US1652900A - Soap product and process of manufacture - Google Patents

Soap product and process of manufacture Download PDF

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Publication number
US1652900A
US1652900A US194116A US19411627A US1652900A US 1652900 A US1652900 A US 1652900A US 194116 A US194116 A US 194116A US 19411627 A US19411627 A US 19411627A US 1652900 A US1652900 A US 1652900A
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Prior art keywords
soap
product
particles
particle
temperature
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US194116A
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English (en)
Inventor
Dallas R Lamont
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IND SPRAY DRYING CORP
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IND SPRAY DRYING CORP
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Application filed by IND SPRAY DRYING CORP filed Critical IND SPRAY DRYING CORP
Priority to US194116A priority Critical patent/US1652900A/en
Priority to GB20817/27A priority patent/GB291041A/en
Priority to DE1927I0031879 priority patent/DE688500C/de
Application granted granted Critical
Publication of US1652900A publication Critical patent/US1652900A/en
Priority to FR647341D priority patent/FR647341A/fr
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    • C—CHEMISTRY; METALLURGY
    • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
    • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
    • C11D13/00—Making of soap or soap solutions in general; Apparatus therefor
    • C11D13/14—Shaping
    • C11D13/20—Shaping in the form of small particles, e.g. powder or flakes

Definitions

  • the present invention relates to the prodish and often remains in a mass at the bot-. duction of a soap product in reasonably fine tom during the entire washing process. Un- 50 state of division, and it has to do particulardissolved soap frequently sticks to garments ly with a soap product of this class having being washed and appears -as a spot on the certain useful novel physical properties and laundered article. Also, in washing maZ- with a process of obtaining and controlling chines, a considerable amount of the soap these physical properties in the product. usually passes the washing machine undis- 55
  • the invention contemplates primarily a subsolved.
  • Such soaps tend vention'is, in a sense, related to the process to lump in water and remain partly un for the manufacture of a finely divided dry dissolved.
  • Lumpy powders, flakes, etc., cansoap product as described in Patent 'No. not be poured or shaken out of the package 70 '1 .GJLSOG.
  • Tlie present invention is based on the ,They'frequently cake and agglomerate in thedscovery that a new product not heretofore carton and to be shaken out at all, require obtained in the art can be produced when the removal of a substantial piece of the carsoap of a certain character of composition ton.
  • the product of the present invention 7 prepared in a certain way for treatment is is un form in particle size and is uickly used and when the several physical variables and completely soluble. it is freeowing of the process are at certain values, the limand does not lump or cake in the carton or its of which have now been reasonably well in water, and it is not dust-y.
  • con- Soap "flakes, chips, and the like are not stitute the subject matter of this applicaquickly and completely soluble in water of tion.
  • the process of the present invention in- 'volves a spray treatment and drying of an appropriate soap material under certain particular controlled process conditions.
  • An apparatus in which the process may be conducted is shown in Figures 6 and 7.
  • the apparatus consists basically of the principal drying or treating chamber 1.
  • the molten soap is delivered into the tower 1 in the form of a spray by means of nozzles 2 located at appropriate intervals about the periphery of the upper end of the tower 1, as shown.
  • the soap is delivered to the nozzles 2 through the soap line 3 which communicates with the soap mixing tanks or crutchers 4.
  • the soap is withdrawn from the crutcher 4 by means of a suitable pump 5 and is forced through the heater 6 into line 3 and from thence to nozzles 2.
  • the pump 5 maintains the'soap in line 3 and at the nozzles 2 at a pressure appropriate for properly spraying the soap, as it issues from the nozzles, into uniform and reasonably finely divided condition.
  • the heater 6 is preferably provided with a thermostatic control device 7 which controls admission of heating steam to the heater and thus regulates the temperature of the soap discharged from the heater to a substantially constant proper value.
  • the line 3 beyond the "heater 6 is steamjacketed, and the steam supplied to the line is regulatcdby an automatic pressure controlling device 8 which functions to maintain the steam at a pressure which is equivalent to the condensation pressure for steam at a temperature equal to that of the soap as it leaves the heater 6. With this arrangement the temperature of the soap leaving the heater remains the same until the soap is delivered into the tower 1 through the nozzles 2, and a uniform temperature of the soap at all of the nozzles 2 is assured.
  • the heated drying or treatin gas is sup-' plied to the tower 1 through uct 9 (best shown in Figure 7) which enters the top of the tower as shown.
  • uct 9 (best shown in Figure 7)
  • Inside of the tower under the discharge end of the duct 9 is tribute the incoming gas uniformly across the section of the tower and to restrict whirling and eddying of the 'gas as it enters the tower.
  • the distributor 10 is positioned above-the soap nozzles 2 so that at the time the gas comes into contact with the soap particles issuing rom the nozzles it is distributed reasonab uniformly across the tower and is proceeding downwardly through the tower in an orderly manner of flow without substantial whirling or eddying. Thus, the particles of the sprayed.
  • liquid soap are carried downwardly in orderly positively controlled flow through the tower by the drying gas.
  • the drying gas comes into contact with all of the sprayed particles of soap at substantially the same temperature, and all of the particles are positively propelled through the tower so that every particle is subjected to a similar treatment by the drying gas for a substantially similar length of time.
  • the heated treating gas supplied to the tower 1 through duct 9 consists of products of combustion from the oil burning furnace 11 diluted and reduced to the proper temperature by air admitted to the system through the damper controlled opening 18. Further dampers 19 and 20 are provided for facilitating operation and permitting ready rcgulation and control of air volumes and air temperatures.
  • the entire contents of the tower are continuously discharged through the outlet opening 13 at the bottom of the tower and from thence are conveyed or elevated to any desired point in the plant by being caused to flow through the discharge duct 14.
  • Duct 14 leads to the collector 15 here shpwn as a centrifugal or cyclone type of collector, which receives the mixed gas and dry product issuing from the tower 1 and delivers the dry product through discharge outlet 16 at the bottom of the collector and sends the spent gas to waste through the outlet 17 at the top of the collector.
  • the finished prod uct discharged from the collector 15 may be conveyed as desired to storage bins, from whenceit may be withdrawn forpackaging and shipment.
  • T is the initial temperature of the treating gas as it enters the top of the tower and first contacts with the sprayed soap issuing from' the nozzles 2.
  • T is an indication of the temperatures at one or more points .along-the'length of the tower, here shown as at, two points, one substantially at the bottom of the tower and the other at a little distance from the bottom.
  • T is the tem- 5 perature of the gas and dry product entering the collector.
  • the temperature of the soap as it is delivered to the nozzles 2 is indicated on the temperature recording instrument T,.
  • This temperature T is taken before the soap enters the individual nozzle pipes 2, which pipes extend a distance of say four feet into the hot tower so that the soap in passing along to the nozzles receives a somewhat furtherpreheating than is indicated by the T reading.
  • the pressures on the soap in the line ahead of the nozzles is indicated on the pressure recording instrumlent P, and a control 22 is located on the instrument board for controlling the speed of the pump 5 to thus permit regulation of the pressure on the soap to exactly the proper value.
  • the particular object of the present proc- 058 is the production of a new type of soap product characterized by the novel and desirable physical properties above referred to. l have discovered that by using the usual high solid content soap of ordinary manufacture and by setting and controlling certain of the process variables within certain limits such properties are obtained and can be controlled or varied in a given kind of soap product by an appropriate control or variation of the process conditions.
  • the particular process conditions, which I have discovered can be manipulated to produce the new kind of product referred to, are
  • the particles of the present product are not ordinarily perfect geometric spheres. They are characteristically of near-spherical, ball-like, generally globular, potato shaped reasonably smooth, rounded conformation, substantially as illustrated in the Figures 1, 4 and 5 of the drawings, as distinguished particularly from, an irregular, sharp cornered, fragmentary, roughened, granular, shredded or extenuatedparticle formation. This typical generally globular formation is shown in Figure 1.
  • the particle size is the particle size.
  • the individual rounded particles which make up the product are of size readily perceptible to the naked eye.
  • Each particle stands out to the eye as an independent unit, and the product appears as an aggregation of these independently.
  • the actual size .of the particles may be controlled as desired within reasonable limits, and it may be desirable for certain reasons to control the particle size to different values for different grades of products in tended for different uses, both for utility and so that the purchasing public may come to associate a certain particle size with a prodnot of a certain class.
  • the average particle is about 0.75 mm. in diameter.
  • a product composed of particles of this size definitely possesses the characteristic appearance and other properties above described which identify it as a new product different from the usual powder soaps, pul-' verized soaps, soap flakes, soap powders, and the like.
  • a product having this particle size is shown in Figure 1, magnified, and in Figure 5 as seen by the eye.
  • the bulk of the product will pass through a 20 mesh sieve in which the openings are 1 mm. square while the bulk of the product is retained on a 40 mesh sieve in which the openings are 0.5 mm. square.
  • the particle size is excessively small, as for instance, where a substantial part of the product is asfine as 100 mesh size, the product becomes floury and dust-like in character even though the globular particle structure is present.
  • the individual component rounded particles of the present product are ordinarily hollow unitarybodies.
  • Each particle is a detached unit consisting of a shell or wall of the dry soap material solidified into the characteristic rounded particle shape and enclosing within it a single void or hollow space.
  • the unitary hollow particle structure is shown in Figure 4. This is in contrast to a spongy material consisting of granules or particles of sponge-like or honeycomb structure.
  • the component particles are usually of irregular fragmentary character and the interior of the particle is a mass of interlacing walls and pores rather than a single void.
  • the thickness of the walls of the particles is controlled by the conditions of the process and may be varied depending upon the characteristic desired in the finished product such as particle size, bulking weight, speed of solubility. etc.
  • the practical limiting minimum thinness of the particle walls is determined by the wall strength which is required to prevent the particles from crushing or breaking under the conditions normally encountered in bulking of the product in bins, handling it through conveyors and filling machines, and shipping it for use.
  • the particles of the present product are made sufliciently stable so that they will withstand such normal handling and shipping conditions without breaking down.
  • This hollow unitary particle structure is important 'inmaking the product quickly and completely soluble and at the same time providing a product of sub stantial particle size which is free from dust,
  • Soap products made by spraying molten soap as heretofore proposed are normally of shredded and fragmentary particle form.
  • the novel structure properties of the present product just described are the result of cercontains an appropriate amount of alkaline matter and which contains about 40% of water.
  • This soap taken from the kettles at temperatures of say to F., which temperatures are ordinarily attained in the manufacture of soap, does not give a satisfactory particle structure.
  • a product produced from molten soap at this temperature is definitely characterized by excessive stringing 'and objectionable stretching out and elongation of the particles. Even with the other process variables at proper values this difiiculty in the product is still fairly evident with soap temperatures (the T, measurement described herein) of as high as say 200 F., although a product produced under this latter condition is much improved.
  • the T measurement described herein
  • the preferred product of the present invention is ordinarily made with initial temperatures in excess of 450 F., usually about 475 or 500 F.
  • the product of Figures 1 and 5 was made at T 475 F.
  • an adequate amount of treating gas which has been suc-' cessfully used in the production of the preferred product at the rate of approximately a ton of substantially dry finished soap product per hour, produced from a corresponding amount of molten soap of about 40% water content sprayed through seven material.
  • pressure spray nozzles is about 30,000 cubic feet of air per minute measured at 475 F.
  • the diameter of the treating tower shown in the drawings is 20 ft. so that the cross sectional area of the stream of treating gas coming into contact with the sprayed soap is about 315 sq. ft., thus giving a mean air velocity of about 95 ft. per minute at the stated temperature.
  • the soap spraying nozzles have discharge openings which are minute relative to the total cross sectional area of the tower as shown in the drawings, and
  • the initial temperature .of the drying gas is that temperature above which the particles of the prodnet are no longer properly formed and stable. If the initial temperature is too high, the particles become disrupted and have the appearance of broken shells. This condition probably results from an excessively rapid generation of steam in the particle due to the excessively high initial temperature, which steam exerts an explosive or disrupting action on the particle and in effect blows it apart or explodes it.
  • the im portant and major portion of the evaporation and drying action occurs, however, by reason ofthe large volume of heated gas which is brought into contact with the sprayed material. This gas must be supplied in adequate quantity to quickly absorb and carry away the moisture removed from the soap stock and dust be supplied at an adequately high initial temperature as above described.
  • the process variables are important in their effect on such physical properties of the product as the unitary hollow particle structure, the particle size, and correlated properties.
  • the generation of steam within the sprayed particles of soap stock probably exerts an expansive or explosive action from within the particle which tends to inflate or puff up the particle.
  • this particle is quickly dried a nicely shaped unitary particle of reasonably thin but stable wall structure containing a single hollow interior space is formed.
  • Higher temperatures with correspondingly greater putting or explosive action produce larger more fully inflated particles. For instance, with a given soap and with all process conditions constant except the initial temperature of the drying gas, I have produced with an initial tern-'- perature of 350 F. particles having an average diameter of about 0.4 mm.
  • Ihe pressure on the soap as it is sprayed from the nozzle is another factor that is importantin its efi'ect on the physical proper-' ties of the product and in its relation to the preheating temperature of the soap and the initial temperature of the drying gas.
  • EX- cessively low pressures, fora given nozzle appear to promote irregularity of particle shape and to produce particles which are block shaped and chunky rather than smoothly rounded. In general the size of the particle decreases with increase in pressure. Variation-in pressure may conveniently be used to correct certain defects in the product.
  • the lower limit for the pressure is that at which a satisfactory spray without streaks or streams of liquid not broken up into drops is formed. Above this value the pressure should be regulated to control the particle size, shape and presence of exploded or disrupted particles along the lines out lined above.
  • the best particle formation and control of conditions has been obtained with pressure type nozzles although reasonably good results under certain conditions have been obtained with atomizing nozzles.
  • l/Vith pressure nozzles of conventional design pressures in excess of 100 lbs. per square inch and less than 350 lbs. per square inch have ordinarily been employed, a pressure of approximately 250 to 275 lbs. per square inch being satisfactory for the production of the preferred type of product above described and shown in Figures 1 and 5.
  • the present product is quickly soluble even in water which is quite cool. When the present product is dropped on water and stirred an immediate diffusion of the soap particles takes place and a practically instantaneous formation of suds followed by a rapid disappearance of the soap particles occurs.
  • the rapid solubility. of the present product is due, in considerable measure, to the large area accessible to the water which is presented by a given weight of the product. The particle walls are very thin.
  • the average thickness of particle wall in the preferred product described above and illustrated in Figures 1 and 2, as taken from measurements of a large ,number of typical particles, is about 0.047 mm.
  • the minimum wall thickness appears to be about 0.037 mm.
  • the maximum thickness appears to be about 0.074. mm.
  • the average flake thickness appears to be about 0.172 mm., which is in excess of'four times the average wall thickness of the particles of the preferred product of this In such products the flakes are somewhat unstable and break downto a certain extent during handling so that a considerable amount of dust is present in the product. In some widely used flakes and chips the average flake thickness is greater than 0.3 mm.
  • the product illustrated in Figures 2 and 3 is, as stated above, of an average particle size of about 0.7 5 mm.
  • substantially none of the particles are as large as 2 mm. in diameter; 100% of the product passes through a mesh sieve in which the openings are 2 mm. square.
  • 85% to 90% passes a 20 mesh sieve (sieve openings 1 mm. square) while only to of the product passes a mesh sieve (sieve openings 0.5 mm. square). Only about 5% to 8% of the product passes a mesh sieve (sieve openings 0.3 mm. square), and only about 1 to 3% of the product passes a 100 mesh sieve (sieve openings 0.15 mm. square).
  • This property is of specialvalue in'collecting, storing and packaging the product by means of automatic machinery, in dispensing the product by means of gravity flow dispensing machines; etc. the use of the product for the reason that the most convenient way for the user to get the product out of the package is to shake orpour it out, and the present product flows out freely and evenly through a small hole so that exactl the proper amount maybe used.
  • the pro uct composed of these hollow unitary rounded fairly large size particles is light bulking. This is due both to the fact that a substantial proportion of the space occupied by the particle is represented by the hollow space on the inside of the particle and the fact that the re ularly shaped relatively large particles 0 the product bulk with substantial voids between particles.
  • the relative bulking Weight of the soap stock from which this light product was produced is about 0.95; the relative bulking weight 'of a chilled solidified cake of soap made from this li uid stock is about 1.02; and the relative bul ing weight of such soap in dry pulverized form is about 0.55.
  • the bulking weight of the product may be varied, within reasonable limits, by varyin the conditions of the process.
  • the particifiar form of product shown in Figures 2 and 3 and described above, has a relative bulking weight of about 0.11.
  • the relative bulking weight can be increased well above this value without difiiculty. I have produced soap products having a reasonable moisture content and having a reasonabl good particle shape, size and structure whic showed bulking weights of from 0.20 to 0.25. When dropped upon a quiet water surface the soap globules flow out evenl upon the water surface and all of them oat, Each )article is independent and no clinging or alling occurs.
  • the present invention therefore, provides a new type of soap product in reasonably finely divided condition.
  • This soap product differs from products of this general class It is also of importance in heretofore produced principally in its characteristic novel physical properties, substantially as described. These novel physical properties are obtained by a particular process of preparation and treatment.
  • the said component particles are used in mass rather than as separate entities and are characteristically of a generally rounded globular shape, so that the product is free from substantial amounts of fine dust-like matter and presents to the eye the characteristic and distinguishing appearance of a. large number of independently visible individually distinct little balls of soap as distinguished particularly from a powder subetantially as illustrated and described, and in which product the said component particlcs are capable of ready independent relative movement without clinging together which promotes ready separation of the said particles upon introduction of the product into water, are capable of maintaining their independent identity during dissolving without tending to form into a lump, and are all substantially immediately accessible to the solvent action of the water, whereby notably rapid and complete solubility is assured and a positive resistance to lumping and balling of the product not heretofore attained in soap products'is effected.
  • a spray processed soap product in which the component particles of the regular commercial run of the product are averagely hollow bodies of rounded generally ball-like shape sufliciently large to readily appear to the eye as independent individually distinct particles of reasonably uniform size and sufficiently small to constitute necessarily a.
  • bulk soap product of such character that the said component particles are used in mass rather than as separate entities, and consist of a shell of dry soap material solidified into the said characteristic rounded shape embodying substantially a single principal void, all substantially as illustrated and described, and in which product the average typical in dividual hollow component articles compriseappreciable amounts 0 soap so that the respective particles are individually distinct bodies capable of ready independent relative movement and ready separation upon introduction into water, are capable of attaining practically immediate contact with water upon being dropped upon the surface thereof and of maintaining their independent identity without sticking together to form masses of undissolved soap, and are large considering the amount of soap contained therein to thereby present an available surface area which is large relative to the amount of soap in the particle, whereby the said soap product is-free from any substantial characterizing amount of powder or dust-like matter,
  • a spray processed bulk soap product of such character that the individual particles of the product are used in mass rather than as separate entities which, in its regular commercial run, is composed of particles that are of characteristically rounded hollovv. generally globular form, substantially as illustrated and described, and are of an average size of not less than 0.3 millimeter, as evidenced by the fact that a preponderating proportion of the product is retained on a 60 mesh sieve, substantially as described, which product possesses a speed of solubility at'least comparable with finely comminuted or flaked soap and is further characterized by freedom from any substantial amount of powder or dust-like material and particularly by freedom from any tendency to lump or mass in water.
  • a spray processed soap product composed principally of independently constituted individually distinct hollow particles of gener ally rounded conformation substantially as illustrated and described, having an average size sufliciently large so that no considerable proportion of the product passes a 60 mesh sieve; substantially as described, and suiliciently small so that the product is necessarily a bulk product of such character that the individualparticles of the soap are uesd in massrather than as separate entities and which, when placedin distilled water at 110 F.
  • the process of producing a reasonably finely divided soap in characteristically rounded hollow generally ball-like particle form which comprises preparing a molten soap containing the usual relatively high percentage of solids ordinaril attained in such soap as commonly manu actured, spraying said soap in reasonably finely divided condition, reheating the said soap so that atthe time o spraying the temperature thereof is sufficiently high to insure formation of a good spray free from stretching and stringing of the soap material, converting the sprayed molten soap into particles having said rounded generally ball-like shape with voids within said respective particles and solidifying said particles into the said hollow rounded generally ball-like shape by bringing into contact with said sprayed molten soap a current of treating gas heated to a temperature of at least 300 F.
  • the process of producing a reasonably finely divided soap in characteristically rounded hollow generally ball-like particle form which comprises preparing a molten soap consisting of substantially pure soap and having a water content of the general order of 30%, spraying said molten soap into a current of treating gas, preheating the said soap so that at the time of spraying it is at a temperature of the general order of 220 F. to thereby favor the formation of a good spray without stretching and stringing of the soap material, and effecting formation of the said characteristically rounded hollow generally ball-like soap particles and solidification thereof into permanent formretaining condition by bringing into contact with said sprayed molten soap a current of treating gas heated to a temperature of approximately 350 F.
  • the process of producing a reasonably finely divided soap product in characteristically rounded hollow globular ball-like form which comprises preparing a molten soap consisting of substantially pure soap and an appropriate added alkaline material in the proportion of not more than a 1:2 ratio of alkaline material to soap solids and having a water content of the general order of 40%, spraying said soap into a current of treating gas, preheating the said soap so that at the time of spraying the temperature thereof is of the general order of 220 F.
  • Patent No. 1,652,900 discloses

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  • Chemical & Material Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Wood Science & Technology (AREA)
  • Organic Chemistry (AREA)
  • Detergent Compositions (AREA)
US194116A 1927-05-25 1927-05-25 Soap product and process of manufacture Expired - Lifetime US1652900A (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
US194116A US1652900A (en) 1927-05-25 1927-05-25 Soap product and process of manufacture
GB20817/27A GB291041A (en) 1927-05-25 1927-08-08 Soap product and process of manufacture
DE1927I0031879 DE688500C (de) 1927-05-25 1927-08-14 Verfahren zur Herstellung eines besonders rasch Ioeslichen Seifenproduktes
FR647341D FR647341A (fr) 1927-05-25 1928-01-05 Produit de savon et procédé pour le fabriquer

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US194116A US1652900A (en) 1927-05-25 1927-05-25 Soap product and process of manufacture

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US1652900A true US1652900A (en) 1927-12-13

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US194116A Expired - Lifetime US1652900A (en) 1927-05-25 1927-05-25 Soap product and process of manufacture

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DE (1) DE688500C (de)
FR (1) FR647341A (de)
GB (1) GB291041A (de)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2830064A (en) * 1955-02-09 1958-04-08 Colgate Palmolive Co Solid sarcosinate particles and method of preparation thereof
DE1089156B (de) * 1953-05-18 1960-09-15 Standard Oil Co Verfahren zur Herstellung von unzusammenhaengenden Hohlteilchen in Form kleiner Blaeschen aus Kunststoff

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1089156B (de) * 1953-05-18 1960-09-15 Standard Oil Co Verfahren zur Herstellung von unzusammenhaengenden Hohlteilchen in Form kleiner Blaeschen aus Kunststoff
US2830064A (en) * 1955-02-09 1958-04-08 Colgate Palmolive Co Solid sarcosinate particles and method of preparation thereof

Also Published As

Publication number Publication date
FR647341A (fr) 1928-11-22
DE688500C (de) 1940-02-22
GB291041A (en) 1928-11-08

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