WO2004099359A1 - Process for producing structured materials - Google Patents
Process for producing structured materials Download PDFInfo
- Publication number
- WO2004099359A1 WO2004099359A1 PCT/EP2004/003778 EP2004003778W WO2004099359A1 WO 2004099359 A1 WO2004099359 A1 WO 2004099359A1 EP 2004003778 W EP2004003778 W EP 2004003778W WO 2004099359 A1 WO2004099359 A1 WO 2004099359A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- less
- structured material
- screw extruder
- detergent composition
- structured
- Prior art date
Links
- 239000000463 material Substances 0.000 title claims abstract description 34
- 238000000034 method Methods 0.000 title claims abstract description 24
- 239000002245 particle Substances 0.000 claims abstract description 22
- 239000000203 mixture Substances 0.000 claims abstract description 20
- 239000003599 detergent Substances 0.000 claims abstract description 19
- 239000002304 perfume Substances 0.000 claims abstract description 6
- 238000004519 manufacturing process Methods 0.000 claims abstract description 4
- 239000003795 chemical substances by application Substances 0.000 claims description 4
- 230000009477 glass transition Effects 0.000 claims description 2
- 239000002609 medium Substances 0.000 description 7
- 239000004615 ingredient Substances 0.000 description 5
- 229920000642 polymer Polymers 0.000 description 5
- 238000001125 extrusion Methods 0.000 description 4
- 239000000047 product Substances 0.000 description 4
- 238000002360 preparation method Methods 0.000 description 3
- OWEGMIWEEQEYGQ-UHFFFAOYSA-N 100676-05-9 Natural products OC1C(O)C(O)C(CO)OC1OCC1C(O)C(O)C(O)C(OC2C(OC(O)C(O)C2O)CO)O1 OWEGMIWEEQEYGQ-UHFFFAOYSA-N 0.000 description 2
- SRBFZHDQGSBBOR-IOVATXLUSA-N D-xylopyranose Chemical compound O[C@@H]1COC(O)[C@H](O)[C@H]1O SRBFZHDQGSBBOR-IOVATXLUSA-N 0.000 description 2
- WQZGKKKJIJFFOK-GASJEMHNSA-N Glucose Natural products OC[C@H]1OC(O)[C@H](O)[C@@H](O)[C@@H]1O WQZGKKKJIJFFOK-GASJEMHNSA-N 0.000 description 2
- GUBGYTABKSRVRQ-PICCSMPSSA-N Maltose Natural products O[C@@H]1[C@@H](O)[C@H](O)[C@@H](CO)O[C@@H]1O[C@@H]1[C@@H](CO)OC(O)[C@H](O)[C@H]1O GUBGYTABKSRVRQ-PICCSMPSSA-N 0.000 description 2
- DLRVVLDZNNYCBX-UHFFFAOYSA-N Polydextrose Polymers OC1C(O)C(O)C(CO)OC1OCC1C(O)C(O)C(O)C(O)O1 DLRVVLDZNNYCBX-UHFFFAOYSA-N 0.000 description 2
- PYMYPHUHKUWMLA-UHFFFAOYSA-N arabinose Natural products OCC(O)C(O)C(O)C=O PYMYPHUHKUWMLA-UHFFFAOYSA-N 0.000 description 2
- SRBFZHDQGSBBOR-UHFFFAOYSA-N beta-D-Pyranose-Lyxose Natural products OC1COC(O)C(O)C1O SRBFZHDQGSBBOR-UHFFFAOYSA-N 0.000 description 2
- WQZGKKKJIJFFOK-VFUOTHLCSA-N beta-D-glucose Chemical compound OC[C@H]1O[C@@H](O)[C@H](O)[C@@H](O)[C@@H]1O WQZGKKKJIJFFOK-VFUOTHLCSA-N 0.000 description 2
- 238000004140 cleaning Methods 0.000 description 2
- 239000000839 emulsion Substances 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- -1 pentatol Chemical compound 0.000 description 2
- 229920001490 poly(butyl methacrylate) polymer Polymers 0.000 description 2
- 239000000725 suspension Substances 0.000 description 2
- 239000006188 syrup Substances 0.000 description 2
- 235000020357 syrup Nutrition 0.000 description 2
- SERLAGPUMNYUCK-DCUALPFSSA-N 1-O-alpha-D-glucopyranosyl-D-mannitol Chemical compound OC[C@@H](O)[C@@H](O)[C@H](O)[C@H](O)CO[C@H]1O[C@H](CO)[C@@H](O)[C@H](O)[C@H]1O SERLAGPUMNYUCK-DCUALPFSSA-N 0.000 description 1
- 229920001817 Agar Polymers 0.000 description 1
- GUBGYTABKSRVRQ-XLOQQCSPSA-N Alpha-Lactose Chemical compound O[C@@H]1[C@@H](O)[C@@H](O)[C@@H](CO)O[C@H]1O[C@@H]1[C@@H](CO)O[C@H](O)[C@H](O)[C@H]1O GUBGYTABKSRVRQ-XLOQQCSPSA-N 0.000 description 1
- FBPFZTCFMRRESA-FSIIMWSLSA-N D-Glucitol Natural products OC[C@H](O)[C@H](O)[C@@H](O)[C@H](O)CO FBPFZTCFMRRESA-FSIIMWSLSA-N 0.000 description 1
- FBPFZTCFMRRESA-KVTDHHQDSA-N D-Mannitol Chemical compound OC[C@@H](O)[C@@H](O)[C@H](O)[C@H](O)CO FBPFZTCFMRRESA-KVTDHHQDSA-N 0.000 description 1
- FBPFZTCFMRRESA-JGWLITMVSA-N D-glucitol Chemical compound OC[C@H](O)[C@@H](O)[C@H](O)[C@H](O)CO FBPFZTCFMRRESA-JGWLITMVSA-N 0.000 description 1
- HMFHBZSHGGEWLO-SOOFDHNKSA-N D-ribofuranose Chemical compound OC[C@H]1OC(O)[C@H](O)[C@@H]1O HMFHBZSHGGEWLO-SOOFDHNKSA-N 0.000 description 1
- 229930091371 Fructose Natural products 0.000 description 1
- 239000005715 Fructose Substances 0.000 description 1
- RFSUNEUAIZKAJO-ARQDHWQXSA-N Fructose Chemical compound OC[C@H]1O[C@](O)(CO)[C@@H](O)[C@@H]1O RFSUNEUAIZKAJO-ARQDHWQXSA-N 0.000 description 1
- GUBGYTABKSRVRQ-QKKXKWKRSA-N Lactose Natural products OC[C@H]1O[C@@H](O[C@H]2[C@H](O)[C@@H](O)C(O)O[C@@H]2CO)[C@H](O)[C@@H](O)[C@H]1O GUBGYTABKSRVRQ-QKKXKWKRSA-N 0.000 description 1
- 239000005913 Maltodextrin Substances 0.000 description 1
- 229920002774 Maltodextrin Polymers 0.000 description 1
- 229930195725 Mannitol Natural products 0.000 description 1
- 229920001100 Polydextrose Polymers 0.000 description 1
- PYMYPHUHKUWMLA-LMVFSUKVSA-N Ribose Natural products OC[C@@H](O)[C@@H](O)[C@@H](O)C=O PYMYPHUHKUWMLA-LMVFSUKVSA-N 0.000 description 1
- 229930006000 Sucrose Natural products 0.000 description 1
- CZMRCDWAGMRECN-UGDNZRGBSA-N Sucrose Chemical compound O[C@H]1[C@H](O)[C@@H](CO)O[C@@]1(CO)O[C@@H]1[C@H](O)[C@@H](O)[C@H](O)[C@@H](CO)O1 CZMRCDWAGMRECN-UGDNZRGBSA-N 0.000 description 1
- TVXBFESIOXBWNM-UHFFFAOYSA-N Xylitol Natural products OCCC(O)C(O)C(O)CCO TVXBFESIOXBWNM-UHFFFAOYSA-N 0.000 description 1
- 240000008042 Zea mays Species 0.000 description 1
- 235000005824 Zea mays ssp. parviglumis Nutrition 0.000 description 1
- 235000002017 Zea mays subsp mays Nutrition 0.000 description 1
- 239000008272 agar Substances 0.000 description 1
- 229940023476 agar Drugs 0.000 description 1
- HMFHBZSHGGEWLO-UHFFFAOYSA-N alpha-D-Furanose-Ribose Natural products OCC1OC(O)C(O)C1O HMFHBZSHGGEWLO-UHFFFAOYSA-N 0.000 description 1
- WQZGKKKJIJFFOK-PHYPRBDBSA-N alpha-D-galactose Chemical compound OC[C@H]1O[C@H](O)[C@H](O)[C@@H](O)[C@H]1O WQZGKKKJIJFFOK-PHYPRBDBSA-N 0.000 description 1
- 239000012736 aqueous medium Substances 0.000 description 1
- PYMYPHUHKUWMLA-WDCZJNDASA-N arabinose Chemical compound OC[C@@H](O)[C@@H](O)[C@H](O)C=O PYMYPHUHKUWMLA-WDCZJNDASA-N 0.000 description 1
- GUBGYTABKSRVRQ-QUYVBRFLSA-N beta-maltose Chemical compound OC[C@H]1O[C@H](O[C@H]2[C@H](O)[C@@H](O)[C@H](O)O[C@@H]2CO)[C@H](O)[C@@H](O)[C@@H]1O GUBGYTABKSRVRQ-QUYVBRFLSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000000679 carrageenan Substances 0.000 description 1
- 235000010418 carrageenan Nutrition 0.000 description 1
- 229920001525 carrageenan Polymers 0.000 description 1
- 229940113118 carrageenan Drugs 0.000 description 1
- 235000005822 corn Nutrition 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 238000007872 degassing Methods 0.000 description 1
- 239000008121 dextrose Substances 0.000 description 1
- 230000003203 everyday effect Effects 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000000796 flavoring agent Substances 0.000 description 1
- 235000019634 flavors Nutrition 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 235000013305 food Nutrition 0.000 description 1
- 239000003205 fragrance Substances 0.000 description 1
- 229930182830 galactose Natural products 0.000 description 1
- 239000008103 glucose Substances 0.000 description 1
- 238000005469 granulation Methods 0.000 description 1
- 230000003179 granulation Effects 0.000 description 1
- 239000000905 isomalt Substances 0.000 description 1
- 235000010439 isomalt Nutrition 0.000 description 1
- HPIGCVXMBGOWTF-UHFFFAOYSA-N isomaltol Natural products CC(=O)C=1OC=CC=1O HPIGCVXMBGOWTF-UHFFFAOYSA-N 0.000 description 1
- 239000000832 lactitol Substances 0.000 description 1
- 235000010448 lactitol Nutrition 0.000 description 1
- VQHSOMBJVWLPSR-JVCRWLNRSA-N lactitol Chemical compound OC[C@H](O)[C@@H](O)[C@@H]([C@H](O)CO)O[C@@H]1O[C@H](CO)[C@H](O)[C@H](O)[C@H]1O VQHSOMBJVWLPSR-JVCRWLNRSA-N 0.000 description 1
- 229960003451 lactitol Drugs 0.000 description 1
- 239000008101 lactose Substances 0.000 description 1
- 238000010412 laundry washing Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000000845 maltitol Substances 0.000 description 1
- 235000010449 maltitol Nutrition 0.000 description 1
- VQHSOMBJVWLPSR-WUJBLJFYSA-N maltitol Chemical compound OC[C@H](O)[C@@H](O)[C@@H]([C@H](O)CO)O[C@H]1O[C@H](CO)[C@@H](O)[C@H](O)[C@H]1O VQHSOMBJVWLPSR-WUJBLJFYSA-N 0.000 description 1
- 229940035436 maltitol Drugs 0.000 description 1
- 229940035034 maltodextrin Drugs 0.000 description 1
- 239000000594 mannitol Substances 0.000 description 1
- 235000010355 mannitol Nutrition 0.000 description 1
- 229960001855 mannitol Drugs 0.000 description 1
- HEBKCHPVOIAQTA-UHFFFAOYSA-N meso ribitol Natural products OCC(O)C(O)C(O)CO HEBKCHPVOIAQTA-UHFFFAOYSA-N 0.000 description 1
- 150000002972 pentoses Chemical class 0.000 description 1
- 239000011295 pitch Substances 0.000 description 1
- 239000001259 polydextrose Substances 0.000 description 1
- 235000013856 polydextrose Nutrition 0.000 description 1
- 229940035035 polydextrose Drugs 0.000 description 1
- 239000000600 sorbitol Substances 0.000 description 1
- 229960002920 sorbitol Drugs 0.000 description 1
- 235000010356 sorbitol Nutrition 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000005720 sucrose Substances 0.000 description 1
- 238000003325 tomography Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 239000000811 xylitol Substances 0.000 description 1
- 235000010447 xylitol Nutrition 0.000 description 1
- HEBKCHPVOIAQTA-SCDXWVJYSA-N xylitol Chemical compound OC[C@H](O)[C@@H](O)[C@H](O)CO HEBKCHPVOIAQTA-SCDXWVJYSA-N 0.000 description 1
- 229960002675 xylitol Drugs 0.000 description 1
- UHVMMEOXYDMDKI-JKYCWFKZSA-L zinc;1-(5-cyanopyridin-2-yl)-3-[(1s,2s)-2-(6-fluoro-2-hydroxy-3-propanoylphenyl)cyclopropyl]urea;diacetate Chemical compound [Zn+2].CC([O-])=O.CC([O-])=O.CCC(=O)C1=CC=C(F)C([C@H]2[C@H](C2)NC(=O)NC=2N=CC(=CC=2)C#N)=C1O UHVMMEOXYDMDKI-JKYCWFKZSA-L 0.000 description 1
Classifications
-
- 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
- C11D3/00—Other compounding ingredients of detergent compositions covered in group C11D1/00
- C11D3/50—Perfumes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/92—Measuring, controlling or regulating
-
- 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
- C11D11/00—Special methods for preparing compositions containing mixtures of detergents
- C11D11/0082—Special methods for preparing compositions containing mixtures of detergents one or more of the detergent ingredients being in a liquefied state, e.g. slurry, paste or melt, and the process resulting in solid detergent particles such as granules, powders or beads
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92504—Controlled parameter
- B29C2948/92542—Energy, power, electric current or voltage
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92504—Controlled parameter
- B29C2948/9258—Velocity
- B29C2948/9259—Angular velocity
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/04—Particle-shaped
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/05—Filamentary, e.g. strands
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/30—Extrusion nozzles or dies
- B29C48/345—Extrusion nozzles comprising two or more adjacently arranged ports, for simultaneously extruding multiple strands, e.g. for pelletising
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2021/00—Use of unspecified rubbers as moulding material
Definitions
- the present invention relates to a process for producing structured materials for use in a detergent composition by use of a screw extruder.
- Modern laundry detergent compositions contain many ingredients, each performing a separate function. The majority of ingredients perform their function by their behaviour in solution. However also, ingredients are added in granular form to achieve an additional benefit, such as carrying a liquid component or to achieve a certain bulk density. Furthermore certain granular components can provide a significant additional benefit if they have a controlled microstructure. This may, for example, be to encapsulate a volatile ingredient to be released during use or to provide controlled sequential release of layered ingredients. However, one potential problem with such materials is that they are difficult to manufacture, especially on the large scale that is required of a laundry detergent composition.
- US 4,804,505 discloses a screw extruder operated in such a way as to maintain the specific mechanical energy at a constant level .
- US 2001/0036503 Al discloses an extrusion process for producing encapsulated flavour or fragrances for use in the foods industry.
- the present invention provides a process for the manufacture of a structured material for use in a detergent composition, wherein the structured material is extruded in a screw extruder with a specific mechanical energy input of less than 75 kJ/kg.
- Screw extruders are used in a wide range of applications.
- Screw extruders are particularly useful if it is desired to produce particles with a controlled microstructure as the extrusion process is more controlled and much less 'random' than, for example, a granulation process.
- the materials processed must usually be quite resistant to shear damage. It is therefore quite challenging to produce relatively shear-sensitive compositions which have a controlled microstructure .
- a screw diameter of at least 40 mm is required. Generally a maximum of around 125 mm is appropriate.
- the throughput is greater than 50 kg/hr, preferably greater than 100 kg/hr.
- the screw extruder is a twin extruder as this provides better heat transfer.
- the specific mechanical energy relates to the amount of energy consumed by the screw extruder during operation per mass of material extruded.
- the skilled person is familiar with this term and it can be calculated by the following relationship:
- Typical values of SME for screw extruders range from 300 to 1000 kJ/kg.
- an SME of less than 75 kJ/kg is used.
- the structured materials which are produced by the method of the present invention are suitable for use in a detergent composition. That means that they would provide some useful function towards the cleaning and/or treatment of fabric materials during use.
- the term structured means that the material has chemical or physical discontinuities within it on a length scale of from 1 to 200 micrometres, preferably from 10 to 100 micrometres. Preferably the discontinuities are regular or ordered.
- the length scale of discontinuity can be determined by X-ray tomography or alternatively by invasive microscopic techniques.
- the structure of the structured material is sensitive enough to suffer shear damage to the structure if the process were operated at a specific mechanical energy input of 300 kJ/kg, preferably at 200 kJ/kg, more preferably at 100 kJ/kg, most preferably at 75 kJ/kg.
- the structure material comprises a glassy material with a glass transition temperature of greater than 0°C, preferably greater than 40 °C, more preferably greater than 80°C.
- Suitable materials are sucrose, glucose, lactose, maltose, fructose, ribose, dextrose, isomalt, sorbitol, mannitol, xylitol, lactitol, maltitol, pentatol, arabinose, pentose, xylose, galactose, hydrogenated corn syrup, maltodextrin, agar, carrageenan, gums, polydextrose and derivitives amd mixtures thereof.
- the structured material which is extruded comprises particles dispersed within a continuous medium.
- this continuous medium is the glassy material as described above .
- the structured material which is extruded comprises particles dispersed within a continuous medium.
- the structured material comprises a laundry benefit agent e.g., perfume. If perfume is present then it is particularly preferred that it is preserved within a continuous medium, preferably the glassy material, and preferably the perfume is present in the discrete particles as described above.
- a laundry benefit agent e.g., perfume. If perfume is present then it is particularly preferred that it is preserved within a continuous medium, preferably the glassy material, and preferably the perfume is present in the discrete particles as described above.
- the extrudates produced by the present invention are suitable for use in detergent compositions.
- the detergent compositions are particulate and suitable for use as a laundry detergent used for everyday fabric cleaning.
- the extrudates produced by the present invention are present in such detergent compositions at a level of from 0.1 to 10 wt%, preferably from 0.5 to 5 wt%, of the detergent composition.
- a conventional emulsion based polymerisation is employed to produce a suspension of polymer (Poly butyl methacrylate) with a mean particle size of 70 to 120 microns in aqueous medium (may include part of continuous medium comprising of Maltose syrup) .
- the maximum concentration of polymer in the suspension is about 40 wt%, which is limited by the viscosity of the system.
- Step 2 Feed Preparation to Screw Extruder
- the emulsion made as in step 1 is then mixed and dispersed efficiently in an agitator with a laundry benefit agent (in this case, perfume) in a ratio of 1:1 based on polymer weight.
- a laundry benefit agent in this case, perfume
- the feed composition is subsequently adjusted to around 20 wt% by manipulating ratio of continuous medium to final polymer concentration. It is clearly critical to maintain a certain level of moisture in feed to reduce viscosity of feed so that it can be handled by a suitable gear pump and ensure uniform dosing to the extruder.
- a twin co-rotating screw extruder (L/D ratio of 40-45) is used to prepare the structured particles in the desired particle size range (500 microns to 1500 microns) for post mixing in a laundry detergent product.
- the extruder is configured by assembly of modular screw elements of appropriate pitches to give desired flow and pressure profile. Further, the external surface is heated (either electrical or oil medium) to maintain desired temperature profile along the section from feed end to product end. The temperature conditions are set to remove moisture from feed to final product moisture less than 2 wt%. In order to facilitate higher moisture removal, four degassing sections are used, two operated at atmospheric pressure and other two operated under vacuum (0.3 to 0.7 bar) .
- the product end of extruder is fitted with a suitable die design to produce strands of 0.8 to 1.0 mm diameter and a face cutter assembly to cut the strands into particles at an appropriate speed (variable up to 3000 rpm) . It is desirable to cool the particles subsequently in a fluid bed operating at low velocity and the particles are directly fed onto a vibro- sieve to collect the product and remove any oversize particles .
- Screw Extruder size 65 mm
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Wood Science & Technology (AREA)
- Organic Chemistry (AREA)
- Mechanical Engineering (AREA)
- Detergent Compositions (AREA)
Abstract
A process for the manufacture of a structured material for use in a detergent composition is disclosed, wherein the structured material is extruded in a screw extruder with a specific mechanical energy input of less than 75 kJ/kg. Preferably the structured material is a glassy material with perfume impregnated particles dispersed within.
Description
PROCESS FOR PRODUCING STRUCTURED MATERIALS
TECHNICAL FIELD
The present invention relates to a process for producing structured materials for use in a detergent composition by use of a screw extruder.
BACKGROUND AND PRIOR ART
Modern laundry detergent compositions contain many ingredients, each performing a separate function. The majority of ingredients perform their function by their behaviour in solution. However also, ingredients are added in granular form to achieve an additional benefit, such as carrying a liquid component or to achieve a certain bulk density. Furthermore certain granular components can provide a significant additional benefit if they have a controlled microstructure. This may, for example, be to encapsulate a volatile ingredient to be released during use or to provide controlled sequential release of layered ingredients. However, one potential problem with such materials is that they are difficult to manufacture, especially on the large scale that is required of a laundry detergent composition.
US 4,804,505 discloses a screw extruder operated in such a way as to maintain the specific mechanical energy at a constant level .
US 2001/0036503 Al discloses an extrusion process for producing encapsulated flavour or fragrances for use in the foods industry.
The present inventors have discovered that screw extrusion provides good control of microstructure and that relatively fragile compositions can be effectively produced with careful control of operating parameters.
The present invention provides a process for the manufacture of a structured material for use in a detergent composition, wherein the structured material is extruded in a screw extruder with a specific mechanical energy input of less than 75 kJ/kg.
DETAILED DESCRIPTION OF THE INVENTION
Screw Extruders
Screw extruders are used in a wide range of applications.
One such application is the generation of particles for use in detergent compositions. Screw extruders are particularly useful if it is desired to produce particles with a controlled microstructure as the extrusion process is more controlled and much less 'random' than, for example, a granulation process. However, due to the high formation pressures experienced in a screw extruder, the materials processed must usually be quite resistant to shear damage. It is therefore quite challenging to produce relatively shear-sensitive compositions which have a controlled microstructure .
In order to achieve a reasonable commercially viable throughput, a screw diameter of at least 40 mm is required. Generally a maximum of around 125 mm is appropriate.
Ideally the throughput is greater than 50 kg/hr, preferably greater than 100 kg/hr.
Preferably the screw extruder is a twin extruder as this provides better heat transfer.
Specific Mechanical Energy
The specific mechanical energy relates to the amount of energy consumed by the screw extruder during operation per mass of material extruded. The skilled person is familiar with this term and it can be calculated by the following relationship:
SME (J/kg) = Torque (Nm) x Screw Speed (r/min) Throughput (kg/min)
Typical values of SME for screw extruders range from 300 to 1000 kJ/kg. For the present invention it is essential that an SME of less than 75 kJ/kg is used. Preferably it is less than 60, preferably less than 40, more preferably less than 30, desirably less than 20, advantageously less than 10 kJ/kg.
Structured Materials
The structured materials which are produced by the method of the present invention are suitable for use in a detergent composition. That means that they would provide some useful function towards the cleaning and/or treatment of fabric materials during use.
The term structured means that the material has chemical or physical discontinuities within it on a length scale of from 1 to 200 micrometres, preferably from 10 to 100 micrometres. Preferably the discontinuities are regular or ordered. The length scale of discontinuity can be determined by X-ray tomography or alternatively by invasive microscopic techniques.
Preferably the structure of the structured material is sensitive enough to suffer shear damage to the structure if the process were operated at a specific mechanical energy input of 300 kJ/kg, preferably at 200 kJ/kg, more preferably at 100 kJ/kg, most preferably at 75 kJ/kg.
Preferably the structure material comprises a glassy material with a glass transition temperature of greater than 0°C, preferably greater than 40 °C, more preferably greater than 80°C. Suitable materials are sucrose, glucose, lactose, maltose, fructose, ribose, dextrose, isomalt, sorbitol, mannitol, xylitol, lactitol, maltitol, pentatol, arabinose, pentose, xylose, galactose, hydrogenated corn syrup, maltodextrin, agar, carrageenan, gums, polydextrose and derivitives amd mixtures thereof.
Preferably the structured material which is extruded comprises particles dispersed within a continuous medium. Preferably this continuous medium is the glassy material as described above .
Preferably the structured material which is extruded comprises particles dispersed within a continuous medium. Preferably these are polymer particles such as polybutylmethacrylate .
In a preferred embodiment the structured material comprises a laundry benefit agent e.g., perfume. If perfume is present then it is particularly preferred that it is preserved within a continuous medium, preferably the glassy material, and preferably the perfume is present in the discrete particles as described above.
Detergent Compositions
The extrudates produced by the present invention are suitable for use in detergent compositions. Preferably the detergent compositions are particulate and suitable for use as a laundry detergent used for everyday fabric cleaning.
Typically the extrudates produced by the present invention are present in such detergent compositions at a level of from 0.1 to 10 wt%, preferably from 0.5 to 5 wt%, of the detergent composition.
EXAMPLES
Step 1: Preparation of Polymeric Particles
A conventional emulsion based polymerisation is employed to produce a suspension of polymer (Poly butyl methacrylate) with a mean particle size of 70 to 120 microns in aqueous medium (may include part of continuous medium comprising of Maltose syrup) . The maximum concentration of polymer in the suspension is about 40 wt%, which is limited by the viscosity of the system.
Step 2 : Feed Preparation to Screw Extruder
The emulsion made as in step 1 is then mixed and dispersed efficiently in an agitator with a laundry benefit agent (in this case, perfume) in a ratio of 1:1 based on polymer weight. The feed composition is subsequently adjusted to around 20 wt% by manipulating ratio of continuous medium to final polymer concentration. It is clearly critical to maintain a certain level of moisture in feed to reduce viscosity of feed so that it can be handled by a suitable gear pump and ensure uniform dosing to the extruder.
Step 3 : Preparation of Structured Particles
A twin co-rotating screw extruder (L/D ratio of 40-45) is used to prepare the structured particles in the desired particle size range (500 microns to 1500 microns) for post mixing in a laundry detergent product. The extruder is configured by assembly of modular screw elements of
appropriate pitches to give desired flow and pressure profile. Further, the external surface is heated (either electrical or oil medium) to maintain desired temperature profile along the section from feed end to product end. The temperature conditions are set to remove moisture from feed to final product moisture less than 2 wt%. In order to facilitate higher moisture removal, four degassing sections are used, two operated at atmospheric pressure and other two operated under vacuum (0.3 to 0.7 bar) . The product end of extruder is fitted with a suitable die design to produce strands of 0.8 to 1.0 mm diameter and a face cutter assembly to cut the strands into particles at an appropriate speed (variable up to 3000 rpm) . It is desirable to cool the particles subsequently in a fluid bed operating at low velocity and the particles are directly fed onto a vibro- sieve to collect the product and remove any oversize particles .
The following results show the measured particle size of the structured particles when added to water. A high value of the volume-surface mean diameter d^ ^ ) indicates that the structured material satisfactorily broke down in solution. A low value indicates that shear damage was caused and subsequent break down in solution did not occur.
Screw Extruder Size: 24 mm
Screw Extruder Size: 44 mm
Screw Extruder size: 65 mm
From the above tables, it is quite clear that with increasing SME, the dispersibility of particles in a laundry washing process decreases due to poor structuring of particles possibly caused by higher shear in extrusion.
Claims
1. A process for the manufacture of a structured material for use in a detergent composition, wherein the structured material is extruded in a screw extruder with a specific mechanical energy input of less than 75 kJ/kg.
2. A process as claimed in claim 1, wherein the screw extruder has a diameter of at least 40 mm.
3. A process as claimed in any preceding claim, wherein the throughput is greater than 50 kg/hr, preferably greater than 100 kg/hr.
4. A process as claimed in any preceding claim, wherein the structure of the structured material would suffer shear damage if the process were operated at a specific mechanical energy input of 300 kJ/kg, preferably at 200 kJ/kg, more preferably at 100 kJ/kg, most preferably at 75 kJ/kg.
5. A process as claimed in any preceding claim, wherein the specific mechanical energy input of the screw extruder is less than 60, preferably less than 40, more preferably less than 30, desirably less than 20, advantageously less than 10 kJ/kg.
6. A process as claimed in any preceding claim, wherein the structured material which is extruded comprises a glassy material with a glass transition temperature of greater than 0°C, preferably greater than 40 °C, more preferably greater than 80 °C.
7. A process as claimed in claim 5 and claim 6, wherein the glassy material is a continuous medium.
8. A process as claimed in any preceding claim, wherein the structured material which is extruded comprises particles dispersed within a continuous medium.
9. A process as claimed in any preceding claim, wherein the structured material comprises a benefit agent preferably a perfume .
10. A process as claimed in claim 8 and claim 9, wherein the benefit agent is contained within the particles.
11. A detergent composition comprising an extrudate obtainable by a process as claimed in any one of claims 1 to 10.
12. A detergent composition as claimed in claim 11, which is particulate and suitable for use as a laundry detergent .
13. A detergent composition as claimed in claim 11 or claim 12, which comprises from 0.1 to 10 wt%, preferably from 0.5 to 5 wt%, of the extrudate.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GBGB0310775.2A GB0310775D0 (en) | 2003-05-10 | 2003-05-10 | Process for producing structured materials |
| GB0310775.2 | 2003-05-10 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2004099359A1 true WO2004099359A1 (en) | 2004-11-18 |
Family
ID=9957824
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/EP2004/003778 WO2004099359A1 (en) | 2003-05-10 | 2004-04-07 | Process for producing structured materials |
Country Status (3)
| Country | Link |
|---|---|
| AR (1) | AR044261A1 (en) |
| GB (1) | GB0310775D0 (en) |
| WO (1) | WO2004099359A1 (en) |
Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0251135A2 (en) * | 1986-06-26 | 1988-01-07 | Applied Automation, Inc. | Extrusion control |
| US4804505A (en) * | 1986-07-12 | 1989-02-14 | Werner & Pfeiderer Gmbh | Method of operating a screw extruder and screw extruders for carrying out said methods |
| US5290496A (en) * | 1990-03-09 | 1994-03-01 | Henkel Kommanditgesellschaft Auf Aktien | Process for the production of granules of a detergent |
| US5916867A (en) * | 1994-01-17 | 1999-06-29 | The Procter & Gamble Company | Process for preparing detergent granules |
| DE19930771A1 (en) * | 1999-07-03 | 2001-01-04 | Henkel Kgaa | Process for the production of detergent tablets |
| US20010036503A1 (en) * | 1999-09-06 | 2001-11-01 | Daniel Benczedi | Process for the preparation of granules for the controlled release of volatile compounds |
-
2003
- 2003-05-10 GB GBGB0310775.2A patent/GB0310775D0/en not_active Ceased
-
2004
- 2004-04-07 WO PCT/EP2004/003778 patent/WO2004099359A1/en active Search and Examination
- 2004-05-07 AR ARP040101554A patent/AR044261A1/en unknown
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0251135A2 (en) * | 1986-06-26 | 1988-01-07 | Applied Automation, Inc. | Extrusion control |
| US4804505A (en) * | 1986-07-12 | 1989-02-14 | Werner & Pfeiderer Gmbh | Method of operating a screw extruder and screw extruders for carrying out said methods |
| US5290496A (en) * | 1990-03-09 | 1994-03-01 | Henkel Kommanditgesellschaft Auf Aktien | Process for the production of granules of a detergent |
| US5916867A (en) * | 1994-01-17 | 1999-06-29 | The Procter & Gamble Company | Process for preparing detergent granules |
| DE19930771A1 (en) * | 1999-07-03 | 2001-01-04 | Henkel Kgaa | Process for the production of detergent tablets |
| US20010036503A1 (en) * | 1999-09-06 | 2001-11-01 | Daniel Benczedi | Process for the preparation of granules for the controlled release of volatile compounds |
Also Published As
| Publication number | Publication date |
|---|---|
| GB0310775D0 (en) | 2003-06-18 |
| AR044261A1 (en) | 2005-09-07 |
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