MXPA02003448A - Process for preparing a foam component. - Google Patents

Abstract

The present invention relates to a process for preparing a foam component, said process comprises the steps of extruding a viscous mixture from a rotating extrusion plate onto a receiving surface. Said process provides a convenient, efficient, simple means of preparing foam components, especially foam components suitable for use in cleaning compositions. The present invention also provides a foam component obtainable therefrom.

Description

PROCEDURE FOR PREPARING A FOAM COMPONENT TECHNICAL FIELD OF THE INVENTION The present invention relates to a process for preparing foam components and for foaming components obtainable therefrom, said process is especially applicable for preparing a foam component which is useful in cleaning compositions such as cleaning compositions for laundry.

BACKGROUND OF THE INVENTION Compositions such as cleaning products, and personal care, cosmetic and pharmaceutical products, generally comprise active ingredients which are to be supplied to water or which are going to be active under aqueous conditions. Many of these active ingredients are sensitive to humidity, changes in temperature, light and / or air during storage. Another problem with many of these active ingredients, particularly enzymes, is that they tend to form dust due to the physical forces directed on them over their handling. This not only creates a waste product, but dust can also cause hygiene and health problems. s. ** Attempts to overcome these problems have led to the development of the protection of these active ingredients by coating agents or encapsulating agents. Typically, these active ingredients are prepared by spraying a coating material onto a core particle comprising the active ingredient to be protected. This procedure is extremely expensive, causes loss of time and is technically difficult to develop. The inventors in the present invention provide a method for preparing foam components that are robust to impacts and do not form dust when they act on physical forces typically encountered during handling. The process of the present invention prepares foam components in a single step, thus avoiding the need for numerous process steps, such as the formation of spheres. Said process provides a fast, simple, convenient and cost effective means to provide a foam component, especially spherical foam components. The foam components that can be obtained by the process of the present invention are more robust in impact and do not form dust when they act on them by physical forces typically encountered during handling. t * za &, - ** '* & r- "Íltitf? JMráiía-. -» * *, í * * ¿¿t?. * * * ... -. < & amp; amp; amp; amp; amp; amp; amp; amp; amp; amp; The present invention provides a method for preparing a foam foam component, said process comprising the steps of extruding a viscous mixture through an opening of a rotating extrusion plate, on a receiving surface, and wherein a gas is incorporated into the said viscous mixture either before, simultaneous with, or subsequently to said viscous mixture which has been extruded through said opening. Preferably, the shortest distance between said extrusion plate and said receiving surface is from 50 micrometers to 3000 micrometers, and preferably the aperture is from a size of 50 micrometers to 3000 micrometers. The present invention also provides a foam component obtainable therefrom.

DETAILED DESCRIPTION OF THE INVENTION PROCEDURE FOR PREPARING A FOAM COMPONENT The process of the present invention, which herein is referred to as the "process", provides a simple, fast, efficient and cost-effective means for preparing foam components, especially foam components. for use in cleaning compositions. Said foam foam component is described in greater detail hereinafter. The process herein comprises the steps of extruding a viscous mixture through an aperture of a rotating extrusion plate, on a receiving surface, and wherein a gas is incorporated in said viscous mixture either before, simultaneous to, or subsequently to, said viscous mixture has been extruded through said opening., Preferably, the shortest distance between said excuse plate and said receiving surface is from 50 micrometers to 3000 micrometers, and preferably the aperture is from a size of 50 micrometers to 3000 micrometers. It may be preferred that the process, especially in the step of extruding the viscous mixture through the opening, is carried out at a temperature of -20 ° C to 100 ° C, preferably -10 ° C to 0 ° C. , or of 10 ° C, and preferably at 90 ° C, or at 80 ° C, or at 70 ° C, or at 60 ° C, or at 50 ° C, 0 to 40 ° C. If the foam component comprises an ingredient, such as an active ingredient, which is sensitive to temperature, then it is preferred to develop the process at a temperature that is compatible with said temperature-sensitive ingredient. For the foam components containing enzymes, this temperature is typically from 0 ° C to 50 ° C, preferably from 10 ° C to 30 ° C.

Viscous mixture The viscous mixture, which in the present invention is referred to as the "mixture", typically has a viscosity of 1 mPa.s at 200000 mPas. The mixture in the present invention is preferably a fluid or liquid. The viscosity in the mixture depends on the chemical and physical properties of the ingredients in the mixture, which typically depend on the ingredients that are required in the foam component. However, if the viscosity is very low, then the mixture will quickly dress through the opening on the receiving surface and will not form extruded particles. On the contrary, if the mixture is very viscous, then said mixture will not have the ability to pass through the opening, or will form extruded nodules, as opposed to the extruded particles, which will require additional cutting steps and possibly steps of formation of spheres before a foam component that can be used is prepared. Typically, the viscosity of the mixture is 2mPas, or 5 mPas, or 7 mPas, or 10 mPas, or 12 mPas, or 15 mPas, or 17 mPas, or 20 mPas, or 22 mPas , or 25 mPas, or 50 mPas, or 1000 mPas, or 150 mPas, or 200 mPas, and typically at 150000 mPas or 100000 mPas, or 25000 mPas, or 12000 mPas, or 10000 mPas, or 8000 mPas , or at 5000 mPas. The mixture typically comprises all the majority of the ingredients that will be present in the foam component. Typically, the mixture comprises a polymeric material, a plasticizer and an active ingredient, and preferably also comprises a stabilizing agent, or a dissolution aid. Said polymeric material, plasticizer, active ingredient, stabilizing agent, dissolution aid, is described in greater detail hereinafter. The water content of the mixture affects the physical and chemical properties of the mixture. Typically, the water content of the mixture is from 0.1% by weight to 80% by weight, preferably from 60% by weight to 80% by weight. If the mixture comprises ingredients especially active ingredients, which are sensitive to water, for example ingredients that degrade in the presence thereof, then it is preferred that the water content of the mixture be as low as possible, perhaps less than 5%. % by weight, or less than 3% by weight, or less than 1% by weight, or less than 0.1% by weight, or it may still be preferred that the mixture be free of water. The term "water" typically means water molecules that are not bound to other compounds, for example the term "water" typically does not include the water content of hydrated molecules such as aluminosilicate but does not include water that is added to the mixture, for example a processing assistant. Alternatively, it may be preferred that the mixture comprises water. For example, if the mixture comprises a polymeric material, it may be preferred that the water also be present in the mixture to act as a plasticizer when forming a foam component from said polymeric material. If water is present in the mixture, then preferably said water is present at a level of at least 3% by weight, or less than 5% by weight, or less than 10% by weight, or less than 20% by weight. weight or even less than 40% by weight. The presence of solid matter in said mixture affects the extrusion process and the subsequent formation of extruded particle. Extrusion of said liquid is typically more difficult when solid matter not dissolved in said mixture is present. Moreover, the extruded particle formed by extruding a mixture comprising undissolved solid matter typically requires additional processing steps such as spheres. Therefore, preferably the blend includes (by weight) less than 30% preferably less than 15%, preferably less than 12%, preferably less than 10%, preferably less than 7%, preferably less than 5%. %, preferably less than 3%, preferably less than 1%, preferably less than 0.1% undissolved solid matter. Very preferably, the mixture does not comprise undissolved solid matter. Typically the undissolved solid matter levels described above refer to the amount of solid matter during the extrusion step of said mixture through an opening in a rotating extrusion plate and on a receiving surface. It may be preferred that the mixture comprises solid matter during the process of the present invention different from the case during the extrusion step. If undissolved solid matter is present during the extrusion step, then preferably the solid matter is in the form of undissolved particles having a particle size less than, and by so much having the ability to pass through, a opening of an approximate size of 50 micrometers to 3000 micrometers, or other preferred sizes of said opening which are described in greater detail hereinafter.

Rotating Extrusion Plate The rotary extrusion plate preferably rotates about 1 rpm at 1000 rpm, preferably at 2 rpm, or at 3 rpm, or at 4 rpm, 5 rpm, or at 6 rpm, or at rpm, or at 7 rpm. rpm, or 8 rpm, or 9 fm, or 10 rpm, and preferably at 900 rpm, or 800 rpm, or 700 rpm, or 600 rpm, or 500 rpm, or 400 rpm, or 300 rpm, or 200 rpm rpm, or at 100 rpm, or at 50 rpm. The rotating extrusion plate can rotate in a clockwise or counterclockwise direction. The rotating extrusion plate typically has an end speed of 0.1 ms "1 to 1600ms" 1, or typically 10 ms "1, or 50 ms" 1, or 100 ms "1, or 150 ms" 1, or 200 ms "1, and typically 900 ms" 1, or 800 ms "1, or 700 ms" 1, or 600 ms' 1, or 500 ms "1, or 400 ms" 1. For the purpose of the present invention, the end speed of the rotating extrusion layer is typically defined as the angular velocity of the outer surface, or outer edge, of said rotating extrusion plate. The direction of rotation, or typically the angular direction of rotation, of the rotary extrusion plate is typically perpendicular as, or perpendicular to, the flow direction of viscous liquid passing through the aperture to the rotating extrusion plate. The rotating extrusion plate is typically a housing that encloses, or at least partially encloses a volume capable of holding the liquid prior to the extrusion step. The housing rotates around said volume, clockwise or counterclockwise. This housing can be a simple housing layer or can be more than one housing layer, for example an outer layer and an inner layer. For the purposes of the present invention, if the rotating extrusion plate is in the form of a housing for a volume, and said housing contains more than one layer, then only one layer needs to be rotated, although it may be preferred that it be more than one layer. , or even that all the layers of the housing rotate. If the housing consists of an outer layer and an inner layer, then preferably the outer layer rotates, although the inner layer can rotate, or it can also rotate both layers, both the inner and the outer. Preferably, the rotating extrusion plate is cylindrical, spherical, or cubic in shape. The rotating extrusion plate may be a polyhedral shape, such as tetrahedral, pentahedral, hexahedral, rhombohedral, heptahedral, octahedral, nonahedral, decahedral, more preferably, the rotating extrusion plate is cylindrical, such as the shape of a barrel.

The rotating extrusion plate comprises an aperture of a size of about 50 micrometers to 3000 micrometers, preferably 100 micrometers to 1000 micrometers. These openings are typically formed by laser cutting the extrusion plate. Typically, said rotating extrusion plate comprises more than one opening, preferably numerous openings. If the rotating extrusion plate comprises more than one opening, then said openings may be of a different size. By deferring the sizes of the openings and the number of openings having the same size, the size distribution of the extruded particle can be controlled, and the extruded particles having a desired particle size distribution can be obtained from the process of the present. Typically, the density of the openings present in said rotating extrusion plate is 0.001 mm "2 to 400 mm" 2, or 0.01 mm "2, or 0.1 mm" 2, or 5 mm "2, or 10 mm. mm "2, or 25 mm" 2, or 50 mm "2, or 100 mm" 2, and preferably 300 mm "2, or 275 mm" 2, or 225 mm'2, or 200 mm " 2, or 175 mm "2, or 150 mm" 2. Different areas of the rotating extrusion plate have a different density of openings present in said area. For example, apertures of smaller size, in a greater density, may be present in an area of the rotating extrusion plate, while apertures of larger size in a smaller density may be present in a different area of said rotary extrusion plate.

If it is preferred that the method of the present invention prepare a spherical foam component, then the aperture preferably has a shape that resembles, or in fact is, a square, rectangle, rhombus, triangle, oval, circle, or diamond, preferably in the form of a diamond. If more than one opening is used in the present invention, then more than one type of aperture shape can be used. It may be preferred that the rotating extrusion plate is at least partially coated, preferably completely coated, with a release agent. The release agent acts to reduce the adhesive properties between the surface of the rotating extrusion plate and the liquid, therefore, the release of said liquid from the rotating extrusion plate, especially during the extrusion step. Typical release agents comprise hydrophobic materials such as wax, oil, fat, combinations thereof, preferably silicone oil. The rotating extrusion plate may also be coated with agents that can reduce the interaction between the rotating extrusion plate and the liquid or part thereof. Among the preferred coatings is the plasma coating, varnish finishes, or a combination of both. These coatings may in addition to being a coating comprising a release agent or may be in combination with the coating of the release agent. Preferred plasma coatings comprise polyethylene, polypropylene or a combination thereof. Typical plasma coatings comprise components known under the trade name Teflon. If the rotating extrusion plate is a housing for a volume with a capacity to hold the liquid, then it may be preferred that both the inner surface and the outer surface are coated, or partially coated, wherein the release agent and / or other coating such as plasma coating. If the rotating extrusion board is a housing comprising more than one layer, then it may be preferred for any layer or part thereof to be coated, or partially coated, with a release people and / or other coating such as a coating plasma. More than one rotary extrusion plate can be used in the process of the present invention, although it is preferred that only one rotary extrusion plate be used in the present invention. Among the preferred rotary extrusion plates for use herein are those known under the trade names Rotoform supplied by Sandvich Conveyor GmbH, and Disk Pastillator supplied by Gausche Machinefabriek.

Extrusion of a viscous mixture The mixture with a rotating extrusion plate through an opening on a receiving surface. The temperature at this process step of preference is as described above.

Typically, the mixture is tampered with by means of adjustment through the opening. The force required to extrude the mixture through the opening depends on the size of said opening, the temperature of said extrusion step, and the physical and chemical properties of said mixture, such as viscosity. The force means may comprise thrust, cut, suction, of liquid through the opening. The force means may be in the form of a solid object, such as a bar, wedge, scraper, or combinations thereof, which pushes or pushes the mixture through the opening. The force medium can also be a pump that can pump the mixture through the opening. A combination of a pump and one or more selected means of a bar, wedge, scraper can also be used herein. The mixture is typically extruded through the opening in the form of a drop of extruded material. Said drop is typically farce on the receiving surface by said force means. The rotation of the rotating extrusion plate typically pushes the drop apart, leaving part of said droplets on the receiving surface to form an extruded particle. The force required to pull the extruded drop to a part must be greater than the yield strength of that drop.

Receiving surface The receiving surface typically receives the extruded material from the rotating extrusion plate, over which said extruded liquid forms an extruded particle. The receiving surface may be a band, a drum, a disc, a plate, or similar or identical to the rotating extrusion plate. Preferably, the receiving surface is a band or a disk. Still, more preferably the receiving surface is a conveyor belt or rotating disk. The shortest distance between the receiving surface and the rotating extrusion plate is from 50 micrometers to 3000 micrometers. For the purpose of the present invention, the shortest distance means the distance that has been measured at the closest point of proximity. Preferably, this distance is the height or cross-sectional distance of the foam component prepared by the process of the present invention. For example, if a spherical foam component having an average diameter of 200 micrometers is required, then the preferred shortest distance between the rotating extrusion plate and the receiving surface is 200 micrometers. The receiving surface can rotate, said rotation can be clockwise or counterclockwise. Preferably the rotating surface rotates clockwise with respect to the rotating extrusion plate. For example, if the rotating extrusion plate rotates in a clockwise direction, then the receiving surface preferably rotates in a direction against the maculae of the watch. This prevents the extruded particles and / or liquid from being spilled or damaged by the rotating extrusion plate when placed on the receiving surface. The receiving surface can be maintained at any temperature, as required, this can include heating or cooling said receiving surface. Preferably, the receiving surface is at a temperature of -20 ° C, at 200 ° C, preferably -10 ° C, or 0 ° C, or 10 ° C, or 20 ° C, and preferably at 150 ° C, or at 100 ° C, or at 99 ° C, or at 75 ° C, or at 60 ° C, or at 50 ° C, or at 40 ° C, or at 30 ° C. if required, the different areas of the receiving surface may be at different temperatures. For example, the first area of the receiving surface may be at a higher temperature than the second area. It may be preferred that the receiving surface be coated, or at least partially coated, with release agents or other coatings such as plasma coating or varnish finishes. Such coatings and release agents were described hereinbefore. If said receiving surface is coated, or partially coated with a release agent, then not only the adhesive properties between the receiving surface and the reduced particle are reduced, allowing a better release of said extruded particle from said receiving surface, but in addition to this , the surface tension between the extruded particle and the receiving surface increases, thereby reducing the contact area between the extruded particle and the receiving surface and as a consequence of this, the particle is more spherical in its shape.

Gas incorporation Gas is incorporated into the liquid by any suitable means. The gas is incorporated into said mixture either before, simultaneous with, or subsequently to said being extruded through said opening. Preferably, the gas is incorporated into said mixture prior to said mixture being extruded through the rotating extrusion plate. The incorporation of the gas in said mixture causes said mixture to foam. Typically, this is due to the physical and / or chemical introduction of said gas into said mixture. Preferred methods are: a) gas injection (dry or aqueous route), optionally under mixing, with high shear mixing (dry or aqueous route), gas dissolution and relaxation including critical gas diffusion (route in dry or aqueous) injection of a compressed gas such as a supercritical fluid; and / or b) chemical gas formation on site, typically by a chemical reaction (s) of one or more ingredients) including the formation of CO2 by an effervescence system; and / or c) steam blowing; or cured by UV radiation.

The gas preferably comprises CO2 N2 or a combination thereof, such as air. The gas can also be a compressed gas such as the supercritical fluid. If said gas is incorporated into said mixture being extruded through an opening, then preferably if the gas forms bubbles in said mixture, these bubbles are smaller than the opening to which said mixture is extruded.

Foam Component The foam component is formed by extruding a mixture through an aperture of a rotating extrusion plate, onto a receiving surface. Typically, the foam component is formed as an extruded particle on the receiving surface. The extruded particle may be a liquid such as a drop, or it may be a solid particle such as a bead or tablet. Preferably the extruded particle is a solid and is typically formed from the extruded liquid that dries on the receiving surface. The foam component can be subjected to certain additional processing steps. For example, the foam component can be transferred from the receiving surface in a fluid count and dried. The temperature of this fluid count drying step is typically 40 ° C to 80 ° C, preferably 40 ° C to 60 ° C.

The foam component is preferably a sphere or spheroid. This is especially true if the receiving surface is coated or partially coated with a release agent such as silicone oil. The gas that is injected into said mixture, especially if it is in a compressed state such as a supercritical fluid; it can return to a gaseous state in the extruded particle and leave holes or spaces in the structure of the extruded particle. This is an important part of the foaming process. It may be preferred that the mixture be at a high temperature or high pressure before being extruded. Under these conditions, the gas can be in a compressed form or a supercritical fluid. Subsequent to the extrusion step, the extruded particle that is formed from the extruded mixture may be at a lower temperature, or pressure, such as under ambient conditions, and the gas returns to a gaseous state and forms the foam of the material extruded This foaming step can occur on the receiving surface. The foam component, which is referred to herein as the "component" typically comprises an active ingredient, a matrix and a dissolution aid. Said active ingredient, matrix and stabilizing agent is described in greater detail in the present invention later. Said component herein is preferably hydrodispersible, or dispersible in water, disintegrating in water or water soluble. Among the water-dispersible components presently have a dispersion capacity of at least 75% or even less than 95%, as measured by the method established hereinafter, which uses a filter-glass with a size of maximum pore of 50 microns; most preferably the component in the present invention is water soluble or disintegrant in water and has solubility or disintegration of at least 50%, preferably at least 75% or even at least 95%, as measured by the method established in the present invention subsequently using a filter-glass with a maximum pore size of 20 microns, mainly: The gravimetric method for determining the water solubility, the disintegration in water or the dispersibility in water of the component in the present invention: 50 grams ± 0.1 grams of the component in the present, are added in a 400 ml beaker, where the weight has been determined, and 245 ml ± 1 ml is added of distilled water. This is vigorously agitated with a magnetic stirrer which has been set at 600 rpm for 30 minutes. The component-mixture is then filtered through a qualitative folded sintered glass filter with pore sizes as defined above (maximum 20 0 50 microns). The water is dried from the collected filtrate by any conventional method, and the weight of the fraction of the remaining component is determined according to the above (the one that dissolves, disintegrates or disperses). Then, the percentage of solubility, disintegration or dispersion capacity can be calculated.

The component in the present invention is typically used to deliver active agents to an aqueous environment. Then, the component in the present, and preferably the matrix thereof is unstable when it comes into contact with the water. This occurs in such a way that the active ingredient (s) or part thereof, which is present in the component, is supplied to a liquid, preferably an aqueous environment such as water. Preferably the component or part thereof denatures, disintegrates, preferably disperses or dissolves in the liquid, preferably in an aqueous environment, most preferably in water. It may be preferred that the active ingredient be rapidly supplied in the water and that the component be such that it disperses or dissolves rapidly, preferably 10% of the component, by weight, dissolves or disperses within 30 minutes after making contact with it. said component with water, or most preferably at least 30% or even at least 30% or even at least 50%, or even at least 70% or even at least 90% (which has been introduced in water at a percentage of 1% in weight concentration). It may still be preferred that this occur in a period within 20 minutes or even 10 minutes or even 5 minutes after making the component contact with water. The solution or dispersion can be measured with the method that was described hereinbefore by measuring the dissolution, disintegration and dispersion of the component in the present.

Preferably the component is such that the total volume of the component changes, preferably is reduced, by at least 10%, compared to the initial total volume, as for example can be determined when adding 1 cm3 of the component to 100 ml of water demineralized and stirred for 5 minutes at a speed of 200 rpm, at a temperature of 25 ° C. Preferably, the change or preferably the reduction, in the total volume is at least 20% or even at least 40% or even at least 60%, or even at least 90% or even at least 100% , for example, since it may be preferred that the entire component be substantially disintegrated, dispersed or preferably dissolved in the water rapidly. This can be measured by the use of any method known in the art, in particular here with a method as follows (double dip technique): 1 cm3 of an elastic component is obtained and introduced into a measuring cylinder microvolumetric of 100 ml that is filled with 50 ml ± 0.1 ml of an inert organic solvent. For example, acetone is used when it is found that the denaturation and / or interaction with the polymeric material in the matrix of this elastic component in the present, for example, is PVA. Another neutral organic medium that can be used according to the nature of the component under investigation is an inert solvent such that the component does not substantially dissolve, disperse, disintegrate or denature due to the solvent.

The cylinder is sealed in the air and allowed to stand for 1 minute for the solvent to penetrate the entire component. The change in volume is measured and taken as the original volume PVA of the foam sample.

Then remove the component of the solvent and allow it to dry in air so that the solvent evaporates.

The component is then placed in a 250 ml beaker containing 100 ml of demineralized water, kept at 25 ° C under agitation at 200 rpm with the aid of a magnetic stirrer, for example. minutes The rest of the component sample, if any, is filtered with a 60mm maya copper filter and placed in an oven at a temperature and during a period such that residual water is removed. The remaining dry component is reintroduced into the measuring cylinder whose volume of acetone has been readjusted to 50 ml. The increase in the total volume is recorded and is taken as the final volume of the Vf component. The decrease of the total volume? V of the component sample is then: vf%? v = - * 100 vi The preference component has a relative density p of 0. 01 to 0.95, more preferably from 0.05 to 0.9 or even from 0.1 to 0.8 or even from 0. 3 to 0.7. Relative density is the ratio of component density (p *), to the sum of the partial densities of all bulk materials which are used to form the component (ps).

The preferred foamed component is used herein as stable to air or stable to contact with air, which means here that the bulk volume of the component or matrix thereof remains substantially the same when exposed to air. This means in particular that the component is preferably retained from 75% to 125% or even from 90% to 110% or even from 95% to 100% of its bulk volume when it is stored in an open beaker (of 9). cm in diameter, without any protective barrier) in an incubator under controlled environmental conditions (humidity = RH 60%, temperature = 25 ° C) for 24 hours. Preferably, the component retains 75% to 125% or even 90% to 110% or even 95% to 100% of its bulk volume under the above storage conditions where the humidity is 80%. The volume change in bulk can be measured by any conventional method. Particularly useful is a digital image recording system that contains a digital camera coupled to a personal computer that is itself equipped with a calibrated image analyzer software. A 1 cm3 sample of the component is obtained and placed in a beaker with a diameter of 9 cm and stored for 24 hours under the above conditions. After 24 hours, the size in the three dimensions is measured with the image analysis recording system. Each sample measurement is repeated three times and the average bulk volume change is calculated in%.

Preferably, the component is such that when it is in the form of particles of an average particle size of 2000 microns or less, these particles also retain 75% to 125% or even 90% to 110% or even 95% to 100%. % of its bulk volume. This, for example, can be measured by placing 20 grams of said particles, or a weight comprising more than 500 particles, in a volumetric precipitator having a diameter of 9 centimeters. The beaker is capped slightly at its base until the particles rearrange themselves into a stable position with a horizontal top surface. The volume is measured. The beaker opened with the particles inside, is carefully placed in the incubator for 24 hours, set at a desired% RH and temperature. The bulk volume after 24 hours is measured and then the bulk volume change in% is calculated. The component comprises (by weight) preferably at least 1% active ingredient (s), most preferably from 5% to 70%, most preferably at least 10% by weight of the component, most preferably from 15% to 20% or even from 25% to 50%. The component comprises (by weight) preferably 10% to 99% matrix, most preferably at least 20% or even 30% to 99%, most preferably 20% or 30% to 90% to 80%. The component comprises (by weight) at least 1% stabilizing agent, most preferably 5%, or 10%, or 15%, or 20%, and 50%, or 40%, or 30%, or 25% Matrix The matrix of the component, which in the present invention is referred to as the "matrix", is typically formed from a polymeric material and preferably a plasticizer. Said polymeric material and said plasticizer are described in greater detail hereinafter. The ratio of plasticizer to polymeric material in the matrix is preferably 1 to 100, more preferably 1 to 70 or 1 to 50, more preferably 1 to 30 or even 1 to 20, depending on the type of plasticizer and polymeric material used . For example, when the polymeric material comprises PVA and the plasticizer comprises glycerin or glycerol derivatives and optionally water, then the ratio is preferably about 1: 15 to 1: 8, wherein the preferred ratio is about 10: 1. The matrix in the present invention may further comprise the active ingredient of the component and / or the dissolving agent of the component in this invention. Said active ingredient and said solution are described in greater detail hereinafter. Entanglement people can also be added to modify the properties of the resulting matrix or component as appropriate. Borate may be useful in the matrix of the present invention. The matrix in the present invention preferably has a glass transition temperature (Tg) between 50 ° C, preferably below 40 ° C, preferably less than 20 ° C, still less than 10 ° C or even less than 0 ° C. Preferably the matrix in the present invention has a Tg of about -20 ° C or even -10 ° C. The Tg of the matrix when used in the present invention is the Tg of the matrix as it is present in the component, which can therefore be a mixture of polymeric material and a plasticizer alone, or a mixture of polymeric material, plasticizer, active ingredient and / or stabilizing agent, and in any case, optional additional ingredients (such as, stabilizing agents, densification aids, fillers, lubricants, etc. as described below) may be present. The Tg as used herein is as defined in the textbook 'Dynamic Mechanical Analysis' (page 53 figure 3.11c on the page 57), as the temperature of a material (matrix) in which the material (matrix) changes from glassy to plasticized, mainly where the chains gain enough mobility to slide through them. The Tg of the matrix of the component of the invention can be measured in a Perkin-Elmer DMA 7e equipment, following the instructions in the operations manual for this equipment, which generates a curve as illustrated in the book Dynamic Mechanical Analysis - page 57, Figure 3-11c. The Tg is the temperature or Frequency log as measured with this equipment, between the glass and the 'plasticized region' ", as defined in said text.The matrix, and preferably the component as a whole, have a specific elasticity, due at its glass transition temperature.

In particular, this means that the matrix and the component are reversibly deformed, absorbing the energy of the impacts or forces so that the component or matrix substantially maintains its bulk volume after physical forces have been applied to the component. You can define the elasticity by the modulus of the elasticity of the matrix, or even the component that once again can be defined by the Young's modulus. This can be calculated from strength or mechanical stress tests known in the art, for example using the Perkin-Elmer DMA 7e equipment and following the manufacturer's experimental procedure over a specific static stress range in percent, mainly in the range of static tension of 10-40%. This represents a maximum voltage that could be applicable during normal manufacturing or handling. Therefore, the elastic modulus as defined in the present invention is the maximum modulus as measured with this equipment in the static tension scale of 10% to 40%. For example, a piece of matrix (or component) of 1 cm3 can be used in the tests carried out with this equipment. The matrix in the present invention typically has an elastic modulus or Young's modulus of less than 4 GN.m'2, or typically less than 2GN.m "2, but typically less than 1 GN.m" 2, but typically even less than 0.5 GN.m'2, or even less than 0.01 GN.m "2, as measured with the Perkin-Elmer DMA 7e kit in particular, a matrix in the present invention containing gas bubbles, for example, that have been formed by the procedures that involve in the introduction of air into the matrix, have an elastic modulus under 0.1 GN.m "2 or even 0.01 GN.m" 2 or even under 0.005 GN.m "2 or even under 0.0001 GN .m "2. Preferably the matrix is flexible, such that it has a relative yield stress greater than 2% or preferably greater than 15% or even greater than 50%, as measured with the Perkin-Elmer DMA equipment. 7e. (The yield stress in this measure is the limit deformation of a part of the matrix to which it is irreversibly deformed). In particular, this means that when a matrix sample has a cross section of a specific length, for example 1 cm, it is compressed with a static force applied along the axis of this cross section where the static force is variable but at least equivalent to twice the atmospheric pressure, the change this length after the removal of this force is at least 90% to 110% of the original length. This can be measured for example using a Perkin-Elmer DMA 7e kit. Similarly, the matrix of preference is flexible in such a way that when a matrix sample having a cross section of a specific length, for example 1 cm, is stretched with a static force applied along the axis of that cross section, where the static force is variable, but at least it is equivalent to twice the atmospheric pressure, and the change of this length after the force removal is at least 90% to 100% of the original length. This can be measured for example with the use of Perkin-Elmer DMA 7e equipment. In particular, when this equipment is used, the static forces applied along the axis of a cross section of a matrix sample of 1 cm3 are gradually increased until the deformation of the component in the direction of the cross section is 70%. Then, the force is removed and the final deformation of the matrix sample in the direction of the cross section is measured. Preferably, this cross section length after the experiment is preferably 90% to 110% of the original length of the cross section, preferably 95% to 105% or even 98% to 100%. The elastic modulus or Young's modulus is related to the relative density, mainly: where p is the relative density of the matrix or even the component, and ps is the relative densities of the components of the matrix or component, as described hereinabove, and E * is the Young's modulus of the matrix or even the component itself, and Es is the components of the matrix or even said component. This means that even a rigid polymeric material with a high Es can be made in a flexible elastic matrix by adjusting the levels and / or type of plasticizer and optionally modifying the density (or for example by introducing gas during the manufacturing process to form a component of foam, as described below). The matrix, or still the entire common component, is in the form of a foam, and preferably such foam forming an interconnected network of open and / or closed cells, in particular a network of solid tubes or plates forming the edges and faces of the cells open and / or closed. The spacing between the cells may contain part of the active ingredient and / or a gas, such as air. Preferably, the ratio of closed cells to open cells of the component matrix, or the component as a whole is more than 1: 1, preferably more than 3: 2, or even more than 2: 1 or even more than 3: 1. . This relationship can be determined by calculating the total volume of a specimen of the matrix or component, VT, (assuming a spherical shape) and then measuring with a Mercury porosimetry test method the open cell volume (Vo) and subtracting the volume of open cell of the total volume must supply the closed cell volume (See: VT = Vo + Vc).

Polymeric Material Any polymeric material can be used to form the matrix in the present invention, preferably the polymeric material itself has a Tg as described above or more typically, it can be formed in a matrix having the Tg as described above using an appropriate amount of plasticizer. Preferably the polymer material comprises or consists of amorphous polymer (s). The polymeric material may consist of a single type of homologous polymer or may be a mixture of polymers. Mixtures of the polymers can be beneficial in particular to control the mechanical properties and / or dissolution of the component, depending on the applications and the requirements thereof. It is preferred that the polymeric material comprises a hydrodispersible or more preferably a water-soluble polymer. Hydrodispersible and water soluble compounds are typically defined as described hereinbefore, as the method for determining the water solubility and hydrodispersibility of the component herein. Preferred hydrodispersible polymers herein have a dispersibility of at least 50%, preferably at least 75% or even at least 95%, as measured by the method set forth herein above using a glass filter with a size of maximum pore of 50 microns; more preferably the polymer herein is a water-soluble polymer having a solubility of at least 50%, preferably at least 75% or even at least 95%, as measured by the method set forth herein above using a filter of glass with a maximum pore size of 20 microns. The polymer can have any average molecular weight, preferably about 1,000,000, or even 4,000 to 250,000 or even 10,000 to 200,000 or even 20,000 to 75,000. Highly preferred may be polymeric material with an average molecular weight of 30,000 to 70,000. Depending on the required properties of the component herein, the polymeric material can be adjusted. For example, to reduce solubility, polymers can be included in the material, which have high molecular weights typically over 50,000, or even over 100,000, and vice versa. For example, to change the solubility, polymers of varying level of hydrolysis can be used. For example, to improve (reduce) the elastic moduli, the link of the polymers can be increased and / or the molecular weight can be increased. It may be preferable that the polymer used in the component in the present invention has a secondary function, for example a function in the composition in which the component is to be incorporated. Thus, for example, for cleaning products it is useful when the polymer in the polymeric material is a color transfer inhibiting polymer, dispersant, and so on.

Preferred are polymers selected from polyvinylalcohols and derivatives thereof polyvinyl glycols and derivatives thereof, polyvinylpyrrolidone and derivatives thereof, cellulose ethers and derivatives thereof, and copolymers of these polymers with another or with other monomers or oligomers. Most preferred are PVP (and derivatives thereof) and / or PEG (and derivatives thereof) and most preferably PVA (and derivatives thereof) or mixtures of PVA with PEG and / or PVP (or derivatives thereof) ). Very preferred may also be a polymeric material that only comprises PVA. Preferably said polymers have a hydrolysis level of at least 50%, more preferably at least 70% or even from 85% to 95%.

Plasticizer Any plasticizer that is suitable to assist in the formation of a matrix as defined herein can be used. It is also possible to use mixtures of plasticizers. Preferably, when water is used, an additional plasticizer is present. Preferably, the plasticizer or at least the plasticizers have a boiling point above 40 ° C, preferably above 60 ° C or even above 95%, or even above 120 ° C, or even above 150 ° C. Preferred plasticizers include glycerol or glycerin, glycol derivatives including ethylene glycol, digomeric polyethylene glycols such as diethylene glycol, triethylene glycol and tetraethylene glycol, polyethylene glycol with an average weight M.W. of less than 1,000, wax and carboceraethanolacetamide, ethanolformamide, triethanolamine or acetate thereof, and salts of ethanolamines, sodium thiocyanates, ammonium thiocyanates, polyols such as 1,3-butanediol, sugars, sugar alcohols, ureas, dibutyl or dimethylollate, oxa monoacids, oxa diacids, diglycolic acids and other linear carboxylic acids with at least one ether group distributed along the chain thereof, water or mixtures thereof. The plasticizer is preferably present at a level of at least 0.5% by weight of the component, preferably by weight of the matrix, provided that when the water is the sole plasticizer, it is present at a level of at least 3% by weight of the component, or preferably by weight of the matrix. Preferably, the plasticizer is present at a level of 1% to 35% by weight of the component or matrix, more preferably 2% to 25% or even 15% or even 10% or even 8% by weight of the component or by weight of the matrix. The exact level will depend on the polymeric material and plasticizer used, but it must be such that the matrix of the component has the desired Tg. For example, when urea is used, the level is preferably 1% to 10% by weight of the matrix, whereas when glycerin or ethylene glycol or other glycol derivatives are used, higher levels, for example 2% to 15%, may be preferable. % by weight of the component or matrix.

Active ingredient The active ingredient can be any material to be delivered to a liquid environment, or preferably an aqueous environment and preferably an ingredient that is active in an aqueous environment. For example, when cleaning compositions are used the component may contain any active cleaning ingredients. The component may also comprise compositions, such as cleaning compositions or personal care compositions. In particular, it is beneficial to incorporate into the component, active ingredients that are sensitive to moisture or that react to contact with moisture, or solid ingredients that have a limited impact strength and tend to form dust during handling. Particularly preferred in the component are the active ingredients, such as enzymes, perfumes, bleaches, bleach activators, fabric softeners, fabric conditioners, surfactants, such as liquid non-ionic surfactants, conditioners, antibacterial agents, brighteners, photobleaches and mixtures thereof. Another active ingredient is a perhydrate bleach, such as metal perborate, metal percarbonates, particularly sodium salts. Also the preferred active ingredients are organic peroxyacid bleach precursors or activator compound, preferably are alkylpercarboxylic precursor compounds of the imide type including the acetylated tetraalkylene diamine N-, N, N1N1, wherein the alkylene group contains 1 to 6 atoms carbon, particularly those compounds in which the alkylene group contains 1, 2 and 6 carbon atoms such as tetraacetyl ethylene diamine (TAED), 3,5,5-trimethyl hexanoyloxybenzene sulfonate (iso-NOBS), sodium nonanoyloxybenzenesulfonate (NOBS) sodium acetoxybenzenesulfonate (ABS) and pentaacetylglucose, but also compounds of the peroxyacid alkyl substituted amide precursor. The highly preferred active ingredients for use in the component in the present invention are one or more enzymes. Preferred enzymes include the lipases, cutinases, amylases, neutral and alkaline proteases, cellulases, endolases, esterases, pectinases, lactases and peroxidases which are commercially available and incorporated into the detergent compositions. Appropriate enzymes are described in US Patents 3,519,570 and 3,533,139. Preferred commercially available protease enzymes include those sold under the trademarks Alcalase, Savinase, Primase, Durazym, and Esperase by Novo Industries A / S (Denmark), those sold under the trademark Maxatase, Maxacal and Maxapem by Gist-Brocades, those sold by Genencor International, and those sold under the trademark Opticlean and Optimasa by Solvay Enzymes. Amylases include, for example, α-amylases obtained from a special species of licheniforms B, described in greater detail in GB-1, 269,839 (Novo). Preferred commercially available amylases include, for example, those sold under the trademark Rapidase by Gist-Brocades and those sold under the trademark Termanyl, Duramyl and BAN by Novo Industries A / S. Highly preferred amylase enzymes can be those described in PCT / US 9703635, and in WO95 / 26397 and WO96 / 23873. The lipase can be of fungal or bacterial origin obtained, for example, from a lipase that produces the species Humicola_sp., Thermomyces sp or Pseudomonas sp including Pseudomonas pseualcalígenes or Pseudomas fluorecens. Also useful is the lipase from chemically or genetically modified agents of these species in the present. A preferred lipase is derived from Pseudomonas pseudoalcalgens, which are described in the European patent granted, EP-B-0218272. Another preferred lipase in the present invention is obtained by cloning the Humicola lanuginosa gene and expressing the gene in Aspergillius oryza, as a host, as described in the European patent application, EP-A-0258 068, which is commercially available from Novo. Industries A / S, Bagsvaerd, Denmark, under the trademark Lipolase. This lipase is also described in U.S. Patent 4,810,414, Huge-Jensen et al, issued March 7, 1989.

Additional preferred ingredients The component of the invention preferably comprises additional ingredients that can improve the dissolution properties of the component in the present invention.

Preferred additional ingredients that improve the dissolution of the component herein preferably comprise; a sulfonated compound such as C 1 -C 4 alkylsulfonates, C 1 -C 4 arylsufonates, diisobutylbenzenesulfonate, toluenesulfonate, cumenesulfonate, xylene sulfonate, salts thereof such as sodium salts thereof, derivatives thereof, or combinations thereof, preferably diisobutylbenzenesulfonate, sodium toluenesulfonate, sodium cumensulfonate, sodium xylene sulfonate and combinations thereof; and / or a d-C4 alcohol, such as methanol, ethanol, propanol, such as isopropanol, and derivatives thereof, and combinations thereof, preferably ethanol and / or isopropanol; and / or a C4-C10 diol such as hexanediol and / or cyclohexanediol, preferably 1,6-hexanediol and / or 1,4-cyclohexanedimethanol; and / or ingredients having the ability to act as absorption agents, such as cellulosic-based ingredients, especially modified cellulose; and / or swelling agents, such as cellulosic based ingredients, especially modified cellulose, and / or swelling agents, such as clays, the preferred clays are smectite clays, especially smectite dioctahedral or trioctrahedral clays, the highly preferred clays are clay montmorillonite and hectorite clay, and other clays found in bentonite clay formations; and / or an effervescence system, a preferred effervescence system comprises an acid source having the ability to react with an alkali source in the presence of water to produce a gas.

The component of the invention preferably comprises additional ingredients that can improve the stability of the active ingredient of the component of the present invention. These additional ingredients typically have the ability to stabilize the active ingredient of the component herein, this is especially preferred when the active ingredient (s) comprise (s) an active ingredient sensitive to moisture or oxidation, such as one or more enzymes. These additional ingredients can also stabilize the matrix of the component herein, and thus indirectly stabilize the active ingredient. These stabilizing ingredients are defined herein as "stabilizing agents". The active ingredient is preferably a compound that stabilizes the active ingredient or matrix, from degradation by moisture and / or by oxidation during storage. The stabilizing agent can be, or comprise, a foam matrix stabilizer. The stabilizing agent can be, or comprise, an active ingredient stabilizer, especially an enzyme stabilizer. Stabilizing agents that have the ability to stabilize the active ingredient indirectly while retaining the foam matrix of the stable component are referred to herein as "foam stabilizers". Foam stabilizers preferably comprise a surfactant such as a fatty alcohol, fatty acid, alkanolamide, amine oxides, or derivatives thereof, or combinations thereof.

Foam stabilizers may comprise betaine, sulfobetaine, phosphine oxide, alkyl sulfoxide, derivatives thereof, or combinations thereof. Other preferred foam stabilizers comprise one or more anions or cations such as mono-, di-, trivalent, or other multivalent metal ions, the salts of sodium, calcium, magnesium, potassium, aluminum, zinc, copper, nickel are preferred. , cobalt, iron, manganese and silver, preferably with an anionic counterion that is a sulfate, carbonate, oxide, chloride, bromide, iodide, phosphate, borate, acetate, citrate, and nitrate, and combinations thereof. The foam stabilizer may comprise finely divided particles, preferably finely divided particles with an average particle size of less than 10 microns, more preferably less than 1 micrometer, still more preferably less than 0.5 micrometers, or less than 0.1 micrometers. Preferred finely divided particles are aluminosilicates such as zeolite, silica, electrolytes described hereinabove as finely divided particles. The foam stabilizer may comprise agar-agar, sodium alginate, sodium dodecylisphate, polyethylene oxide, guar gum, polyacrylate, or derivatives thereof, or combinations thereof. The foam stabilizer may be coating that is separated from the matrix of the component in the present invention. The foam stabilizer typically includes in a partial form, preferably includes in a total form, the component herein or the active ingredient thereof. The coating typically is in contact with, preferably in such a manner as to form a coating, the active ingredient prior to said active ingredient that is in contact with the polymeric material or the plasticizer of the matrix, and preferably that is incorporated in the component in the present. The liner can typically be in contact with, preferably in such a way as to form a cover, the component in the present subsequent to the polymeric material and the plasticizer forming the matrix, and preferably subsequent to the active ingredient that is in contact with said matrix or which is incorporated into the component in the present. The preferred coating comprises polymers, typically selected from polyvinylalcohols and derivatives thereof, polyethylene glycols and derivatives thereof, polyvinylpyrrolidone and derivatives thereof, cellulose ethers and derivatives thereof, and copolymers of these polymers with one or other monomers or oligomers. Most preferred are PVP (and derivatives thereof) and / or PEG (and derivatives thereof) and most preferably PVA (and derivatives thereof) or mixtures of PVA with PEG and / or PVP (or derivatives thereof) ). These polymers do not form the matrix of the component herein. Thus, these polymers are different from the polymeric materials of the foam matrix.

A preferred coating comprises compounds such as glycerol or glycerin, glycol derivatives including ethylene glycol, digomeric polyethylene glycols such as diethylene glycol, triethylene glycol and tetraethylene glycol, polyethylene glycol with an average weight M.W. of less than 1, 000, wax and carbocera, ethanolacetamide, ethanolformamide, triethanolamine or acetate thereof, and salts of ethanolamines, sodium thiocyanates, ammonium thiocyanates, polyols such as 1,3-butanediol, sugars, sugar alcohols, ureas, dibutyl or dimethyltalate, oxa monoacids, oxa diacids, diglycolic acids and other linear carboxylic acids with at least one ether group distributed along the chain thereof, water or mixtures thereof. These compounds do not form the foam matrix of the component herein. Thus, these compounds are different from the plasticizers of the foam matrix. Preferred stabilizing agents that have the ability to stabilize the active ingredient directly, especially if said active ingredient comprises one or more enzymes, are defined herein as "active stabilizers" or "enzyme stabilizers". Typically active stabilizers interact directly, and stabilize, the active ingredient. Typical active stabilizers for use in the present invention preferably comprise a surfactant. Suitable surfactants for use herein are those described above as suitable surfactants for use as matrix stabilizers. In addition to these surfactants, other surfactants suitable for use herein as surfactants such as sodium alkylsulfonates, sodium alkoxysulfonates, preferred alkoxysulfonates are those comprising from 10 to 18 carbon atoms in any conformation, preferably linear, and with an average degree of ethoxylation of 1 to 7, preferably 2 to 5. Other preferred active stabilizers comprise boric acid, formic acid, acetic acid and salts thereof. These acid salts preferably comprise counterions such as calcium and / or sodium. Active stabilizers comprise cations such as calcium and / or sodium. Preferably calcium chloride and / or sodium chloride. Other active stabilizers comprise small peptide chains ranging from 3 to 20, preferably from 3 to 10 amino acids, which interact and stabilize the active ingredient, especially enzyme (s). Other active stabilizers comprise small nucleic acid molecules that typically comprise from 3 to 300, preferably from 10 to 100 nucleotides. Typically the nucleic acid molecules are deoxyribonucleic acid and ribonucleic acid. The nucleic acid molecules may take the form of a complex with other molecules such as proteins, or they may complex with the active ingredient of the present component, especially enzyme (s).

Suitable stabilizers for use in the present invention, especially when the component in the present invention comprises a bleach, comprise antioxidant and / or reducing agents such as thiosulfonate, methionine, urea, thiourea dioxide, guanidine hydrochloride, guanidine carbonate, guanidine sulfanate, monoethanolamine, triethanolamine, amino acids such as glycine, sodium glutamate, proteins such as albumin and casein from bovine serum, tert-butylhydroxytoluene, 4-4, -butylidenebis (6-tert-butyl-3-methyl-phenol), 2, 2'-butyl-bis-bis (6-tert-butyl-4-methylphenol), (monosterelated cresol, cysteine, phenolmonostearate, phenolmonostereoate, 1,1-bis (4-hydroxy-phenyl) -cyclohexane, or derivatives thereof, or a combination Other active stabilizers may comprise a reversible inhibitor of the active ingredient Without the desire to be limited by theory, a reversible inhibitor of an active ingredient is considered., especially if the active ingredient comprises one or more enzymes, can complex with, and improve the stability of, said active ingredient, and thus, stabilizes the active ingredient during storage. When the active ingredient is released, typically in a liquid environment, the reversible inhibitor dissociates from the active ingredient and the active ingredient then has the ability to perform the desired action for which it was designed. Active stabilizers suitable for use in the present invention comprise sugars. Sugars typically for use herein include those selected from the group consisting of sucrose, glucose, fructose, raffinose, trehalose, lactose, maltose, derivatives thereof, and combinations thereof. The active stabilizer may also comprise sugar alcohols such as sorbitol, mannitol, inositol, derivatives thereof, and combinations thereof. It may be preferable that the active stabilizer be in the form of a coating or barrier that at least partially encloses the component herein or the active ingredient therein, preferably completely encloses the component herein or the active ingredient thereof. , especially an enzyme.

EXAMPLES EXAMPLE 1 A process for preparing a foam component 4700g of a 33 w / w% solution of polyvinylalcohols (the average molecular weight is 30,000 to 70,000) are mixed with 150.3g of glycerol and 019.8g of citric acid in a high shear mixer until a soft foam is formed. This mixture is transferred to a feed tank, and is pumped, using a gear pump, into a drum, known under the trademark Rotoform supplied by Sandvik Conveyor GmbH. The drum is punched with openings having a size of 1,000 micrometers, separated by 2,500 micrometers. The perforated drum is placed on a soft surface drum, the shortest distance (the distance at the nearest point of proximity) is 1, 000 micrometers. The perforated drum rotates at 15 rpm at the same time as the mixture is pumped through the apertures of the perforated drum and onto the soft surface drum coated with silicone oil heated to 30 ° C, to form pellets in said smooth surface drum . When coating a quarter of the smooth surface drum with pellets, the extrusion process is stopped and the pellets are dried in hot air at a temperature of 70 ° C until the surfaces of the pellets are dry to the touch. The resulting dry pellets are peeled from the soft surface drum and harvested.

EXAMPLE 2 A process for preparing a foam component 4700g of a 33 w / w% polyvinyl alcohol solution (average molecular weight is 30,000 to 70,000) is mixed with 3,360g of enzyme solution (5% by weight of the active enzyme and 85% by weight of water), 159.3g of glycerol and 155g of cyclohexanedimethanal in a high shear mixer until a soft foam is formed. This mixture is transferred to a feed tank, and is pumped, using a gear pump, into a drum, known under the trademark Rotoform supplied by Sandvik Conveyor GmbH. The drum is punched with openings having a size of 1,000 micrometers, separated by 2,500 micrometers. The perforated drum is placed on a soft surface drum, the shortest distance (the distance at the nearest point of proximity) is 1, 000 micrometers. The perforated drum rotates at 15 rpm at the same time as the mixture is pumped through the apertures of the perforated drum and onto the soft surface drum coated with silicone oil heated to 30 ° C, to form pellets in said smooth surface drum . When coating a quarter of the smooth surface drum with pellets, the extrusion process is stopped and the pellets are dried in hot air at a temperature of 70 ° C until the surfaces of the pellets are dry to the touch. The resulting dry pellets are peeled from the soft surface drum and harvested.

EXAMPLE 3 A method for preparing a foam component A solution of 4000g is prepared by mixing 1, 464.0g of polyvinylalcohol (average molecular weight is 30,000 to 70,000) 2,282.0g of enzyme solution (5% by weight of the active enzyme and 85% by weight of water), 150.4g of glycerol and 103.6 sodium thiosulfate in a high shear mixer until a soft foam forms. This mixture is transferred to a feed tank, and is pumped, using a gear pump, into a drum, known under the trademark Rotoform supplied by Sandvik Conveyor GmbH. The drum is punched with openings having a size of 300 micrometers, spaced 100 micrometers apart. The perforated drum is placed on a smooth surface steel conveyor belt. The perforated drum rotates at 100 rpm at the same time as the mixture is pumped through the openings of the perforated drum and onto a soft-surfaced steel conveyor belt coated with silicone oil heated to 30 ° C, to form pellets in said band of smooth surface. When the entire length of the smooth-surfaced steel conveyor is covered with pellets, the extrusion process is stopped and the pellets are dried in hot air at a temperature of 70 ° C until the surfaces of the pellets are dry to the touch . The resulting dry pellets are peeled from the soft surface drum and harvested.

EXAMPLE 4 A process for preparing a foam component A 4000g solution is prepared as described in Example 3 with the exception of having CO2 gas dissolved in the solution. The CO2 solution is obtained by placing the described solution in a 10L pressure vessel, and loading the pressure vessel with CO2 gas, until a pressure of 10197.16 kg / cm2 is achieved. The CO2 feed is stopped at this point, and the pressure vessel and its content area is allowed to reach the equilibrium of dissolution. This mixture is pumped directly from the pressure vessel, using a gear pump, into a drum, known under the trademark Rotoform which supplies a conveyor belt Sandvik Conveyor GmbH. The drum is punched with openings having a size of 300 micrometers, spaced 100 micrometers apart. The perforated drum is placed on a smooth surface steel conveyor belt. The perforated drum rotates at 100 rpm at the same time as the mixture is pumped through the apertures of the perforated drum and onto a smooth surface steel belt coated with silicone oil to form pellets in said smooth surface band. The steel conveyor belt is sprayed with a cooling medium on the side opposite the side where the pellets are formed. The cooling spray means results in a temperature of -10 ° C that immediately prepares the pellets. The pads are removed from the mild steel strip, optionally with the help of a spatula blade. Upon removal, the pellets fall by gravity or are transported in a similar manner, to a fluidized drying / coating bed where moisture removal is effected. Additionally, an additional coating can be applied in the drying / coating fluid bed. The resulting dried, coated pellets are removed from the drying / coating fluid bed.

Claims (15)

NOVELTY OF THE INVENTION CLAIMS

1. - A process for preparing a foam component, said process comprising the steps of extruding a viscous mixture through an aperture of a rotating extrusion plate, into a receiving surface, and wherein a gas is incorporated into said viscous mixture either before, simultaneously with or after said viscous mixture to be extruded through said opening.

2. The process according to claim 1, further characterized in that said viscous mixture has a viscosity of 25mPas at 20000mPas, preferably 50mPas at 10000mPas.

3. The method according to any of the preceding claims, further characterized in that the shortest distance between said extrusion plate and said receiving plate is 50 micrometers to 3,000 micrometers.

4. The method according to any of the preceding claims, further characterized in that said opening has the size of 50 micrometers to 3,000 micrometers.

5. The process according to any of the preceding claims, further characterized in that said viscous mixture has a water content of 0.1% by weight to 80% by weight, preferably 60% by weight to 80% by weight.

6. The method according to any of the preceding claims, further characterized in that the direction of rotation of the rotating extrusion plate is perpendicular to the flow direction of the viscous liquid through the opening of said rotating extrusion plate.

7. The process according to any of the preceding claims, further characterized in that said viscous mixture comprises an element selected from the group consisting of polymeric material, plasticizer, active ingredient, combination thereof, and preferably comprises a selected element from the group consisting of dissolution aids, stability aids, or combination thereof.

8. The process according to any of the preceding claims, further characterized in that said viscous mixture is extruded through said opening at a temperature of 0 ° C to 50 ° C.

9. The method according to any of the preceding claims, further characterized in that said opening has the shape of a diamond, a square or a circle, or a triangle, preferably a diamond.

10. The method according to any of the preceding claims, further characterized in that said gas comprises carbon dioxide, nitrogen, or a combination thereof such as air.

11. The process according to any of the preceding claims, further characterized in that said rotating extrusion plate rotates from 1 rpm to 1000 rpm, preferably 10 rpm at 200 rpm, and the peak speed of said rotary extrusion plate is 0.1ms-1 to 1600ms-1.

12. The method according to any of the preceding claims, further characterized in that said receiving surface and / or said rotating extrusion plate is partially coated with a release agent.

13. The method according to any of the preceding claims, further characterized in that said foam component is water-soluble or water-dispersible.

14. The use of a method as claimed in any of the preceding claims, for preparing a foam component suitable for use in cleaning compositions, fabric care compositions, personal care compositions, cosmetic compositions, pharmaceutical compositions, preferably for incorporating into the same active ingredients selected from the group consisting of enzymes, perfumes, surfactants, brighteners, dyes, foam suppressants, bleaches, bleach activators, fabric softeners, antibacterial agents, effervescence systems , and mixtures thereof.

15. A component of foam that is obtained by a method according to any of claims 1 to 13.