospheres	0.50000
Dye	0.00001

100.00000

Active Premix
Raw material	%w/w
Fragrance	0.75000
Active	0.30000

1.05000

This is a semi translucent formulation with high glycerin content. The background is not white so the marbleized effect is dark pink over a very light white-pinkish color.

Claims (12)

1. Process for the preparation of a soap material comprising the steps of:

mixing a soap noodle, a frangible particulate comprising a benefit agent and optionally one or more other agents; and extruding the mixture through an extruder.

2. A process according to claim 1, wherein the benefit agent comprises a dye.

3. A process according to claim 1 or 2, wherein the frangible particulate makes up from 0.01 to 20wt% of the overall mixture.

4. A process according to claim 1, 2 or 2, wherein the particulate comprises a shell, including a polymeric material.

5. A process according to claim 1,2, 3 or 4, wherein the shell, comprises a cellulosic material.

6. A process according to claim 5, wherein the cellulosic material comprises CMC.

7. A process according to any one of the proceeding claims, wherein the particulate has a particle size in the range of 0.1 to 4mm.

8. A process according to claim 7, wherein the particulate has an average particle of about 3mm.

9. A process according to any one of the preceding claims, wherein the frangible particulate is contained in a liquor prior to addition to the soap noodle.

10. A process according to any one of the preceding claims, wherein the extrusion process is continuous

11. A process according to any one of the preceding claims, further comprising a cutting and / or a moulding step.

12. A process according to claim 11, wherein the soap is in the form of a shaped bar.

Intellectual

Property Office

Application No: GB 1707920.3