US20050059564A1

US20050059564A1 - Lubricant for conveyor system

Info

Publication number: US20050059564A1
Application number: US10/978,962
Authority: US
Inventors: Minyu Li; Richard Johnson
Original assignee: Ecolab Inc
Current assignee: Ecolab USA Inc
Priority date: 2002-02-11
Filing date: 2004-11-01
Publication date: 2005-03-17

Abstract

A composition and method of lubricating conveyor tracks or belts is herein described wherein the lubricant composition contains a fatty acid, a neutralizing agent, a polyalkylene glycol polymer and a monomeric polyol; also described are methods of manufacture of such lubricant compositions. The compositions may also comprise additional functional ingredients.

Description

CROSS REFERENCE TO RELATED APPLICATION

The present application is a continuation in part of U.S. patent application Ser. No. 10/073,824 filed Feb. 11, 2002, and U.S. patent application Ser. No. 10/640,586, filed Aug. 13, 2003, both of which are incorporated by reference in their entirety.

FIELD OF THE INVENTION

The invention pertains to a lubricant suitable for use on a conveyor system and a method of making and using such lubricant. More particularly, the invention pertains to a non-solid conveyor lubricant composition having a high fatty acid concentration, and methods of making and using the same.

BACKGROUND

In many industries, including, for example, the food and beverage processing industry, containers and other articles are transported from one location to another location by conveyors such as belt conveyors. In many such conveyor systems, a lubricating composition is used on the conveyor. One of the reasons that a lubricating composition is used is to facilitate movement and reduce the damage to the container resulting from mechanical impact between the containers and the rubbing action among the containers and between the containers and the belt. For example, occasionally in such systems, the containers are stopped on the conveyor due to a back up on the conveyor. While the containers are stopped, the belt is often still moved continuously. To facilitate the smooth transportation of the containers, a lubricating composition can be applied onto the surface of the conveyor belt and/or the containers.
A lubricating composition may be used on a variety of containers including food and beverage containers, household and commercial cleaning product containers, and containers for oil, antifreeze or other industrial fluids. Examples of container materials include glass, plastic (e.g. polyolefins such as polyethylene and polypropylene; polystyrenes; polyesters such as polyethylene terephthalate (PET) and polyethylene naphthalene (PEN); polyamides, polycarbonates; and mixtures or copolymers thereof); metals (e.g. aluminum, tin or steel); papers (e.g. untreated, treated, waxed or other coated papers); ceramics; and laminates or composites of two or more of these materials (e.g. laminates of PET, PEN, or mixtures thereof with another plastic material). The containers may have a variety of sizes and forms including cartons (e.g. waxed cartons or TETRAPACK™ boxes), cans, bottles and the like. Included in the description of the containers of the invention are containers for carbonate beverages such as colas, fruit flavored drinks, root beers, ginger ales, carbonated water, etc. Also included are containers for malt beverages such as beers, ales, porters, stouts, etc. Additionally, containers for dairy products such as whole, 2%, or skim milk are included along with containers for juices, Koolaid® (and other reconstituted drinks), tea, Gatorade®, or other sports drinks, neutraceutical drinks and still (non-carbonated) water. Further, food containers for flowable but viscous or non-Newtonian foods such as catsup, mustard, mayonnaise, applesauce, yogurt, syrups, honey, etc. are within the scope of the invention. The containers can be virtually any size including (e.g.) five gallon water bottles, one gallon milk containers, two liter carbonated beverage containers, twenty ounce water bottles, pint or one half pint yogurt containers and others. Such beverage containers can be of various designs. Designs can be entirely utilitarian with a shape useful simply for filling, transportation, sales, and delivery. Alternatively, the beverage container can be shaped arbitrarily with designs adapted for marketing of the beverage including the classic “Coke” contour shape, or any other decorative, trademarked, distinctive, or other design can be incorporated into the bottle exterior.
When a lubricating composition is used, it is often applied as a liquid lubricant composition. The advantage of using a liquid lubricant is that it is more easily dispensed onto the conveyor. However, liquid lubricants require a large volume of storage space. Solid lubricants typically require less storage space but require unique dispensing mechanisms. Consequently, there is a need for a more concentrated lubricant that requires less storage volume than typical liquid lubricant compositions, but can be readily dispensed like a liquid lubricant.
Fatty acid compositions are excellent conveyor lubricants because they are both effective lubricants and many are considered a food additive which is useful in the food and beverage industry. However, high concentration fatty acid compositions are difficult to make. Fatty acid compositions require the presence of a neutralizer to solubilize the fatty acid. As the concentration of the fatty acid is increased, more neutralizer is necessary and this often results in a solid composition. Accordingly, there is a need for a more concentrated non-solid lubricant, and a non-solid fatty acid lubricant in particular, that requires less storage than a typical lubricant composition, but can be readily dispensed like a liquid lubricant.

SUMMARY

Surprisingly, it has been discovered that a high concentration non-solid fatty acid lubricant composition can be prepared using a fatty acid, a neutralizer, a polyalkylene glycol polymer, and a monomeric polyol. Such compositions provide the benefits of requiring less storage space while being able to use dispensing equipment normally used for dispensing liquid lubricants onto a conveyor. In addition, such non-solid fatty acid compositions also provide some detergency benefits. Further, they have the ability to be made out of food additive ingredients which is beneficial in the food and beverage industry. Finally, they can serve as a booster for lubricants that are traditionally used on PET lines. By acting as a booster, the compositions of the invention allow a plant to maintain a large supply of PET lube that is used for both PET lines and other lines such as can lines, and a smaller tank of the compositions of the invention, which may be added only to the can lines to provide additional lubricity as well as the other benefits, such as detergency.
The compositions of the invention may optionally be composed either partially or exclusively of food additive ingredients. Also, the compositions of the invention may optionally include additional functional ingredients that enhance the effectiveness of the composition as a lubricant, or enhance or provide other functional aspects to the composition.
These and other embodiments will be apparent to those of skill in the art and others in view of the following detailed description of some embodiments. It should be understood, however, that this summary, and the detailed description illustrate only some examples of various embodiments, and are not intended to be limiting to the invention as claimed.

DETAILED DESCRIPTION OF SOME EMBODIMENTS

Definitions
For the following defined terms, these definitions shall be applied, unless a different definition is given in the claims or elsewhere in this specification.
All numeric values are herein assumed to be modified by the term “about,” whether or not explicitly indicated. The term “about” generally refers to a range of numbers that one of skill in the art would consider equivalent to the recited value (i.e., having the same function or result). In many instances, the term “about” may include numbers that are rounded to the nearest significant figure.
Weight percent, percent by weight, % by weight, wt %, and the like are synonyms that refer to the concentration of a substance as the weight of that substance divided by the weight of the composition and multiplied by 100.
The recitation of numerical ranges by endpoints includes all numbers subsumed within that range (e.g. 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4 and 5).
As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. Thus, for example, reference to a composition containing “a compound” includes a mixture of two or more compounds. As used in this specification and the appended claims, the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.
The use of the terms “antimicrobial” and “biocide” in this application does not mean that any resulting products are approved for use as an antimicrobial agent or biocide.
As discussed above, the invention generally relates to a non-solid fatty acid lubricant composition and methods of making and using a non-solid fatty acid lubricant composition. “Non-solid” compositions of the invention include those compositions that are fluidable. Non-solid compositions include those compositions that are pumpable. Some examples of non-solid compositions are those compositions having viscosities up to about 10,000 centipoise, for example up to about 5,000 centipoise, from about 100 to about 5,000 centipoise, from about 100 to about 1,500 centipoise, and from about 100 to about 500 centipoise when measured using spindle 5 at 60 RPM on a Brookfield RVDVI+ viscometer. The compositions of the invention include a fatty acid, a neutralizer, a polyalkylene glycol polymer, and a monomeric polyol. The compositions of the invention may optionally be made either exclusively or partially using food additive ingredients. The compositions of the invention may also optionally include additional functional ingredients that enhance the effectiveness of the composition as a lubricant, or enhance or provide other functional aspects to the composition.
The compositions of the invention provide several benefits over the prior art. For example, the compositions of the invention take up less storage space than typical liquid lubricant compositions but can still be dispensed using liquid dispensers unlike solid lubricant compositions. Additionally, the compositions of the invention may optionally either partially or exclusively be composed of food additive ingredients, which is beneficial in the food and beverage industry. Further, the compositions of the invention provide detergency benefits. Finally, the compositions of the invention may be used as a booster which can help in reducing plant costs and storage space in a plant that uses multiple lubricants for different conveyor lines, such as lines using PET bottles or cans.
The compositions of the invention can be applied on a conveyor without further dilution, or they can be diluted with a carrier to form a lubricant mixture. Additionally, the compositions of the invention may be used as a booster, and mixed with another lubricant.
While the compositions of the invention are particularly useful as conveyor lubricants, it is understood that the compositions of the invention may be used in any environment where it may be desirable to have a non-solid concentrated fatty acid composition, such as environments where detergency would be beneficial, or other environments where lubricant is desired such as a machine lubricant.
Fatty Acid
The term “fatty acid” includes any of a group of carboxylic acids that can be derived from or contained in an animal or vegetable fat or oil. Fatty acids are composed of a chain of alkyl groups and characterized by a terminal carboxyl group. The alkyl groups can be linear or branched. The fatty acid can be saturated or unsaturated. In some embodiments, the chain of alkyl groups contain from 4 to 24 carbon atoms, in some embodiments from 6 to 24 carbon atoms, and in some embodiments from 12 to 18 carbon atoms. The lubricant composition can include combinations or mixtures of different fatty acids. One particular fatty acid that is suitable is oleic acid, but as set forth above, a broad variety of other fatty acids or combinations or mixtures thereof are contemplated for use.
In at least some embodiments, at least a portion of the fatty acid remains a free fatty acid, in that it is not neutralized. In some embodiments, substantially all of the fatty acid remains a free fatty acid. As discussed above, in some previous lubricants, the use of a fatty acid component required the use of an alkali neutralizing agent, for example to neutralize the fatty acid into a fatty acid soap. Such alkali neutralizing agents would undesirably increase the alkalinity content of the lubricant. Embodiments of the invention that include a reduced amount of such neutralizing agent, or do not include any such neutralizing agents, however, can be formulated such they do not include undesirable levels of alkalinity. For example, in some embodiments, the level of the total alkalinity is 100 ppm or less, as measured as calcium carbonate, and in some embodiments, the level of the alkalinity is 50 ppm or less. In some embodiments, such levels of alkalinity are in the use compositions, while a concentrated composition prior to dilution into a use composition may have higher levels of alkalinity.
Examples of preferred fatty acids include oleic acid, coconut fatty acid, and tall oil fatty acid. The fatty acid component can comprise in an embodiment, at least about 20 wt. %, 21 wt. %, 22 wt. %, 23 wt. %, 24 wt. %, 25 wt. %, 26 wt. %, 27 wt. %, 28 wt. %, and 29 wt. % of the final lubricant concentrate.
Neutralizing Agents
The lubricating composition can also include a neutralizing agent for various purposes, for example, to neutralize a portion of the fatty acid component. Additionally, many surfactants are most effective in the neutral pH range. Moreover, acidic conditions might lead to chemical attack on certain thermoplastics and metal parts. Therefore, in some embodiments, a portion of the fatty acid component, or the available acid from the surfactants employed, e.g. the phosphates, is neutralized. However, in some embodiments, as discussed above, it is desirable to provide a composition with a relatively low level of alkalinity, for example, in compositions for use with certain thermoplastic containers or conveyors, such as PET containers. Therefore, in such embodiments, relatively low levels of alkali neutralizing agent is used. For example, in some embodiments, the level of the total alkalinity at diluted or use concentration is 100 ppm or less, and in some embodiments, the level of the alkalinity is 50 ppm or less. For example, in some embodiments, the alkalinity can be calculated as percent CaCO₃at diluted or use concentration, as described in the examples below. In some embodiments, a diluted use solution can have total alkalinity levels in these ranges, while the concentrated composition prior to dilution can have higher levels of alkalinity.
Some commonly used neutralizing agents are the alkaline metal hydroxides such as potassium hydroxide and sodium hydroxide. Another class of neutralizing agent is the alkyl amines, which may be primary, secondary, or tertiary or, alkanolamines, such as monoethanolamine, diethanolamine and triethanolamine, or cyclic amines such as morpholine. The neutralizing agent may also be ammonia. Finally, the neutralizing agent may also be a known buffer such as sodium carbonate, potassium carbonate, sodium phosphate, sodium hydrogen phosphate, and sodium dihydrogen phosphate.
Fatty alkyl substituted amines can also be used as neutralizing agents wherein the first substitute group of the amine is a saturated or unsaturated, branched or linear alkyl group having between 8 to 22 carbon atoms, alkyl group or hydroxyalkyl group having 1 to 4 carbons, or an alkoxylate group, and the third substitute group of the amine is an alkylene group of 2 to 12 carbons bonded to a hydrophilic moiety, such as —NH₂, —OR, SO₃amine alkoxylate, alkoxylate, and the like. These amines can be illustrated by the formula:

wherein R₁is an alkyl group having between 8 to 22 carbon atoms, and R₂is a hydrogen, alkyl group or hydroxyalkyl group having 1 to 4 carbons or an alkoxylate group, R₃is an alkylene group having from 2 to 12 carbon atoms, and X is a hydrogen or a hydrophilic group such as
—NH₂, —OR, —SO₃amine alkoxylate, amine alkoxylate, alkoxylate, and the like.
Examples of amines useful for neutralization are: dimethyl decyl amine, dimethyl octyl amine, octyl amine, nonyl amine, decyl amine, ethyl octyl amine, and the like, and mixtures thereof.
When X is —NH₂, preferable examples are alkyl propylene amines such as N-coco-1,3,diaminopropane, N-tallow-1,3,diaminopropane and the like, or mixtures thereof.
Examples of preferable ethoxylated amines are ethoxylated tallow amine, ethoxylated coconut amine, ethoxylated alkyl propylene amines, and the like, and mixtures thereof.
Examples of preferred neutralizing agents include potassium hydroxide and sodium hydroxide. Generally, when added into the lubricant concentrate, the neutralizing agent is present in the range of about 20% by weight or less, in some embodiments, less than about 10% by weight, and in some embodiments about 5% by weight or less.
Though a lubricant concentrate can be formulated with pH in a wide alkaline or acidic range, in some embodiments, the pH of the composition is in the range of about 4 and 11, and in some embodiments is in the range of about 5 and 9.
Monomeric Polyol
The composition includes a monomeric polyol having 2 or more —OH groups. The composition may include one monomeric polyol, or a mixture of more than one monomeric polyol. Examples of suitable monomeric polyols include propylene glycol, hexylene glycol, and glycerol. The preferred monomeric polyol is propylene glycol, hexylene glycol, or a mixture thereof.
Polyalkylene Glycol Polymer
The term “polyalkylene glycol polymer” includes polymers of alkylene oxides or derivatives and mixtures or combinations thereof. For example, in some embodiments, polyalkylene glycol polymers can include polymers of the following general formula, and derivatives thereof:
H—O—(RO)x-H
wherein R is a linear or branched alkyl, and x is a positive integer, and in some embodiments is in the range of about 4 to 500 for low molecular weight polyalkylene glycol polymers, and in some embodiments up to about hundreds of thousand for high molecular weight polyalkylene glycol polymers. Some examples of commercially available lower molecular weight polyalkylene glycol polymers include Carbowax™ and Ucon™ products available from the Dow Chemical Company, and some examples of commercially available higher molecular weight polyalkylene glycol products include POLYOX™ products available from the Dow Chemical Company.
As is apparent from above, the term “polyalkylene glycol polymer” also can include derivatives of such polyalkylene glycol polymers. Some examples of such derivatives can include polyalkylene glycol polymers modified by substitution on one or more of the terminal hydroxyl groups. For example, one or more of the terminal hydroxyl groups can be substituted with alkyl or acyl groups to form an ether, or a carbonyl group to form an ester. Some examples of such derivatives include compounds of the following formulas:
R′—O—(RO)x-H R′—COO—(RO)x-H
wherein R′ is linear or branched alkyl or aryl, and in some embodiments is in the range of C₁-C₂₆alkyl or aryl, in some embodiments is in the range of C₂-C₁₈alkyl or aryl, and in some embodiments is in the range of C₁₂to C₁₈alkyl or aryl. Some specific examples of such ether and ester derivatives of polyalkylene glycol include: Ethal SA20, Polyoxyethylene (20) stearyl alcohol from Ethox Chemicals, Lumulse 100-S, Polyethylene glycol 1000 monostearate from Lambent Technologies, myrj 45, Polyoxylene (8) stearate from Uniqema (ICI Surfactants).
The polyalkylene glycol polymer component can be in the form of a homopolymer, or mixtures or combinations of homo polymers, or can include copolymers, such as block or random copolymers, or mixtures of combinations of such copolymers, or can include mixtures or combinations of homo polymers and copolymers. In some examples, the polyalkylene glycol polymers range in molecular weight from about 200 to several million, in some embodiments from about 200 to about 100,000, in some embodiments from about 200 to about 20,000, and in some embodiments from about 200 to about 10,000. The polyalkylene glycol polymer components can be in liquid, paste or solid form.
In some particular embodiments, the polyalkylene glycol polymer includes homopolymers of polyethylene glycols, polypropylene glycols, or block and random copolymers of ethylene oxide and propylene oxide, and derivatives of mixtures of any of these. For example, block copolymers of ethylene oxide and propylene oxide are known in the art as nonionic surfactants and are commercially available. One example of a trade name for such block copolymers is Pluronics®, manufactured by BASF.
One particular type of polyalkylene glycol polymer used in some embodiments includes ethylene oxide/propylene oxide copolymer wherein the polymer is prepared by the controlled addition of propylene oxide to the two hydroxyl groups of propylene glycol. Ethylene oxide is then added to sandwich this hydrophobe between hydrophilic groups, controlled by length to constitute from 10% to 80% (by weight) of the final molecule. This type of polymer is best illustrated by the following formula:

The x, y, and x′ in the formula have no definite integers, but depend on the amount of ethylene oxide and propylene oxide in the desired polymer. In this particular embodiment, ethylene oxide constitutes anywhere from 10 to 80 wt-%.
A second type of block copolymer in some embodiments is that prepared by adding ethylene oxide to ethylene glycol to provide a hydrophile of designated molecular weight. Propylene oxide is then added to obtain hydrophobic blocks on the outside of the molecule thereby creating another sandwich. The structure of this polymer is illustrated as follows:

The content of ethylene oxide can range from 10 to 80 wt-%. In some specific embodiments, the block copolymers are those between the molecular weight range of 800 to 40,000 and comprise polypropylene oxide sandwiched by polyethylene oxide blocks wherein the ethylene oxide constitutes from about 10 to 80 wt-% of a copolymer. One particular example of a useful block copolymer is that polymer identified as Pluronic® F-108, which has an average molecular weight of 14,600, a meltlpour point of 57° C., is a solid at room temperature with a viscosity of 2,800 cps at 77° C. and a surface tension in dynes/cm of 41 at 25° C., @0.1%.
Examples of preferred polyalkylene glycols include the block copolymers, such as the 50HB fluids commercially available from the Dow Chemical Company (Midland, Mich.) such as, Ucon 50HB55, Ucon 50HB100, Ucon 50HB170, Ucon 50HB260, Ucon 50HB400, Ucon 50HB660, and Ucon 50HB2000. Other examples included the oxypropylene polymers LB-65, LB-165, LB-385, LB-625, and LB-1145, commercially available from the Dow Chemical Company, the difunctional polymers containing 75% oxyethylene and 25% oxypropylene 75-H-450, 75-H-1400, and 75-H-9500, commercially available from the Dow Chemical Company; Carbowax polyethylene glycols such as Carbowax 200, 300, 400, and 600, commercially available from the Dow Chemical Company; and the Carbowax methoxypolyethylene glycols such as Carbowax 350, 550, and 750, commercially available from the Dow Chemical Company. The polyalkylene glycol component can comprise a very broad range of weight percent of the entire composition, depending upon the desired properties. For example, the polyalkylene glycol polymer can comprise in the range from about 1 to about 99 wt.-% of the total composition, in some embodiments in the range of about 1 to about 50 wt.-% of the total composition, and in some embodiments in the range of about 3 to about 25 wt.-% of the total composition.
Food Additive
In many industries, including the food and beverage industry, it may be desirable that any composition or chemical that comes into contact with foods and beverages, including conveyor lubricants, be suitable for human consumption such that when the composition or chemical comes into direct, indirect, or incidental contact with the food or beverage, it does not render the food or beverage unfit for consumption by humans or mammals. “Direct, indirect, or incidental contact” means that the food or beverage acquires an amount of the composition. “Food or beverage” as used in this application means any substance ingested by humans or mammals including liquid, solid, semisolid, composite comestible material in the form of water, carbonated beverage, a food, juice, sports beverage, snack, edible container, or carrier. The term “food additive” means that a composition or chemical may be safely administered to humans and mammals. The food additive compositions or chemicals, when combined together to make the compositions of the invention, preferably both perform the desired function and pass the stringent guidelines of the federal regulations.
Examples of fatty acids that are suitable food additives include the following oleic acid, tall oil fatty acid, and refined coconut oil.
Examples of neutralizing agents that are suitable food additives include sodium and potassium hydroxide, morpholine and urea.
Examples of polyalkylene glycol polymers that are suitable food additives include Carbowax™ and Ucon™ products available from the Dow Chemical Company, or block and random copolymers of ethylene oxide and propylene oxide, and derivatives or mixtures of any of these. One example of a trade name for such block copolymers is Pluronics® and is manufactured by BASF.
An example of a monomeric polyol that is a suitable food additive includes propylene glycol.
Other Ingredients
Other active ingredients may optionally be used to improve the effectiveness of the lubricant. Some non-limiting examples of such additional active ingredients can include: surfactants, (cationic, anionic, amphoteric, and nonionic), stabilizing/coupling agents, dispersing agents, anti-wear agents, antimicrobial agents, foam inhibiters/generators, viscosity modifiers, sequestrants/chelating agents, bleaching agents such as hydrogen peroxide and others, secondary lubricants, dyes, odorants, and the like, and other ingredients useful in imparting a desired characteristic or functionality in the lubricant composition. The following describes some examples of such ingredients.
Surfactants
The lubricant concentrate may also contain surfactants, cationic, anionic, amphoteric, and nonionic, or mixtures thereof. For a discussion on surfactants, see Kirk-Othmer, Surfactants in Encyclopedia of Chemical Technology, 19:507-593 (2d Ed. 1969), which is incorporated by reference herein.
Some examples of anionic surfactants suitable for use include carboxylates, sulfates, sulfonates, phosphates, and mixtures thereof. Some examples of phosphates include alkyl orthophosphates such as stearyl acid phosphate, alkyl polyphosphates and alkyl ether phosphate (alkyl phosphate ester). Some phosphate esters have alkyl chains with 8 to 16 carbon atoms. In some embodiments, the phosphate is a linear alcohol alkylate phosphate ester, particularly a C₈to C₁₀alcohol ethoxylate phosphate ester. Some embodiments include alkaline salts of C₈to C₁₀saturated and unsaturated fatty acids, such as, for example, tall oil, oleic or coconut oil. One particular example includes a sodium tall oil soap. When used in the lubricant composition, in some embodiments the anionic surfactant can be present in a range of up to about 50 wt-%.
Some examples of cationic cosurfactants suitable for use include quaternary ammonium surfactants with one or two long chain fatty alkyl groups and one or two lower alkyl or hydroxyalkyl substituents. Preferable examples are alkylbenzyl dimethyl ammonium chloride wherein the alkyl groups are a stearyl, tallow, lauryl, myristyl moiety, and the like, and mixtures thereof. When used in the lubricant composition, in some embodiments the cationic cosurfactants can be present in a range of up to about 50 wt-%.
Some examples of nonionic surfactants include polyalkylene oxide condensates of long chain alcohols such as alkyl phenols and aliphatic fatty alcohols. Some specific examples contain alkyl chains of C₆to C₁₈. Typical examples are polyoxyethylene adducts of tall oil, coconut oil, lauric, stearic, oleic acid, and the like, and mixtures thereof. Other nonionic surfactants can be polyoxyalkylene condensates of fatty acid amines and amides having from about 8 to 22 carbon atoms in the fatty alkyl or acyl groups and about 10 to 40 alkyloxy units in the oxyalkylene portion. An exemplary product is the condensation product of coconut oil amines and amides with 10 to 30 moles of ethylene oxide. It is possible to form a block copolymer by condensing different alkylene oxides with the same fatty acid amine or amide. An example is a polyoxalkylene condensate of a long chain fatty acid amine with three blocks of oxyalkylene units wherein the first and third block consists of propylene oxide moiety and the second block consists of ethylene oxide moiety. The block copolymer may be linear or branched.
Yet another kind of nonionics are alkoxylated fatty alcohols. Typical products are the condensation products of n-decyl, n-dodecyl, n-octadecyl alcohols, and a mixture thereof with 3 to 50 moles of ethylene oxide.
Some specifically suitable nonionics for the present lubricant compositions are alkylene oxide adducts of relatively low degree of polymerization alkylglycosides. These oxyalkylated glycosides comprise a fatty ether derivative of a mono-, di-, tri-, etc. saccharide having an alkylene oxide residue. Preferable examples contain 1 to 30 units of an alkylene oxide, typically ethylene oxide, 1 to 3 units of a pentose or hexose, and an alkyl group of a fatty group of 6 to 20 carbon atoms. An oxyalkylated glycoside compares with the general formula of:
H-(AO)_m-G_y-O—R
where AO is an alkylene oxide residue; m is the degree of alkyl oxide substitution having an average of from 1 to about 30, G is a moiety derived from a reducing saccharide containing 5 of 6 carbon atoms, i.e. pentose or hexose; R is saturated or nonsaturated fatty alkyl group containing 6 to 20 a carbon atoms; and y, the degree of polymerization (D.P.) of the polyglycoside, represents the number of monosaccharide repeating units in the polyglycoside, is an integer on the basis of individual molecules, but may be an noninteger when taken on an average basis when used as an ingredient for lubricants.
Some specific examples include sorbitan fatty acid esters, such as the Spans® and the polyoxyethylene derivatives of sorbitan and fatty acid esters known as the Tweens®. These are the polyoxyethylene sorbitan and fatty acid esters prepared from sorbitan and fatty esters by addition of ethylene oxide. Some specific examples of these are polysorbate 20, or polyoxyethylene 20 sorbitan monolaurate, polysorbate 40, or polyoxyethylene 20 sorbitan monopalmatate, polysorbate 60, or polyoxyethylene 20 sorbitan monostearate, or polysorbate 85, or polyoxyethylene 20 sorbitan triolyate. Used in the lubricant composition, in some embodiments the nonionic surfactant can be present in a range of up to about 50 wt-%.
Additionally, in some embodiments, the lubricant can include a nonionic surfactant that is an alkylpolyglycoside. Alkylpolyglycosides (APGs) also contain a carbohydrate hydrophile with multiple hydroxyl groups.
APGs are fatty ether derivatives of saccharides or polysaccharides. The saccharide or polysaccharide groups are mono-, di-, tri-, etc. saccharides of hexose or pentose, and the alkyl group is a fatty group with 7 to 20 carbon atoms. Alkylpolyglycoside can be compared with the general formula of:
G_x-O—R
where G is moiety derived from a reducing saccharide containing 5 of 6 carbon atoms, i.e. pentose or hexose; and R is saturated or nonsaturated fatty alkyl group containing 6 to 20 carbon atoms; x, the degree of polymerization (D.P.) of the polyglycoside, representing the number of monosaccharide repeating units in the polyglycoside, is an integer on the basis of individual molecules, but may be a noninteger when taken on an average basis when used as an ingredient for lubricants. In some embodiments, x has the value of less than 2.5, and in some embodiments is in the range or 1 and 2.
The reducing saccharide moiety, G can be derived from pentose or hexose. Exemplary saccharides are glucose, fructose, mannose, galactose, talose, gulose, allose, altrose, idose, arabinose, xylose, lyxose and ribose. Because of the ready availability of glucose, glucose is a common embodiment in the making of polyglycosides.
The fatty alkyl group in some embodiments is a saturated alkyl group, although unsaturated alkyl fatty group can be used. It is also possible to use an aromatic group such as alkylphenyl, alkylbenzyl and the like in place of the fatty alkyl group to make an aromatic polyglycoside.
Generally, commercially available polyglycosides have alkyl chains of C₈to C₁₆and average degree of polymerization in the range of 1.4 to 1.6. In some embodiments, a lubricant composition of the invention can include up to about 50 wt-%, and in some embodiments in the range of about 3 wt-% to 10 wt-% of alkylpolyglycoside.
Stabilizing/Coupling Agents
In a lubricant concentrate, stabilizing agents, or coupling agents can be employed to keep the concentrate homogeneous, for example, under cold temperature. Some of the ingredients may have the tendency to phase separate or form layers due to the high concentration. Many different types of compounds can be used as stabilizers. Examples are isopropyl alcohol, ethanol, urea, octane sulfonate, glycols such as hexylene glycol, propylene glycol and the like. The stabilizing/coupling agents can be used in an amount to give desired results. This amount can range, for example, from about 0 to about 30 wt.-% of the total composition.
Detergents/Dispersing Agents
Detergents of dispersing agents may also be added. Some examples of detergents and dispersants include alkylbenzenesulfonic acid, alkylphenols, carboxylic acids, alkylphosphonic acids, and their calcium, sodium, and magnesium salts, polybutenylsuccinic acid derivatives, silicone surfactants, fluorosurfactants, and molecules containing polar groups attached to an oil-solubilizing aliphatic hydrocarbon chain.
Some examples of suitable dispersing agents include triethanolamine, alkoxylated fatty alkyl monoamines and diamines such as coco bis(2-hydroxyethyl)amine, polyoxyethylene(5-)coco amine, polyoxyethylene(15)coco amine, tallow bis(-2 hydroxyethyl)amine, polyoxyethylene(15)amine, polyoxyethylene(5)oleyl amine and the like.
The detergent and/or dispersants can be used in an amount to give desired results. This amount can range, for example, from about 0 to about 30 wt.-% of the total composition.
Anti-Wear Agents
Anti-wear agents can also be added. Some examples of anti-wear agents include zinc dialkyldithiophosphates, tricresyl phosphate, and alkyl and aryl disulfides and polysulfides. The anti-wear and/or extreme pressure agents are used in amounts to give the desired results. This amount can range, for example, from 0 to about 20 wt.-% of the total composition.
Antimicrobial Agents
Antimicrobial agents can also be added. Some useful antimicrobial agents include disinfectants, antiseptics, and preservatives. Some non-limiting examples include phenols including halo- and nitrophenols and substituted bisphenols such as 4-hexylresorcinol, 2-benzyl-4-chlorophenol and 2,4,4′-trichloro-2′-hydroxydiphenyl ether, organic and inorganic acids and its esters and salts such as dehydroacetic acid, peroxycarboxylic acids, peroxyacetic acid, methyl p-hydroxy benzoic acid, cationic agents such as quaternary ammonium compound, phosphonium compounds such as tetrakishydroxymethyl phosphonium sulphate (THPS), aldehydes such as glutaraldehyde, antimicrobial dyes such as acridines, triphenylmethane dyes and quinines and halogens including iodine and chlorine compounds. The antimicrobial agents can be used in amounts to provide the desired antimicrobial properties. In some examples, the amount can range from 0 to about 20 wt.-% of the total composition.
Foam Inhibiters/Generators
Foam inhibitors or foam generators can also be used. Some examples of foam inhibitors include methyl silicone polymers. Some examples of foam generators include surfactants such as non-ionic, cationic, and amphoteric compounds. The foam inhibitors/generators can be used in amounts to provide the desired results. The foam modifiers can be used in an amount to give desired results. This amount can range, for example, from about 0 to about 30 wt.-% of the total composition.
Viscosity Modifiers
Viscosity modifiers can also be used. Some examples of viscosity modifiers include pour-point depressants and viscosity improvers, such as polymethacrylates, polyisobutylenes polyacrylamides, polyvinyl alcohols, polyacrylic acids, high molecular weight polyoxyethylenes, and polyalkyl styrenes. The modifiers can be used in amounts to provide the desired results. In some embodiments, the viscosity modifiers can range for 0 to about 30 wt.-% of the total composition.
Sequestrants/Chelating Agents
In addition to the aforementioned ingredients, it is possible to include other chemicals in the lubricant concentrates. For example, where soft water is unavailable and hard water is used for the dilution of the lubricant concentrate, there is a tendency for the hardness cations, such as calcium, magnesium, and ferrous ions, to reduce the efficacy of the surfactants, and even form precipitates when coming into contact with ions such as sulfates, and carbonates. Sequestrants can be used to form complexes with the hardness ions. A sequestrant molecule may contain two or more donor atoms which are capable of forming coordinate bonds with a hardness ion. Sequestrants that possess three, four, or more donor atoms are called tridentate, tetradentate, or polydentate coordinators. Generally the compounds with the larger number of donor atoms are better sequestrants. The preferable sequestrant is ethylene diamine tetracetic acid (EDTA), such as Versene products which are Na₂EDTA and Na₄EDTA sold by Dow Chemicals. Some additional examples of other sequestrants include: iminodisuccinic acid sodium salt, trans-1,2-diaminocyclohexane tetracetic acid monohydrate, diethylene triamine pentacetic acid, sodium salt of nitrilotriacetic acid, pentasodium salt of N-hydroxyethylene diamine triacetic acid, trisodium salt of N,N-di(beta-hydroxyethyl) glycine, sodium salt of sodium glucoheptonate, and the like.
Bleaching Agents
The compositions of the invention may include a bleaching agent or a decolorizing agent. Examples of suitable bleaching agents include acetone peroxide ammonium persulfate; azodicarbonamide, benzoyl peroxide carbon activate, catalase, chloromethylated aminated styrene divinylbenzene resin ammonium chloride, H₂O₂.BrO₃; lipoxidase, sodium hydrosulfite, sodium hypochlorite, sodium metabisulfite, sodium sulfite, and sulfur dioxide.
Dyes and Oderants
Various dyes and odorants including perfumes and other aesthetic enhancing agents may also be included in the composition. Dyes may be included to alter the appearance of the composition, as for example, any water soluble or product soluble dye, any FD&C approved dye, Direct Blue 86 (Miles), Fastusol Blue (Mobay Chemical Corp), Acid Orange 7 (American Cyanamid), Basic Violet 10 (Sandoz), Acid Yellow 23 (GAF), Acid Yellow 17 (Sigma Chemical), Sap Green (Keyston Analine and Chemical), Metanil Yellow (Keyston Analine and Chemical), Acid Blue 9 (Hilton Davis), Sandolan Blue/Acid Blue 182 (Sandoz), Hisol Fast Red (Capitol Color and Chemical), Fluorescein (Capitol Color and Chemical), Acid Green 25 (Ciba-Geigy), and the like.
Fragrances or perfumes that may be included in the composition include for example terpenoids such as citronellol, aldehydes such as amyl cinnamaldehyde, a jasmine such as CIS-jasmine or jasmal, vanillin, and the like.
Stress Crack Inhibitors
The composition may optionally include a stress crack inhibitor to make the compositions of the invention more compatible with a PET container. Examples of suitable stress crack inhibitors include alkyl phosphoric esters, alkyl aryl phosphoric esters.
Friction Modifiers
Some non-limiting examples of useful friction modifiers include fatty acids with 12-18 carbon atoms, fatty alcohols, esters of fatty acids such as glycerides, fatty amines and amides.
Secondary Lubricant
A variety of secondary lubricants can be employed in the lubricant compositions, including hydroxy-containing compounds such as polyols (e.g., glycerol and propylene glycol); polyalkylene glycols (e.g., the CARBOWAX™ series of polyethylene and methoxypolyethylene glycols, commercially available from the Dow Chemical Company and Dowanol DPM (dipropylene glycol methyl ether) available from Dow); linear copolymers of ethylene and propylene oxides (e.g., UCON™ 50-HB-100 water-soluble ethylene oxide:propylene oxide copolymer, commercially available from the Dow Chemical Company); and sorbitan esters (e.g., TWEEN™ series 20, 40, 60, 80 and 85 polyoxyethylene sorbitan monooleates and SPAN™ series 20, 80, 83 and 85 sorbitan esters, commercially available from ICI Surfactants). Other suitable secondary lubricants include phosphate esters, amines and their derivatives, and other commercially available secondary lubricants that will be familiar to those skilled in the art. Derivatives (e.g., partial esters or ethoxylates) of the above lubricants can also be employed. For applications involving plastic containers, care should be taken to avoid the use of lubricants that might promote environmental stress cracking in plastic containers.
Finally, a variety of silicone materials can be employed as a secondary lubricant, including silicone emulsions (such as emulsions formed from methyl(dimethyl), higher alkyl and aryl silicones; functionalized silicones such as chlorosilanes; amino-, methoxy-, epoxy- and vinyl-substituted siloxanes; and silanols). Suitable silicone emulsions include E2175 high viscosity polydimethylsiloxane (a 60% siloxane emulsion commercially available from Lambent Technologies, Inc.), E2145 FG food grade intermediate viscosity polydimethylsiloxane (a 35% siloxane emulsion commercially available from Lambent Technologies, Inc.), HV490 high molecular weight hydroxy-terminated dimethyl silicone (an anionic 30-60% siloxane emulsion commercially available from Dow Corning Corporation), SM2135 polydimethylsiloxane (a nonionic 50% siloxane emulsion commercially available from GE Silicones) and SM2167 polydimethylsiloxane (a cationic 50% siloxane emulsion commercially available from GE Silicones). Other silicone materials include finely divided silicone powders such as the TOSPEARL™ series (commercially available from Toshiba Silicone Co. Ltd.); and silicone surfactants such as WP30 anionic silicone surfactant, WAXWS-P nonionic silicone surfactant, QUATQ-400M cationic silicone surfactant and 703 specialty silicone surfactant (all commercially available from Lambent Technologies, Inc.). Preferred silicone emulsions typically contain from 30 wt. % to 70 wt. % water. Non-water-miscible silicone materials (e.g., non-water-soluble silicone fluids and non-water-dispersible silicone powders) can also be employed in the lubricant if combined with a suitable emulsifier (e.g., nonionic, anionic or cationic emulsifiers). Again, care should be taken to avoid the use of emulsifiers or other surfactants that promote environmental stress cracking in plastic containers.
Lubricant Composition and Use
As previously discussed, the compositions of the invention are non-solid compositions in order to provide a concentrated fatty acid lubricant that requires less storage volume than typical liquid lubricant compositions, but can be readily dispensed like a liquid lubricant.
In some embodiments it is preferable that the lubricant concentrate have a carrier fluid. The carrier fluid aids in the dispensing and dilution of the concentrate in water before application on the conveyor belt and thermoplastic containers. Water is the most commonly used and preferred carrier for carrying the various ingredients in the formulation of the lubricant concentrate. It is possible, however, to use a water-soluble solvent, such as alcohols and polyols. These solvents may be used alone or with water. Some examples of suitable alcohols include methanol, ethanol, propanol, butanol, and the like, as well as mixtures thereof. Some examples of polyols include glycerol, ethylene glycol, propylene glycol, diethylene glycol, and the like, as well as mixtures thereof. Generally, when added into the lubricant concentrate, the carrier is present in the range of about 1% to 90% by weight. When the lubricant is diluted in water for applying to a belt, water may be present in the diluted lubricating solution in the range of about 50% to 99.9 wt-%.
In some embodiments, the lubricant concentrate is diluted with a diluent, for example water, in a concentrate/diluent ratio of 1:50 to 1:1000 before using. In another aspect, a method of lubricating a continuously-moving plastic conveyor system for transporting a container is practiced by applying diluted aqueous thermoplastic compatible lubricating composition to the surface of the plastic conveyor. This application may be by means of spraying, immersing, brushing and the like. The dilution may be done either batchwise by adding water into a container with a suitable amount of the concentrate or continuously online. Online dilution is usually done by the regulated injection of a stream of concentrate into a stream of water at a steady rate. The injection of the concentrate can be achieved by a pump, for example, metering pump, although other injection means are possible. Water of varying quality, for example, tap water, soft water, and deionized water may be used. The water may also be heated or chilled.
In some other embodiments, the compositions can be applied in relatively low amounts, and do not require dilution with significant amounts of a carrier. In some such embodiments, the composition provides a thin, substantially non-dripping lubricating film. In contrast to dilute embodiments, such embodiments can provide drier lubrication of the conveyors, and/or containers, a cleaner and drier conveyor line and working area, and reduced lubrication usage, thereby reducing waste, cleanup, and disposal problems.
In yet some additional embodiments, it may be desirable to provide one or more of the various components of the composition in separate containers until it is desired to make the final composition. For example, the polyalkylene glycol polymer component, the fatty acid component, the neutralizing agent component, and the monomeric polyol component can be provided in separate containers until it is desired to make the composition. Such an arrangement allows for the separate components to be available for use in other compositions. For example, the polyalkylene glycol polymer component could be useful in a separate lubricant composition that does not include the fatty acid component. Likewise, the fatty acid component could be useful in a separate lubricant composition that does not include the polyalkylene glycol polymer component. By maintaining such components in separate containers until it is desired to combine them to make the lubricant composition containing both, the components are potentially available for use in other systems. The mixing of the components can be made in concentrates or mixed after dilution. The mixing of the dilution can be made at the point of application or before at the mechanical system of transporting the product to the intended use sites.
The lubricant composition, either concentrated or diluted, can be applied to a conveyor system surface that comes into contact with containers, the container surface that needs lubricity, or both. Any suitable method of applying the lubricant to the conveyor surface and/or the container surface can be used. Some examples of application methods include spraying, wiping, rolling, brushing, atomizing, dipping, and the like, or a combination of any of these. The lubricant composition can be applied to the surface by continuous, intermittent, or one time application. In at least some embodiments, only portions of the conveyor that contact the containers need to be treated. Likewise, in some embodiments, only portions of the container that contact the conveyor, or in some embodiments, that contact other containers, need to be treated. The lubricant can be formulated as a permanent composition that remains on the container or conveyor throughout its useful life, or can be a semi-permanent, or temporary composition.
The surface of the conveyor that supports the containers can be made of a wide variety of materials, for example, fabric, metal, plastic, elastomer, composites, or combinations or mixtures of these materials. Any type of conveyor system used in the container field can be treated according to some embodiments of the invention. Some examples of conveyors, containers, methods of application, and the like are disclosed in International Patent Application publication number WO 01/12759, the entire disclosure of which is incorporated herein by reference for all purposes.
In some embodiments, the lubricant composition can also be formulated to include additional desirable characteristics. For example, it may be desirable to provide a lubricating composition that is has biodegradability and nontoxicity. The public is increasingly aware of the ecological problems caused by the release of man-made chemicals in the environment. More stringent governmental regulations are being implemented to respond to this public concern. Therefore, in some embodiments, the lubricating composition would desirably contain chemicals that are more biodegradable and less toxic than conventional chemicals used in lubricant concentrates. In some embodiments, it may also be desirable that the lubricating composition be compatible with inks or dyes that are used on the surface of the containers. For example, it may be desirable that the lubricant composition be compatible with inks used for date code on some containers, and does not remove such ink from the containers.
For a more complete understanding of the invention, the following examples are given to illustrate some embodiment. These examples and experiments are to be understood as illustrative and not limiting. All parts are by weight, except where it is contrarily indicated.

EXAMPLES

The following chart provides a brief explanation of certain chemical components used in the following examples:

TABLE 1


Trade Names and Corresponding Description of Some Chemicals
Used in the Examples

Tradename/Chemical Name	Description	Provider

Oleic Acid	Fatty Acid	Various
Potassium Hydroxide (45%)	Neutralizer	Various
Ucon 50HB660	Polyalkylene Glycol	Dow
	Polymer
Propylene Glycol	Monomeric Polyol	Various
Na₂EDTA	Chelating Agent	Various
Ethylene Glycol	Monomeric Polyol	Various
Hexylene Glycol	Monomeric Polyol	Various
Ethyl Alcohol	Viscosity Modifier	Various
Na₄EDTA	Chelating Agent	Various
Ucon LB285	Polyalkylene Glycol	Dow
Ucon 50HB55	Polyalkylene Glycol	Dow
Carbowax 300	Polyalkylene Glycol	Dow

The chart in Table 2 shows the mix order for the ingredients in the formulas. The ingredients were mixed for 30 minutes and allowed to sit for at least 12 hours at room conditions and then measured with a Brookfield DVI+ viscometer. The formulas were then observed and their viscosity measured when possible.

TABLE 2


Mix Order

Formula	Ingredient 1	Ingredient 2	Ingredient 3	Ingredient 4	Ingredient 5	Ingredient 6	Ingredient 7	Ingredient 8

1	DI H2O	UCON 50HB660	Oleic Acid	KOH 45%	Na2EDTA
2	DI H2O	Propylene Glycol	Oleic Acid	KOH 45%	Na2EDTA
3	DI H2O	Oleic Acid	KOH	Na2EDTA
4	DI H2O	Propylene Glycol	UCON 50HB660	Oleic Acid	KOH	Na2EDTA
5	DI H2O	Hexylene Glycol	Na4EDTA	UCON LB285	Oleic Acid	KOH 45%
6	DI H2O	Hexylene Glycol	Na4EDTA	UCON LB285	Oleic Acid	KOH 45%
7	DI H2O (39.5%)	Hexylene Glycol	Na4EDTA	UCON LB285	Oleic Acid	KOH 45%	Hexylene Glycol	DI H2O (2.5%)
		(8.9%)					(2.5%)
8	DI H2O (41.1%)	Hexylene Glycol	Na4EDTA	UCON 50HB55	Oleic Acid	KOH 45%	DI H2O (2.9%)
9	DI H2O (43.7%)	Hexylene Glycol	Na4EDTA	UCON 50HB55	Oleic Acid	KOH 45%	DI H2O (3.3%)
10	DI H2O (47.9%)	Hexylene Glycol	Na4EDTA	UCON 50HB55	Oleic Acid	KOH 45%	DI H2O (2.1%)
11	DI H2O	Hexylene Glycol	Na4EDTA	Carbowax 300	Oleic Acid	KOH 45%	Hexylene Glycol	Carbowax 300
		(5.7%)		(11.2%)			(2.8%)	(2.8%)
12	DI H2O	Hexylene Glycol	Na4EDTA	Oleic Acid	KOH 45%
13	DI H2O	Propylene Glycol	Na4EDTA	UCON 50HB660	Oleic Acid	KOH 45%
14	DI H2O	Ethylene Glycol	Na4EDTA	UCON 50HB660	Oleic Acid	KOH 45%
15	DI H2O	Hexylene Glycol	Na4EDTA	UCON 50HB660	Oleic Acid	KOH 45%
16	DI H2O	Ethyl Alcohol	Na4EDTA	UCON 50HB660	Oleic Acid	KOH 45%
17	DI H2O (41.5%)	Hexylene Glycol	Na4EDTA	UCON 50HB660	Oleic Acid	KOH 45%	DI H2O (2.5%)
18	DI H2O (45%)	Hexylene Glycol	Na4EDTA	UCON 50HB660	Oleic Acid	KOH 45%	DI H2O (2%)
19	DI H2O (47.5%)	Hexylene Glycol	Na4EDTA	UCON 50HB660	Oleic Acid	KOH 45%	DI H2O (2.5%)
20	DI H2O (41%)	Propylene Glycol	Na4EDTA	UCON 50HB660	Oleic Acid	KOH 45%	DI H2O (3%)
21	DI H2O (44%)	Propylene Glycol	Na4EDTA	UCON 50HB660	Oleic Acid	KOH 45%	DI H2O (3%)
22	DI H2O (48%)	Propylene Glycol	Na4EDTA	UCON 50HB660	Oleic Acid	KOH 45%	DI H2O (2%)
23	DI H2O	Na4EDTA	KOH 45%	Hexylene Glycol	UCON	Oleic Acid
					50HB55
24	DI H2O	Na4EDTA	Hexylene Glycol	UCON 50HB55	Oleic Acid	KOH 45%	Hexylene Glycol
			(8.3%)				(9.2%)
25	DI H2O	Hexylene Glycol	UCON 50HB55	Na4EDTA	Oleic Acid	KOH 45%	Hexylene Glycol
		(7.2%)					(2.5%)
26	DI H2O (38.6%)	Hexylene Glycol	Na4EDTA	UCON 50HB55	Oleic Acid	KOH 45%	DI H2O (4.1%)	Oleic Acid
						(23.5%)
27	DI H2O	Hexylene Glycol	Na4EDTA	UCON 50HB55	Oleic Acid	KOH 45%	(4.7%)
28	DI H2O	Hexylene Glycol	Na4EDTA	UCON 50HB55	Oleic Acid	KOH 45%
29	DI H2O	Hexylene Glycol	Na4EDTA	UCON 50HB55	Oleic Acid	KOH 45%
30	DI H2O	Hexylene Glycol	Na4EDTA	UCON 50HB55	Oleic Acid	KOH 45%
31	DI H2O	Hexylene Glycol	Na4EDTA	UCON 50HB55	Oleic Acid	KOH 45%
32	DI H2O	Hexylene Glycol	Na4EDTA	UCON 50HB55	Oleic Acid	KOH 45%

Example 1

Impact on Viscosity of Various Additives

Example 1 examined the impact of various additives on the viscosity of a high concentration fatty acid composition. For this example, four formulas were prepared (see Table 3).

TABLE 3


Viscosity Study Results

Formula (in wt. %)

	1	2	3	4

Deionized Water	47	47	59	47
Oleic Acid	25	25	25	25
Potassium	12.5	12.5	12.5	12.5
Hydroxide
(45%)
Polyalkylene Glycol	12	0	0	6
(Ucon 50HB660)
Propylene Glycol	0	12	0	6
Na₂EDTA	3.5	3.5	3.5	3.5
Observation	Solidified	Very high	Solidified	Low viscosity.
		viscosity.		Easy flow.
		Uniform.		Uniform liquid.
Viscosity	Not	7550 cps	Not	985 cps
	Tested		Tested

Table 3 shows that the combination of polyalkylene glycol (50HB660) and monomeric polyol (propylene glycol) is necessary to achieve a concentrated fatty acid composition with a low viscosity (easy flow). Formula 1 contained only polyalkylene glycol polymer without the monomeric polyol. The resulting composition solidified. Formula 2 contained only the monomeric polyol without the polyalkylene glycol polymer. The resulting composition was very thick having a viscosity of 7550 cps when measured at room temperature with a HA/HB spindle 6 on a Brookfield DV I+ viscometer. Formula 3 did not contain either the monomeric polyol or the polyalkylene glycol polymer and the resulting composition solidified. Finally, Formula 4 contained equal amounts of the polyalkylene glycol polymer and the monomeric polyol and the resulting formula had a low viscosity, easy flow, and uniform composition with a viscosity of 984 cps when measured at room temperature with a HA/HB spindle 6 on a Brookfield DV I+ viscometer.

Example 2

Example 2 determined the impact of the choice of polyalkylene glycol on viscosity. For Example 2, hexylene glycol was used as the monomeric polyol. The polyalkylene glycol in Example 1, 50HB660 was replaced with 50HB55, LB285 and Carbowax 300. The formulas used for this example are listed in Table 4, along with the viscosity results and product observations. The formulas are listed as weight percents.

TABLE 4


Impact of Various Polyalkylene Glycol Polymers on Viscosity

Formula (in wt. %)

	5	6	7	8	9	10	11	12

DI H2O	47	50	42	44	47	50	38.9	47
Oleic Acid	25	25	24.8	25	25	25	23.5	25
KOH (45%)	12.5	12.5	12.4	12.5	12.5	12.5	11.8	12.5
LB285	6	3	5.9	0	0	0	0	0
50HB55	0	0	0	9	6	3	0	0
Carbowax 300	0	0	0	0	0	0	14	0
Hexylene Glycol	6	6	11.4	6	6	6	8.5	12
Na4EDTA	3.5	3.5	3.5	3.5	3.5	3.5	3.3	3.5
Observation	Hazy,	Slight	Mostly	Clear,	Clear,	Clear,	Clear,	Clear,
	separated	separation	uniform,	smooth,	smooth,	smooth,	smooth,	smooth,
			slightly oily	pourable	pourable	pourable	pourable	pourable
			appearance
Viscosity	Not tested	720	113.3	146.7	320	1546	153.3	386.7
(spindle 5 @
60 rpm)

When LB285 was used in Formulas 5-7, the product was not as uniform as when other polyalkylene glycol polymers were used. Formula 5 had equal parts LB285 and hexylene glycol. Formula 5 was hazy and it separated. Formulas 6 and 7 were more uniform than Formula 5 but still separated in Formula 6 or had an oily film on the top of the product in Formula 7. Formula 7 had the lowest viscosity of the formulas using LB285. Formulas 8-10 used 50HB55 instead of LB285 or 50HB660. Formulas 8-10 were all clear, smooth, and pourable. Formulas 8-10 produced viscosities lower than similar formulas using Ucon 50HB660 as the polyalkylene glycol (see Table 2 Formulas 2 and 4). Formula 11 used Carbowax 300 instead of Ucon 50HB660. Formulas made with Carbowax 300 were very thick unless the hexylene glycol concentration was increased. Formula 11 with the Carbowax 300 produced a clear, smooth and pourable composition.

Example 3

Example 3 determined the impact of the choice of monomeric polyol on viscosity. Ucon 50HB600 was used as the polyalkylene glycol polymer and propylene glycol, ethylene glycol, hexylene glycol, and ethyl alcohol were used as the monomeric polyols. The formulas used for this example are listed in Table 5, along with the viscosity results and product observations. The formulas are listed as weight percents.

TABLE 5


Impact of Various Monomeric Polyols on Viscosity

Formula (in wt. %)

	13	14	15	16

DI H2O	47	47	47	47
Oleic Acid	25	25	25	25
KOH (45%)	12.5	12.5	12.5	12.5
50HB660	6	6	6	6
Propylene Glycol	6	0	0	0
Ethylene Glycol	0	6	0	0
Hexylene Glycol	0	0	6	0
Ethyl Alcohol	0	0	0	6
Na4EDTA	3.5	3.5	3.5	3.5
Observation	Clear,	Separates	Clear, smooth,	Lowest
	smooth,		pourable, lower	viscosity,
	pourable		viscosity than	but
			propylene glycol	separates
Viscosity	1060	Not	380	Not
(spindle 5 @		Tested		Tested
60 rpm)

Formula 13 used propylene glycol as the monomeric polyol. Formula 13 produced a clear, smooth, pourable composition having a viscosity of 1060 centipoise as measured with spindle 5 at 60 RPM on a Brookfield RV DV I+ viscometer. Formula 14 used ethylene glycol as the monomeric polyol. Formula 14 separated and did not form a uniform composition. Formula 15 used hexylene glycol as the monomeric polyol. Formula 15 produced a clean, smooth, pourable composition having a viscosity of 380 as measured with spindle 5 at 60 RPM on a Brookfield RV DV I+ viscometer. The viscosity of Formula 15 using hexylene glycol, was lower than the viscosity of Formula 13 using propylene glycol. Finally, Formula 16 used ethyl alcohol as the monomeric polyol. Formula 16 appeared to have the lowest viscosity, but since it separated and did not form a uniform composition, a specific viscosity value was not obtained.

Example 4

Example 4 determined the impact of the amount of polyalkylene glycol on viscosity. For this example, either propylene glycol or hexylene glycol was used as the monomeric polyol. The concentration of the monomeric polyol was kept constant at 6 wt. %. Ucon 50HB660 was used as the polyalkylene glycol. The concentration of the Ucon 50HB660 was either 3 wt. %, 6 wt. % or 9 wt. %. The formulas used for this example are listed in Table 6, along with the viscosity results and product observations. The formulas are listed as weight percents.

TABLE 6


Impact of the Amount of Polyalkylene Glycol on Viscosity

Formula (in wt. %)

	17	18	19	20	21	22

DI H2O	44	47	50	44	47	50
Oleic Acid	25	25	25	25	25	25
KOH (45%)	12.5	12.5	12.5	12.5	12.5	12.5
50HB660	9	6	3	9	6	3
Hexylene Glycol	6	6	6	0	0	0
Propylene Glycol	0	0	0	6	6	6
Na4EDTA	3.5	3.5	3.5	3.5	3.5	3.5
Observation	Clear,	Clear,	Clear,	Clear,	Clear,	Clear,
	smooth,	smooth,	smooth,	smooth,	smooth,	smooth,
	pourable	pourable	pourable	pourable	pourable	pourable
Viscosity (spindle 5	193.3	380	1353	506.7	1060	3213
@ 60 rpm)

Table 6 shows that higher concentrations of Ucon 50HB660 yielded lower viscosities. For example, Formula 17 with 9 wt. % of the Ucon 50HB660 had a viscosity of 193.3 when measured with spindle 5 at 60 RPM on a Brookfield RV DV I+ viscometer, compared to Formulas 18 and 19 with 6 wt. % and 3 wt. % respectively of Ucon 50 HB660 which had viscosities of 380 and 1353 respectively when measured with a spindle 5 at 60 RPM on a Brookfield RV DV I+ viscometer. Likewise, Formula 20, with 9 wt. % of the Ucon 50HB660 had a viscosity of 506.7 when measured with spindle 5 at 60 RPM on a Brookfield RV DV I+ viscometer compared to Formulas 21 and 22 with 6 wt. % and 3 wt. % respectively of Ucon 50HB660 and viscosities of 1060 and 3213 respectively when measured with spindle 5 at 60 RPM on a Brookfield RV DV I+ viscometer. All formulas in Table 5 produced a clear, smooth, pourable composition. Formulas 17-19, where hexylene glycol was used as the monomeric polyol, had lower viscosities than their counterparts in Formulas 19-21, where propylene glycol was used as the monomeric polyol.

Example 5

Example 5 determined how much fatty acid could be included and still result in a non-solid composition. For this example hexylene glycol was used as the monomeric polyol and Ucon 50HB55 was used as the polyalkylene glycol. The formulas used for this example are listed in Table 7, along with the product observations. The formulas all listed as weight percents.

TABLE 7


Impact of Fatty Acid Concentration on Viscosity

Formula (in wt. %)

	23	24	25	26	27	28	29	30	31	32

DI H2O	12.5	13.8	30.3	42.7	36.5	36.5	42.5	41	39.5	38
Oleic Acid	50	34.3	30	28.2	29.2	30	26	27	28	29
KOH (45%)	25	17.2	15	11.7	14.6	15	13	13.5	14	14.5
50HB55	18	12.4	10.8	8.4	8.8	9	9	9	9	9
Hexylene	12	17.5	9.7	5.6	5.8	6	6	6	6	6
Glycol
Na4EDTA	7	4.8	4.2	3.4	5.1	3.5	3.5	3.5	3.5	3.5
Observation	Very	Less	Hazy,	Clear, but	Hazy,	Hazy,	Clear,	Clear,	Clear,	Hazy,
	thick,	viscous, but	separates	separates	separates	separates	smooth,	smooth,	smooth,	separates
	hazy,	hazy,					pourable	pourable	pourable.
	gel-	separates							Very
	like								slightly
									oily
									appearance
									on top.
Viscosity	Not	Not Tested	Not	Not	Not	Not	153.3 cps	173.3 cps	186.7 cps	Not Tested
	Tested		Tested	Tested	Tested	Tested

Table 7 shows that a fatty acid concentration of 28 wt. % could be obtained while achieving a non-solid composition.

Example 6

Example 6 tested an alcohol and glycerin to determine their impact on viscosity.

The formulas used for this example are listed in Table 7, along with the product observations. All formulas are listed as weight percents. The formulas were mixed in the order they appear from top to bottom in Table 8.

	TABLE 8


	Formula

	33	34	35	36

DI H2O	47	47	47	47
1-Hexanol	6	6
Glycerine			6	6
Na4EDTA	3.5	3.5	3.5	3.5
UCON 50HB660	6		6
UCON 50HB55		6		6
Oleic Acid	25	25	25	25
KOH 45%	12.5	12.5	12.5	12.5
Comments	Separated	Separated	Uniform	Uniform
Viscosity	Not Tested	Not Tested	3513 cps	1833 cps

Table 8 shows that when hexanol was used, the composition separated. However, the glycerin formed a uniform composition. Viscosity was measured using spindle 5 at 60 RPM on a Brookfield RVDVI+ viscometer.
The foregoing summary, detailed description, and examples provide a sound basis for understanding the invention, and some specific example embodiments of the invention. Since the invention can comprise a variety of embodiments, the above information is not intended to be limiting. The invention resides in the claims.

Claims

1. A non-solid fatty acid lubricant composition having a viscosity up to about 10,000 centipoise when measured using spindle 5 at 60 RPM at room temperature comprising:

(a) at least about 25 wt. % of a fatty acid;

(b) a neutralizer;

(c) a polyalkylene glycol polymer; and

(c) a monomeric polyol.

2. The composition of claim 1, wherein the composition further comprises an additional functional ingredient.

3. The composition of claim 1, wherein the additional functional ingredient is selected from the group consisting of surfactants, stabilizing/coupling agents, dispersing agents, anti-wear agents, antimicrobial agents, foam inhibiters/generators, viscosity modifiers, sequestrants/chelating agents, bleaching agents, stress crack inhibitors, friction modifiers, film forming agents, secondary lubricants, dyes, odorants, and mixtures thereof.

4. The composition of claim 1, wherein the viscosity of the composition is from about 100 centipoise to about 5,000 centipoise when measured using spindle 5 at 60 RPM at room temperature.

5. The composition of claim 1, wherein the viscosity of the composition is from about 100 centipoise to about 1,500 centipoise when measured using spindle 5 at 60 RPM at room temperature.

6. The composition of claim 1, wherein the fatty acid is oleic acid.

7. The composition of claim 1, wherein the neutralizer is potassium hydroxide.

8. The composition of claim 1, wherein the polyalkylene glycol polymer is a block copolymer.

9. The composition of claim 1, wherein the monomeric polyol is selected from the group consisting of hexylene glycol, propylene glycol, and mixtures thereof.

10. The composition of claim 1, wherein the fatty acid comprises at least about 28 wt. % of the total composition.

11. The composition of claim 1, wherein the neutralizer comprises from about 3 wt. % to about 20 wt. % of the total composition.

12. The composition of claim 1, wherein the polyalkylene glycol polymer comprises up to about 25 wt. % of the total composition.

13. The composition of claim 1, wherein the monomeric polyol comprises up to about 25 wt. % of the total composition.

14. The composition of claim 1, further comprising a carrier.

15. The composition of claim 14, wherein the carrier is selected from the group consisting of water, methanol, ethanol, propanol, or butanol, or mixtures thereof.

16. A method of lubricating a conveyor system for transporting a container, the method comprising:

(a) providing a lubricant concentrate, the lubricant concentrate having a viscosity up to about 10,000 centipoise when measured using spindle 5 at 60 RPM at room temperature, the lubricant concentrate comprising:

(i) at least about 25 wt. % of a fatty acid;

(ii) a neutralizer; and

(iii) a monomeric polyol;

(b) mixing the lubricant concentrate with a carrier to form a lubricant composition; and

(c) applying the lubricant composition to a surface of a belt or track of the conveyor.

17. The method of claim 16, wherein the lubricant concentrate further comprises a polyalkylene glycol polymer.

18. The method of claim 16, wherein the lubricant concentrate has a viscosity from about 100 centipoise to about 5,000 centipoise when measured using spindle 5 at 60 RPM at room temperature.

19. The method of claim 16, wherein the lubricant concentrate has a viscosity from about 100 centipoise to about 1,500 centipoise when measured using spindle 5 at 60 RPM at room temperature.

20. The method of claim 16, wherein the fatty acid comprises at least about 28 wt. % of the total composition.

21. The method of claim 16, wherein the neutralizer comprises from about 5 wt. % to about 20 wt. % of the total composition.

22. The method of claim 17, wherein the polyalkylene glycol polymer comprises up to about 25 wt. % of the total composition.

23. The method of claim 16, wherein the monomeric polyol comprises up to about 25 wt. % of the total composition.

24. The method of claim 16, wherein the container is a plastic container.

25. The method of claim 16, wherein the container is a metal container.

26. The method of claim 16, wherein the container is a glass container.

27. The method of claim 16, wherein the carrier comprises water, methanol, ethanol, propanol, or butanol, or mixtures thereof.

28. The method of claim 16, wherein the lubricant composition is thermoplastic compatible.

29. The method of claim 16, wherein the lubricant composition is polyethylene terephthalate compatible.

30. The method of claim 16, wherein the composition has an alkalinity level of less than about 100 ppm.

31. The method of claim 16, wherein the composition has an alkalinity level of less than about 50 ppm.

32. The method of claim 16, wherein the composition is a dry lubricant.

33. The method of claim 16, wherein the composition is a non-dripping liquid lubricant.

34. The method of claim 16, wherein the composition further comprises an additional functional ingredient.

35. The composition of claim 34, wherein the additional functional ingredient is selected from the group consisting of surfactants, stabilizing/coupling agents, dispersing agents, anti-wear agents, antimicrobial agents, foam inhibiters/generators, viscosity modifiers, sequestrants/chelating agents, bleaching agents, stress crack inhibitors, friction modifiers, film forming agents, secondary lubricants, dyes, odorants, and mixtures thereof.

36. The method of claim 16, wherein the composition is compatible with ink used on the containers.