MXPA01001173A - Method of reducing fines in a powdered product and fabric cleaner produced therefrom - Google Patents

Abstract

A method that produces a powdered fabric cleaner is disclosed. The cleaner has a reduced level of fines. One introduces at least one particulate material and at least one liquid material into a mixing vessel to form a mixture, blends the mixture for a first period of time, chops the mixture for at least a portion of the first period of time, and thereafter blends the mixture without chopping for a second period of time. In one form the cleaning composition has at least 80%by weight of inorganic salt carrier particulates, 1-10%by weight of flow agent particulates, and 0.1 - 15%by weight of a liquid active material, such as a fragrance, a surfactant, a solvent, or a pesticide. At least 90.0%of the composition particulates have a particle size greater than 0.105 millimeters.

Description

"TO METHOD TO REDUCE FINE IN A POWDER PRODUCT AND FABRIC CLEANER PRODUCED TO START FROM THE SAME REFERENCES CROSSED TO RELATED APPLICATIONS This application claims benefit of United States Provisional Patent Application No. 60 / 094,847 filed on July 31, 1998.

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to methods for reducing fines in powdered products, and more particularly to a method for reducing fines in textile powder treatment compositions, and powder textile treatment compositions prepared by the method. 2. Description of the Related Art Household cleaning compositions are often supplied in a liquid or powder form. For example, carpet cleaning compositions have been available for some time in both liquid and powder form. Liquid carpet cleaning compositions have typically been the first choice of many consumers. However, due to the disadvantages in liquid compositions, such as a The tendency to cause shrinkage, killing of gloss or wicking effect, of carpet fibers, dry carpet cleaning compositions, has become very popular. Examples of dry, powdered carpet cleaning compositions can be found in US Patents. Nos. 4,666,940, 4,552,777. 4,493,781, 4,395,347 and 4, 161, 449. However, dry carpet cleaners and certain other household powders have a tendency to lose their free-flowing properties during storage. For example, powdered products can be compacted or "bound" due to sediment and / or their tendency to absorb moisture from ambient air. The agglutinated product is difficult to fill as well as distribute from the containers. Therefore, flow agents (also known as anti-agglutination agents) are often added to powder compositions in order to maintain the free flow of the powder. Flow agents typically contain particles of small size and low density known as "fines" that can easily exist in the air. The fines can be very irritating to the nasal passages. In addition, a large number of fines in the ambient air can build a static charge. In consumer products such as a dry, powdered carpet cleaner, fines can be difficult to vacuum. Also, the fines that are removed may not remain trapped inside a typical paper vacuum bag. As a result, a cloud of fine dust can also develop during aspiration that can be irrigated to the nasal passages. In addition, fines can leave an unpleasant looking residue on shoes, clothing and surfaces in the home. In the field of dry carpet cleaners, efforts to reduce fines have previously focused on the incorporation of additional components in the cleaning formulation or the use of purification techniques. For example, the US Patents. Nos. 4, 161, 449 and 4,552,777 disclose a conventional process for preparing a dry carpet carpet cleaning composition. These patents mention that a dry powder carpet cleaning composition can include a dry powder inorganic salt carrier, a dry powder anti-caking agent, a liquid fragrance and a liquid de-oiling agent. Typical inorganic salt carriers include sodium sulfate, sodium chloride, sodium carbonate, sodium bicarbonate, sodium borate, sodium citrate, sodium tripolyphosphate and sodium nitrate, suitable anti-agglutination agents include starch, silica, grain powders, wood powders, talc, pumice, clays and calcium phosphates; Conventional fragrances are volatile odorous agents, liquids that include essential oils and aromatic chemicals; and liquid, typical depollution agents may be alkyl phthalate, mineral oil, glycols, ethoxylated alcohols, alcohols, glycol ethers, vegetable oils, naphtha, mineral spirits and naphthalene sulfonates. To prepare a dry carpet cleaning composition according to the above methods described in the U.S. Patents. Nos. 4, 161, 449 and 4,552,777, (1) dry powders, such as vehicle and agglomerating agent, are mixed dry in a first stage, (2) liquid components, such as fragrance and any agent of de-dusting, separately mixed together in a second step, (3) the mixtures prepared in steps (1) & (2) are mixed, and (4) if necessary, the final product is purified to remove the undesirable fines and lumps. Therefore, it is apparent that the methods described in these patents depend on the liquid depollution and debugging agents to control the fines in the final, dry carpet cleaning product. These extra ingredients (ie, dedusting agents) or process steps (ie, debugging) increase manufacturing costs, and in the case of debugging, may require measures to control the fines removed by debugging. In this way, further advances are desired to provide a solution to the problem of fines.

SUMMARY OF THE INVENTION It is evident that improved methods for mixing and agglomerating powder products can be used to reduce fines in a final powder product without the need for de-oiling agents or purification techniques. Accordingly, these improved methods can be used to produce a particulate fabric or textile fiber cleaning composition that meets the need for a dry textile cleaning composition having a minimum level of fines. Agglomeration is the process of joining particulates or fine powders in large masses with mechanisms of pressure, agitation and / or others. Agglomeration techniques include: (1) pressure compaction, such as briquetting, tabletting and use of a granule mill; (2) tamboreación or granulation and (3) freezing by dew. In the context of household particulate or dry powder cleaning chemicals, drumming or granulation is the typical process of choice. A method for producing a particulate fabric fiber or fabric cleaning composition is disclosed which includes the steps of introducing at least one particulate material into a mixing vessel, introducing at least one liquid material into the mixing vessel to form a mixture, mixing the mixture for a first period of time, separating the mixture by at least a portion of the first period of time and then mixing the mixture without separation for a second period of time. The method produces a particulate fabric cleaning composition having acceptable flow characteristics that results in still a reduced level of fines without the need for a debugging step to remove the fines. For the purposes of this patent, cloth includes synthetic and / or natural fiber products such as carpets, upholstery, clothing and even clothing.

Without attempting to be bound by theory, it is believed that the separation creates greater surface area (which is otherwise reduced by mixing liquid with solids) and that larger area allows fine particles of the particulate materials (such as silica fines in a composition of Dry carpet cleaning) to join the larger particles in the mixture by agglomeration. Note that this is surprising since separation can be expected to increase dust / fines. Also, in the method of the present invention, the inclusion of a period of mixing and separation of the mixture serves to agglomerate the particles and at the same time to break up any large agglomerated particle that can clog the container. In other words, the mixing serves to agglomerate smaller particles while the separation serves to break up agglomerations with larger oversize. This helps to distribute any liquid material and to create exposed, additional sticky surfaces to which fines can be attached. It is particularly desirable to reduce the particles in the size range of 200 mesh (0.074 mm aperture) and thinner. The separation process is a mixed to the high cut that generally cuts large agglomerated particles in the liquid interface between particles. However, individual particles can be cut through the body of the particle. Therefore, as used herein, the term "separation" refers to an action that can cut agglomerations of particles into a liquid-solid interface or a solid-solid interface. The step of introducing liquid material into the mixing vessel and the step of mixing and separating the mixture for a first period of time can be carried out simultaneously. Although the liquid material can be added to the mixing vessel in any manner, it is preferred that the liquid materials are introduced into the mixing vessel at a uniform flow rate, more preferably by a spray that provides a spray in order to produce a uniform powder . As used in this, the term "acceptable flow characteristics" for a fabric cleaner means that the composition can be dispensed without obturation of conventional agitator type receptors that are widely used for packaging household cleaning compositions and have outlets of approximately 5 millimeters in diameter. A version of a fabric cleaning composition or particulate textile fiber produced in accordance with the invention includes at least 80% by weight particulates of the inorganic salt carrier; 1-10% by weight of particulates of the flow agent, and 0.1-15% by weight of a liquid active material selected from fragrances, surfactants, solvents, pesticides, and mixtures thereof. For example, the liquid may comprise 1-10% by weight of an acaricidal agent. Other standard fabric cleaning additives can also be included. At least 90% of the particulates of the composition have a particle size greater than 0.105 millimeters. The composition can be applied without dusting the synthetic or natural textile fibers or the fabric and removed by aspiration. Accordingly, it is an object of the present invention to provide a method for preparing a dry particulate fabric cleaning composition having a fines level lower than particulate, dry fabric cleaning compositions typically produced by conventional methods. It is another object of the present invention to provide a method for reducing fines in a particulate fabric cleaning composition produced by agglomeration techniques without the need for de-oiling agents or purification techniques. It is still another object of the present invention to provide a method for preparing a dry fabric cleaning composition which reduces the amount of fines that may become available in the air during manufacture and use, and which maintains the desired flow properties, fragrance and / or active supply of the cleaning composition. It is still another object of the present invention to provide a particulate fabric cleaning composition prepared from liquid and particulate materials that has a low level of fines that may become available in the air during use, and that has the desired flow properties of a composition for cleaning fabrics or particulate textile fiber. These and other objects and advantages of the present invention will be apparent from the following description. The description is merely of the preferred embodiments. To assess the full scope of the invention, the claims should be reviewed.

DETAILED DESCRIPTION OF THE INVENTION The compositions of the invention are particularly and beneficially adapted for use in the cleaning of woven fabrics of the woven or interlaced type, mainly in strands or fibers. The compositions are believed most useful in the treatment of rugs and carpets. The textile fabric formed may be of vegetable, synthetic or animal origin, including mixtures thereof. Typical synthetic fabrics that can be beneficially treated by the present composition include viscose rayon, acetate rayon, polyamide, polyester polyolefin and acrylic. Other fibers of vegetable or animal origin that can be treated include cotton, jute, ramin, wood and the like. The compositions of the present invention can also be designed to hold textile fabrics by including suction means. In practice, the cleaning composition is applied to the surface, being allowed to remain (for example, a few minutes to a few hours) and then removed by aspiration or the like. The composition can be applied to the carpet by spraying an agitator-type container or through the use of any conventional particulate distribution means. The term "liquid active material" preferably designates a material that provides active properties to a fabric cleaning composition or particulate textile fiber. For example, the liquid active material used in the fabric cleaning composition or textile fiber may be a fragrance for odor control, a surfactant for cleaning, a cleaning solvent or a pesticide for pest control, such as an acaricide to control ticks and mites. The liquid active materials may be: (1) a fragrance, such as a liquid volatile odorous agent that includes essential oils and aromatic chemicals; (2) a solvent suitable for cleaning textile fibers, such as an ether alcohol (for example, a monomethyl ether of ethylene glycol); (3) a surfactant or surfactant mixture suitable for cleaning textile fibers selected from any of the four basic groups of surface active agents including anionic (such as alkali metal salts of sulfate esters or sulfonates containing aliphatic hydrocarbon radicals) higher than 8 or more carbon atoms), non-ionic (such as polyethylene oxide condensates of aliphatic alcohols having 8 or more carbon atoms), cationic (such as quaternary ammonium compounds), and amphoteric (such as salts of tertiary amine oxide having a hydrophobic radical attached to the nitrogen atom); (4) an acaricide, such as benzyl benzoate; or (5) mixtures of any of the liquid active materials listed above. In the fabric cleaning composition or textile fiber - * - - • "• - - -" = - - ^ - ^^ • - - "" • -J ~ - ".-« «> ^ ~. - ^ .. to . of the present invention, suitable particulate carriers are inorganic salt carriers such as sodium sulfate, sodium chloride, sodium carbonate, sodium bicarbonate, sodium borate, sodium citrate, sodium tripolyphosphate, sodium nitrate and mixtures thereof. Suitable flow agents include silica, metal oxides such as alumina, and metal titanates. A version of a particulate fabric cleaning composition made in accordance with the present invention includes at least 80% by weight particulates of the inorganic salt carrier, 1-10% by weight particulate flux agent, and 0.1-15%. by weight of liquids selected from the group consisting of fragrances, surfactants, solvents, pesticides and mixtures thereof, wherein at least 90% of the particulates of the composition have a particle size greater than 0.105 millimeters. A preferred embodiment is hereinafter set forth in claim 10. A version of the method of the invention is a method for producing a fabric cleaning composition that includes the steps of introducing at least one particulate material into a mixing container., introducing at least one liquid material into the mixing vessel to form a mixture, mixing the mixture for a first period of time, separating the mixture for at least a portion of the first period of time, and then mixing the mixture without separation by a second period of time, wherein at least 90% of the resulting composition are particulates having a particle size greater than 0.105 millimeters. An exemplary embodiment of the most preferred version of the composition is produced by: (1) adding 71% by weight of sodium sulfate, 20% by weight of sodium bicarbonate and 4% by weight of amorphous silica hydrate to a ribbon mixer which has separation blades; (2) add a combination of 4.6% by weight of liquid benzyl benzoate and 0.4% liquid fragrance to the mixer while mixing; (3) mix with tape for a total of 2 minutes (or more if necessary to complete the transfer of liquid to the product); (4) Mix with high speed separating ribbons and blades for 2.5 minutes; (5) deactivate the separating blades and continue mixing with ribbons for an additional 5.5 minutes; (6) mix with separating blades and tapes for 0.5 minutes; and (7) deactivate the separating blades and continue mixing with ribbons for 5 minutes. In certain circumstances, the mixing times may be extended to accommodate the primary materials with finer materials. If necessary, a mixing and separation step can last 1 minute, and then a mixing step can run two minutes. These extra stages can be repeated as necessary. However, it is preferred that each mixing and separation step is followed by a mixing step without separation so that any fines generated by the separation process can be allowed to agglomerate in the further mixing step. It should be noted that this specific embodiment and the following Examples are illustrative in nature and should not be used to limit the scope of the invention. The process can be facilitated by the use of a paddle mixer equipped with high speed flat or conical separating knives or a ribbon mixer equipped with high speed flat or conical separating knives. A suitable paddle mixer is a paddle mixer of the "Marion" trademark equipped with a spacer, and is available from Marion Mixer Company, Marion, Iowa, USA. A suitable tape mixer has a horizontal 'U' shaped container complete with the separating blades and stirring tapes, and is available from American Process Systems, Gurnee, Illinois, USA. The tapes, interior and exterior, operate in opposite directions to provide a uniform movement of material and effect a homogeneous mixture. The paddle mixer or ribbon blender motors should be sized appropriately for the density of the final, dry carpet cleaning formulation. The mixers or mixers include: a unit of 1 .7 m3 (60 cubic feet) of capacity with a main motor of 75 horsepower and four separating blades of 20 horsepower; and (2) a unit of 2.83 m3 (100 cubic feet) with a main engine of 1 00 horsepower and four separating blades of 20 horsepower. All process equipment (including the mixer, mixing blades and filling equipment) are preferably clean and dry before starting the process, as the water can adversely affect the product. Evaluation The level of particle agglomeration was evaluated using a "Agitation and Smoke" test and a granulometry. In the "Agitation and Smoke" test, approximately 1 13.49 g (7 ounces) of material was placed in a 226.8 g (8 oz) glass jar and the jar was sealed. The jar is then vigorously shaken by hand. The jar opens immediately and is observed to determine if any dust particles arise from the container (ie, the material "smokes"). The "Agitation and Smoke" test evaluates the dusty quality of a product. In the granulometry, the particle size distributions are identified using standard sized screens. A suitable granulometer is a CSC Scientific Screen Stirrer Catalog No. 18480. A typical granulometry includes loading 100 grams of sample into the granulometer and using the standard screen sizes of EU 20 (0.84 mm aperture), 40 (0.42 mm) , 60 (0.25 mm), 80 (0.1 77 mm), 100 (0.149 mm), 120 (0.125 mm), 140 (0.105 mm), 170 (0.088 mm), 200 (0.074 mm) and 230 (0.062 mm) for Separate the particles by size. Example 1 A dry carpet cleaning composition was prepared using the following ingredients: ^^^^^^^^^^^^^^^^^^ _ ^^^^ _. ^^ -__ teaá-i ^^ __ ^ £ - ^ ----- £ - ^ - ^ - Ingredient Weight in kg% by weight SODIUM SULFATE, ANO (Vehicle) 96.6 (213.0) 71.00 SODIUM BICARBONATE, GRANULAR BASS (Vehicle) 27.2 (60.0) 21.00 BENCILO BENZOATE (Acaracida) 5.4 (12.0) 4.60 SILICA, ATED AMORPHOUS (Flow Agent) 6.3 (13.8) 4.00 FRAGRANCE (Fragrance RB 1907 / A manufactured by Takasago 0.5 (1.2) 0.40 International Corp.) 13604 (300.00) 100.00 To prepare the dry carpet cleaning composition, the dry ingredients (sulfate sodium, sodium bicarbonate and silica) were added to a ribbon blender, such as the ribbon blender described above. Benzyl benzoate was unexpected for the visible evidence of crystallization, since it is preferred that the benzyl benzoate be completely liquid. If necessary, the temperature of benzyl benzoate can be raised to 75 ° + 5 ° F (23 ° + 2 ° C) to reverse any crystallization. The liquid fragrance and the benzyl benzoate were then mixed together and poured over the dry ingredients in the ribbon blender. The ingredients were then mixed in the ribbon mixer in the following sequence: (1) 2 minutes of ribbon mixing; (2) 2.5 minutes of ribbon mixing with activated separating blades; (3) 5.5 minutes of ribbon mixing; (4) 0.5 minutes of ribbon mixing with activated separating blades; and (5) 5 minutes of ribbon mixing. The dry powder carpet composition produced by this method was evaluated using the "Agitation and Smoke" test described above, and "smoke" was not evident.

- • "'- *". * - Example 2 In an alternative, sodium sulfate and sodium bicarbonate were loaded into the ribbon blender and subjected to 4 minutes of ribbon mixing. The liquid ingredients (benzyl benzoate and fragrance) were mixed together and applied to sodium sulfate and sodium bicarbonate as a spray mist using a pressurized spray vessel with fine conical style nozzles while all the ingredients were subjected to 3 minutes of ribbon mixing. The ingredients were subjected to 1 minute of mixing of tape with activated separating blades. The silica was then added to the ribbon blender and the ingredients were subjected to 3 minutes of ribbon mixing with activated separating blades.

The ingredients in the ribbon mixer were subjected to 5 minutes of ribbon mixing. A sample was obtained from the mixer and it was discovered by visual inspection that adding the liquid ingredients through a spraying device produced a more homogeneous mixture than the mixture of Example 1. Example 3 A carpet cleaning composition was prepared using the ingredients listed in Example 1 and another method for mixing and agglomerating the ingredients. The dry ingredients (sodium sulfate, sodium bicarbonate and silica) were first added to the ribbon mixer and then the liquid ingredients (benzyl benzoate and fragrance) were mixed together and sprayed on the dry ingredients in the rf ^ * s | g ^^ ribbon mixer during ribbon mixing. The dew was a coarse, uniform spray from a fan-shaped, flat nozzle. The ingredients were mixed in the ribbon mixer in the following sequence: (1) 2 minutes of ribbon mixing during the application of the liquid spray; (2) 2.5 minutes of ribbon mixing with activated separating blades; (3) 5.5 minutes of ribbon mixing; (4) 0.5 minutes of ribbon mixing with activated separating blades; and (5) 5 minutes of ribbon mixing. The dry powder carpet composition produced by this method was evaluated using the "Agitation and Smoke" test described above after 10, 10.5, 13.0 and 5.5 minutes of mixing according to the mixing sequence. The "Agitation and Smoke" test produced the following results: (1) after 10 minutes of mixing (which included 2.5 minutes of separation beginning after two minutes); the "smoke" of the composition began to disappear; (2) After 1 0.5 minutes of mixing, the "smoke" of the composition reappeared as a result of the separation process; and (3) after 13 and 1 5.5 minutes of mixing, the "smoke" of the composition has disappeared. The agglomeration of the powder was acceptable after 10 minutes. This example shows that this application of the liquid ingredients in a coarse spray, instead of a vapor, reduces the fine level much more significantly. In addition, the use of a process that includes the alternate stages of mixing for a first period of time, separation by a portion of the first The period of time, and then mixing for a second period of time results in a carpet cleaning composition with a low level of fines as measured by the "Agitation and Smoke" test. Example 4 A dry carpet cleaner group was prepared using the ingredients of Example 1 and the following sequence of steps. The dry ingredients (sodium sulfate, sodium bicarbonate and silica) were first added to the ribbon blender and then the liquid ingredients (benzyl benzoate and fragrance) were mixed together and sprayed over the dry ingredients in the ribbon blender during the mixed tape. The dew was a coarse, uniform spray from a fan-shaped, flat nozzle. The ingredients were mixed in the ribbon mixer in the following sequence: (1) 2 minutes of ribbon mixing during the application of the liquid spray, which took 50 seconds at 103.4 kPa (15 psi); (2) 2.5 minutes of ribbon mixing with activated separating blades; (3) 5.5 minutes of ribbon mixing; (4) 0.5 minutes of ribbon mixing with activated separating blades; and (5) 5 minutes of ribbon mixing. Samples of the dry powder carpet composition were taken from the mixer after 10, 11, 15 and 15.5 minutes of mixing according to the mixing sequence. The samples were evaluated using the granulometry described above, that is, 100 grams of each sample were placed in the granulometer and separated by size using the sizes of 1 ^ ~ M * .¿ ». t. AND ^ Ja = * tA standard screen of E.U. 20 (0.84 mm opening), 40 (0.42 mm opening), 60 (0.25 mm), 80 (0.1 77 mm), 100 (0.149 mm), 120 (0.125 mm), 140 (0.105 mm), 1 70 ( 0.088 mm), 200 (0.074 mm) and 230 (0.062 mm). The results were as follows: TABLE 1 Looking at Table I, it can be seen that the level of fines (as defined by the particles passing through the screen 170) varies depending on the stage of the mixing / separation process. For example: (1) after 10 minutes of mixing / separation according to the mixing sequence (ie, 2 minutes of ribbon mixing, 2.5 minutes of ribbon mixing with separation, and 5.5 minutes of ribbon mixing), 3.7 grams of the composition passed through the screen 170; (2) after 1 1 minutes of mixing / separation (ie, 2 minutes of ribbon mixing, 2.5 minutes of ribbon mixing with separation, 5.5 minutes of ribbon mixing, 0.5 minutes of ribbon mixing with separation and 0.5 minutes of ribbon mixing), 5.1 grams of the composition passed through the screen 170; (3) after 1 1 .5 minutes of mixing / separation (ie, 2 minutes of ribbon mixing, 2.5 minutes of ribbon mixing with separation, 5.5 minutes of ribbon mixing, 0.5 minutes of ribbon mixing with separation and 1 minute of ribbon mixing), 2.0 grams of the composition passed through the 1 70 screen; and (4) after 15.5 minutes of mixing / separation (ie, 2 minutes of ribbon mixing, 2.5 minutes of ribbon mixing with separation, 5.5 minutes of ribbon mixing, 0.5 minutes of ribbon mixing with separation and 5 minutes of mixing mixed ribbon), 0.0 grams of the composition passed through the 170 screen. Without attempting to bind by theory, the variation in the level of fines during the whole mixing / separation process can probably be explained as follows. After 10 minutes of mixing / separation according to the mixing sequence, the method of the present invention produces a composition having an acceptable level of fine as demonstrated by the "Agitation and Smoke" test carried out in Example 3 above. The level of fines (as defined by the particles passing through the screen 170) was 3.7% (3.7 grams for a sample of 100 grams) after 10 minutes. In the first 10 minutes of a sequence of mixing, the ingredients were mixed, mixed with separation and mixing. After 1 1 minutes of mixing / separation according to the mixing sequence, the level of fines (as defined by the particles passing through the screen 170) rose to 5.1%. This indicates that the 0.5 minute mixing and separation period serves to break up the larger agglomerations and release the fines. After 1 1 .5 minutes of mixing / separation according to the mixing sequence, the level of fines (as defined by the particles passing through the screen 170) was reduced to 2.0%. This indicates that the use of a mixing / stripping step and a mixing step after the initial 10 minutes of the mixing / stripping sequence serves to further decrease the level of fines in the composition. After 15.5 minutes of the mixing / separation sequence, the fines have been effectively removed. The data in the above table also indicate that the carpet cleaning powder produced in the examples will be free-flowing powders that are acceptable for distribution in agitator type containers used in the carpet cleaning field. In addition, carpet cleaning dust will have a reduced level of fines. Referring to Table I, it can be observed that: after 10 minutes of mixing / separation according to the mixing sequence, 93.5% of the particles have a particle size greater than 0.105 millimeters, after 1 1.5 minutes, 95.2 % of the particles have a particle size greater than 0.105 millimeters and 91.9% of the particles have a particle size greater than 0.125 millimeters, and after 1 5.5 minutes, 99.9% of the particles have a particle size greater than 0.105 millimeters, 99.5% of the particles have a particle size greater than 0.125 millimeters, and 96.1% of the particles have a particle size greater than 0.149 millimeters. In each of these periods of time, substantially all the particles have a particle size of less than 0.42 millimeters. The method produces a particulate carpet cleaning product that has a low level of fines as measured by granulometry, but at the same time avoids producing a carpet cleaning product with large agglomerations that impede the distribution of agitator type containers used in field. Example 5 A dry carpet cleaner group was prepared using the ingredients of Example 1 and the following sequence of steps. The dry ingredients (sodium sulfate, sodium bicarbonate and silica) were first added to the ribbon blender and then the liquid ingredients (benzyl benzoate and fragrance) were mixed together and sprayed on the dry ingredients in the ribbon blender during the mixed tape. The dew was a coarse, uniform spray from a fan-shaped, flat nozzle. The ingredients were mixed in the ribbon mixer in the following sequence: (1) 2 minutes of ribbon mixing during the application of the liquid spray; (2) 3.5 minutes of ribbon mixing with activated separating blades; (3) 20.5 minutes of ribbon mixing. Samples of the dry powder carpet composition were taken from the mixer after mixing and evaluated using the "Agitation and Smoke" test described above. After mixing, no "smoke" of the composition could be detected. This indicates that the use of another process that includes the alternate stages of mixing, mixing with stirring and mixing, results in a carpet cleaning composition with a low level of fines as measured by the "Agitation" test. and Smoke. " INDUSTRIAL APPLICATION The method of the present invention can be easily used with currently known filling techniques and production equipment for powder and granular treatment compositions. In addition, the carpet cleaning compositions produced by the present method can be applied to a carpet when spraying a stirrer-type container or through the use of any conventional particulate dispensing means. Other modifications and variations of the present invention will be apparent to those skilled in the art from an examination of the above specification. Therefore, the other variations of the present invention can be made even when such variations are not specifically discussed above.

V "

Claims (1)

CLAIMS 1. A particulate fabric cleaning composition comprising: at least 80% by weight particulates of the organic salt vehicle; 1-10% by weight of particulate flux agent; and 0.1-15% by weight of the liquid selected from the group consisting of fragrances, surfactants, solvents, pesticides, and mixtures thereof, wherein at least 90% of the particulates of the composition have a particle size greater than 0.105 millimeters . 2. The composition according to claim 1, characterized in that: at least 95% of the particulates of the composition have a particle size greater than 0.105 millimeters. 3. The composition according to claim 1, characterized in that: at least 99% of the particulates of the composition have a particle size greater than 0.105 millimeters. 4. The composition according to claim 1, characterized in that: at least 90% of the particulates of the composition have a particle size greater than 0.125 millimeters. 5. The composition according to claim 1, characterized in that: ?? u i-É-i-a? Í --- -? At least 99% of the particulates in the composition have a particle size greater than 0.125 millimeters. The composition according to claim 1, characterized in that: the liquid comprises 1-10% by weight of an acaricidal agent. The composition according to claim 6, characterized in that: the acaricidal agent is benzyl benzoate. The composition according to claim 1, characterized in that: the particulates of the flow agent comprise silica. The composition according to claim 1, characterized in that: the particulates of the inorganic salt carrier are selected from the group consisting of sodium sulfate, sodium bicarbonate, and mixtures thereof. 10. A carpet cleaner powder, comprising: at least 80% by weight particulates of the inorganic salt vehicle selected from the group consisting of sodium sulfate, sodium chloride, sodium carbonate, sodium bicarbonate, sodium borate , sodium citrate, sodium tripolyphosphate, sodium nitrate and mixtures thereof; 1-10% by weight of silica; - * - .aafc! I & - ^.

1 - . 1-10% by weight benzyl benzoate; and 0.1-5% by weight of a fragrance, wherein at least 90% of the particulates of the composition have a particle size greater than 0.105 millimeters. eleven . The composition according to claim 10, characterized in that: at least 99% of the particulates of the composition have a particle size greater than 0.105 millimeters and less than 0.42 millimeters. 12. The composition according to claim 10, characterized in that: at least 99% of the particulates of the composition have a particle size greater than 0.125 millimeters and less than 0.42 millimeters. A method for producing a fabric cleaning composition comprising the steps of: (a) introducing at least one particulate material into a mixing vessel; (b) introducing at least one liquid material into the mixing vessel to form a mixture; (c) mixing the mixture for a first predetermined period of time; (d) separating the mixture by at least a portion of the first predetermined time period; and (e) then mixing the mixture without separation by a second predetermined period of time, wherein at least 90% of the resulting composition are particulates having a particle size greater than 0.105 millimeters. The method according to claim 13, characterized in that: the particulate material comprises an inorganic salt carrier and a flow agent. The method according to claim 1, characterized in that: at least 95% of the resulting composition are particulates having a particle size greater than 0.105 millimeters. The method according to claim 13, characterized in that: at least 99% of the resulting composition are particulates having a particle size greater than 0.105 millimeters. 17. The method according to claim 13, characterized in that: the composition is formed without a purification step. 18. The method according to claim 13, characterized in that: steps (b) and (c) are carried out simultaneously. 19. The method according to claim 13, characterized ^ ¡^ U ^^^^^^^ because: the liquid material is introduced into the mixing vessel by a sprinkler. The method according to claim 13, characterized in that: step (d) is carried out in a belt mixer with separating blades. twenty-one . The method according to claim 13, characterized in that: step (d) is carried out in a paddle mixer with separating knives. ^ y ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ ffi ^^^^^ - ^^^^ ^^^^^^^^^^^^^^^ g ^^^^^^^^^^^^^^^ g ^^^^^ Jl