WO2006040035A1 - System and process for preparing shaped solid detergent - Google Patents
System and process for preparing shaped solid detergent Download PDFInfo
- Publication number
- WO2006040035A1 WO2006040035A1 PCT/EP2005/010641 EP2005010641W WO2006040035A1 WO 2006040035 A1 WO2006040035 A1 WO 2006040035A1 EP 2005010641 W EP2005010641 W EP 2005010641W WO 2006040035 A1 WO2006040035 A1 WO 2006040035A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- mould
- melt
- cast
- composition
- soap
- Prior art date
Links
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
- C11D17/00—Detergent materials or soaps characterised by their shape or physical properties
- C11D17/0047—Detergents in the form of bars or tablets
- C11D17/0052—Cast detergent compositions
-
- C—CHEMISTRY; METALLURGY
- C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
- C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
- C11D13/00—Making of soap or soap solutions in general; Apparatus therefor
- C11D13/14—Shaping
- C11D13/16—Shaping in moulds
Definitions
- the present invention relates to a system and a process for continuous casting of melt cast compositions such as soaps, detergent tablets and the like.
- the invention relates to a system and method for continuous casting of such melt cast compositions involving solidification and shaping of the melt-cast composition during traverse of the melt through a mould which favours continuous and effective mould filling and release as well as flexibility in generating a wide range of cast products.
- Soap or non-soap detergent based shaped articles are conventionally known to be produced by way of extrusion or by casting routes.
- the extrusion process usually involve a plodder or extruder to take care of compaction and shaping of the article and by continuous extrusion of the soap /non-soap detergent through the extruder, continuous production of logs or billets can be obtained which can subsequently be stamped and shaped into tablets or bars.
- the casting route is usually used for producing soaps with high formulation flexibility such as transparent or translucent soaps and those with high liquid content, which cannot be readily processed following the extrusion route.
- US-A-2, 385,322 discloses a machine for solidifying and stacking a material that may be extruded and solidified comprising means to extrude said material and means to receive and support the extruder material while it is solidified, means for feeding a rack into position to receive the solidified material, means to automatically feed a second rack into said position as the preceding rack is filled, means to severe the extruded stick and means to feed a rack passed the severing means whereby the severed product may be placed on the rack.
- the system is basically a highly mechanized and complex mould filling, solidification and release system.
- GB-A-597322 discloses an improved method of making soap bars or tablets by rapidly chilling molten 63% soap so as to solidify the soap within a few seconds and thereafter without subjecting it to a drying operation, plodding the solidifying soap where one or more steps are taken to increase the degree to which the soap mass is compacted during plodding.
- the above process teaches that the solidification of the molten soap be effected by rapid chilling in a matter of few seconds instead of by frame, slab or bar-cooling. Such rapid chilling produce soap which is firm and tough and possess adequate solidity and plasticity for satisfactory plodding and stamping.
- EP-A-321,179 discloses a method of casting soap or detergent wherein liquid or semi liquid soap is filled into a pack made of flexible film such that the material occupies the whole of the pack. The pack is then tightly sealed to extrude air and the material is allowed to set in the pack to obtain cast-in-pack tablets.
- This process helps in producing a continuous string of packed soap sachets.
- the process although refers to a continuous methods of casting requires sealing and pressurizing of individual sachets and is supposed to significantly slow down the throughput rates. Moreover, the process essentially calls for the use of extendable or shrinkable polymers to avoid formation of wrinkles on the cast tablets.
- WO-A-03/0125110 refers to yet another continuous process for casting of soaps and the like, comprising the steps of (i) filling a continuous tube of flexible material with a melt of the castable compositions, where the tube acts as a sleeve to the composition such that the desired cross section area of the filled sleeve is obtained i.e. independent of its perimeter, (ii) solidifying and simultaneously shaping the said melt by cooling the said sleeve in or on a suitable mould.
- the process produces cast-in-sleeves logs that can be cut into billets/ tablets and optionally flow rapped.
- a novel system for continuous casting of melt-cast products such as soaps, detergents and the like, comprising (i) a substantially vertically disposable mould unit to favour solidification/casting of the melt cast composition during an upstream motion through said mould unit; (ii) said mould unit being operatively connected at its lower end to a supply source of the melt-cast composition and (iii) means for controlling the temperature of the melt in the mould unit to achieve the desired solidification and shaping during traverse of the melt from the bottom of said mould towards the top thereof which top is adapted to eject the formed cast product .
- the present inventors have solved this problem of non- uniform filling of the horizontal or inclined mould with the molten solution and the possible subsequent problem of air-pockets in the cast bar, by providing a means for bringing about a resistance to the flow of the molten solution during the start-up stage.
- Another object of the present invention is to provide a simple and cost-effective continuous casting system and process which would enable on-line continuous production of shaped products such as soaps, detergent tablets and the like without the need for separate unit operations for cooling and shaping of the product in the moulds and which favour solidifying and shaping of the molten soap during a simple traverse of the soap through a selective cooling- plus-moulding unit.
- Another object of the present invention is to provide a simple and effective system and method of continuous casting and shaping of soap, detergent products, which enable greater flexibility in controlling the characteristics of the product form such as those required for obtaining special quality product like soaps with high solvent content such as transparent or translucent cast bar and/or with advantageous benefit/aesthetic agent incorporation.
- Yet further object of the present invention is to provide a system and a method for continuous casting and shaping of castable products such as soap, detergents and the like, which involve minimal labour and facilitate automated production of cast and shaped bars of wide variety.
- Yet further object of the present invention is to provide a system and method of continuous casting for product such as soap/detergents and the like, which favour achieving various shapes of bars by mere replacement of a mould unit in the system thereby imparting greater flexibility and convenience of continuous casting of such products.
- Another object of the present invention is directed to provide a system and method of continuous casting of soaps/ detergents which avoid wastage and need for recycling and favour cost-effective continuous on-line production of shaped bars/articles.
- Yet further object of the present invention is to provide a system and method for manufacturing cast products continuously which would enable selective incorporation of colour/benefit/ aesthetic agents into the product formed at desired levels and/or at desired locations/dispersion without disturbing the continuous production, thereby overcoming limitations in adding such benefit/aesthetic agents in the conventional casting process including batch or the semi-continuous processes presently available.
- Yet another object of the present invention is to provide a system and method for continuous casting of melt-cast formulations in moulds while ensuring product exit from the mould in the horizontal direction, thereby enabling simple and effective downstream operations like shaping, stamping and cutting, which are preferably carried out on surfaces in the horizontal direction.
- a system for continuous casting of melt- cast products such as soaps, detergents and the like, comprising: i. a substantially horizontal or inclined mould unit to favour solidification/casting of the melt-cast composition during its traverse through said mould unit, said mould unit being operatively connected at its inlet end to a supply source of the melt-cast composition ; ii. means for controlling the temperature of the melt-cast composition in the mould unit to achieve the desired solidification and shaping during traverse of said composition from the inlet end of said mould towards the outlet end thereof, said outlet end being adapted to eject the formed cast product; and iii. means for providing a resistance to flow of the melt- cast composition to ensure uniform filling up of the said composition, substantially free of air pockets, in the mould during the startup of the said system.
- Said system for continuous casting of melt-cast products can advantageously comprise a high-surface area heat exchanger provided ahead of the shaping mould to improve the efficiency of cooling and throughput.
- the system of the invention comprises: i. a horizontally disposed mould unit, said mould unit being operatively connected at its inlet end to a supply source for the melt-cast composition; ii. means for controlling the temperature in the mould unit to achieve the desired cooling comprising a cooling jacket located on the mould and having means for continuous supply of coolant there-through to facilitate on-line cooling, solidification and shaping of the melt-cast composition during its traverse from the inlet end of the mould to the outlet end, and iii. means for providing a resistance to flow of the melt- cast composition to ensure uniform fill-up of the said composition in the mould, substantially free of air- pockets during the startup of the said system.
- melt-cast composition is not subjected to high thermal shocks, especially at the inlet end of the mould. This is preferably achieved by ensuring a low and controlled thermal gradient on the melt- cast composition during its traverse from the inlet to the outlet end of the mould.
- the means for controlling the temperature of the melt-cast composition in the mould such as the cooling jacket is adapted so as to produce a selective temperature gradient or distinct temperature zones through which the composition is allowed to traverse in the mould.
- selective temperature control of melt-cast composition is facilitated so as to achieve said solidification and shaping based upon the constitution of the soap formulation.
- a heating zone is preferably provided near the exit of the jacketed mould/caster to improve the slip of the bar and its throughput.
- the jacketed mould selectively includes means for selective injection of benefit/aesthetic agents in the soap formulation during the solidification/shaping process while it traverses the mould unit which cannot be achieved in case of any of the known batch as well as the conventional slip casting systems.
- the possibility of varied temperature gradient in the jacketed mould and such provision for injection of benefit/aesthetic agents together facilitate providing even in case of continuous casting, injection of any secondary material into the main bar while keeping it segregated.
- the viscosity of the cast soap material would vary along the flow direction due to cooling and therefore, the injected material with a wide range of viscosity can be used by appropriately choosing the injection point or points.
- the system of the present invention effectively provides for the first time, by way of a continuous moulding system, a mechanism which would favour solidification and shaping of the soap during its traverse in the selective mould unit advantageously utilizing the relative flow between the melt and mould surface.
- the means for providing a resistance to flow of the melt to ensure uniform fill-up of the melt in the mould, substantially free of air-pockets, during the startup of the system is preferably achieved by filling a part of the mould towards the outlet end of the mould with the solidified composition.
- any mechanical means for example a piston means or a plug means having a frictional resistance along the internal walls of the mould similar to the resistance experienced by the solidified composition may be provided during the startup stage along a length at the outlet end of the mould.
- the length along which the resistance to flow is provided, closer to the outlet end of the mould, is preferably equal to or greater more than the length over which the cast composition has substantially solidified during the steady - state operation.
- a method for continuous casting of melt- cast compositions such as soaps, detergents and the like, comprising: (i) supplying a molten melt-cast composition through a substantially horizontal or inclined mould unit having temperature control means from the inlet end and allowing the composition to traverse towards the outlet end in the mould while providing a resistance to flow of the melt-cast composition during the startup of the process and (ii) controlling the mould temperature to thereby favour solidification and shaping of the composition into cast product in the mould which cast product ejects from the outlet end of the mould unit.
- the mould unit temperature is controlled by regulating the means for controlling the temperature in the mould unit to achieve the desired casting.
- the coolant temperature and/or its path can be regulated to facilitate on-line differential cooling to favour solidification and shaping based on the type of melt composition.
- the continuous production of cast bars is achieved by way of controlled filling of the soap melt in the substantially horizontal or inclined mould.
- Such a method that provides for a resistance to flow of the melt at the start-up of the process was found to take care of any problems of air pockets and non-uniform filling.
- the above method it is possible to selectively regulate the temperature in the cooling jacket and to provide for a selective temperature gradient during the cooling of the melt to achieve the cast.
- the zone of the jacketed mould just adjacent the exit/outlet of the formed bars can be selectively heated by a heating mechanism to facilitate the non-stick and easy throughput of the bars.
- the cross section of the mould can be selectively changed by simple change over of the releasable secured mould to obtain shaped bars of desired cross section through a continuous process.
- This provides for a simple mechanism for obtaining continuously shaped bars of varied cross section through a simple route and with less involvement of labour.
- the above method is simple, cost-effective (avoids wastage's and recycling of wastes) and ensures production of shaped bars repeatedly and continuously avoiding uneven bar and/or recycling of the product to attain uniformity in manufacture.
- the above method of on-line continuous generation of bars would facilitate, controlling the temperature gradient during the cooling of the melt during the casting process thereby facilitate maintaining desired forms and constitution of the product.
- benefit/aesthetic agents or soap of different composition/colour for example colouring agents, slurry to provide stripes and/or benefit agents can be introduced during the casting process in the mould unit which is never possible in case of batch processes or in case of the flexible sleeve casting presently available as a continuous casting method.
- a secondary material including soap can be continuously injected into the main bar while keeping it segregated.
- the viscosity of the cast soap material will vary along the flow direction due to cooling and therefore the injected material with a wide range of viscosity can be used by appropriately choosing the injection position during traverse of the cast formulation through the jacketed mould.
- different products can be cast such as a soap, detergent, deodorant or confectioneries including non-quick setting materials at high-throughput rates.
- the process is particularly preferred for home and personal care compositions such as soap and detergent bars.
- Any conventional melt-cast detergent composition is suitable for the process of the invention. This would allow much desired high formulation flexibility by way of a controlled continuous casting.
- the particularly preferred soap composition include saturated fatty acid soap, detergent actives and possibly upto 60% water with or without other additives and benefit agents.
- the detergent actives suitable for use in the invention include any non-soap detergent actives or the salts of unsaturated fatty acids.
- Non-soap detergent actives are suitably selected from anionic, nonionic, cationic, amphoteric or zwitterionic surfactants or their mixtures.
- the benefit/aesthetic agents which can be incorporated/injected during the casting include liquid benefit agents/additives and liquid skin benefit materials such as anti-aging compounds, emollients, moisturizers, and sunscreens.
- Solubilisers as suitable additives for use in the detergent composition include monohydric and polyhydric alcohols such as propylene glycol, sorbitol, and glycerin.
- the melt-cast formulation can also include other optional ingredients such as hair conditioning agents, fillers, colours, perfume, opacifier, preservatives, one or more water insoluble particulate materials such as talc, kaolin, polysaccharides and other conventional ingredients.
- the mould temperature can be regulated based on the melt which can be of any suitable temperature, such as up to 120 0 C, preferably between 40 0 C to 90 0 C.
- Figure 1 is a schematic illustration of the system for the continuous on-line production of soap/detergent bars in accordance with the present invention.
- the system for such continuous casting in accordance with the present invention basically involves a jacketed mould (1) which is covered by the cooling jacket (2) as a tube in tube arrangement.
- the cooling jacket which surrounds the mould, is provided with cooling means such as the coolant entry (3) and the coolant exit (4) .
- the coolant can be pumped co-currently or counter currently or in cross-flow.
- the mould (1) as shown in the figure is preferably and selectively horizontally disposed to facilitate a horizontal feed of the soap melt from the inlet end of the mould for the continuous casting.
- the soap melt is metered into the mould (1) through the inlet end by operative connection of the inlet (5) of the mould to the soap melt source (6) through a metering pump (7) .
- multiple parallel tubes are used, either with individual cooling jackets or a bank of tubes can be cooled using an outer shell as in a multi-tube heat exchanger.
- the tubes are preferably in rectangular or triangular pitch.
- An appropriate multi-head metering pump or individual pumps for each tube may be used.
- the moulding jacket is adapted to facilitate a desired temperature gradient for the soap melt during its traverse from the inlet end of the mould and until it exits as the formed bar from the outlet.
- effective temperature control gadgets can be provided which can facilitate attaining such temperature gradient depending upon the soap formulation to be formed.
- the system can also include injection means (8) selectively disposed in relation to the mould to favour selective injection of colouring/benefit/aesthetic agents or even soap of different composition/colour in the soap during its traverse through the mould unit.
- injection means (8) selectively disposed in relation to the mould to favour selective injection of colouring/benefit/aesthetic agents or even soap of different composition/colour in the soap during its traverse through the mould unit.
- the- selective provision of temperature gradient and the disposition of the injection means would favour flexibility in obtaining on-line continuous production of shaped bars with varied constitution, structure, characteristic and appearance.
- the method of on-line production of such shaped bars involving the above system is simple and continuous.
- a substantial length of the mould (e.g. 30 to 50%) of the mould unit at the outlet end is filled with the solidified soap composition (9) .
- the soap melt through the metering pump is continuously fed from the inlet end of the mould unit.
- the soap melt is forced through the mould unit (1) and in the process the same is selectively cooled to the desired extent and at desired stages during its traverse through the mould to facilitate solidification and shaping maintaining the desired constitution and character of the formed bar.
- various colouring/benefit/ aesthetic agents could be introduced by injection into the soap during its motion in the mould.
- the formed bars exit as cast bars (10) from the outlet of the mould.
- the above system and method of the invention advantageously provide for a continuous casting for soap/detergent bars and the like wherein the casting of the formulation i.e. the solidification and shaping is achieved during the traverse of the formulation in a stationery mould.
- This makes for advantageous use of the system of continuous moulding where there is a relative flow between the liquid and the mould material .
- the horizontal or inclined mould allows the system of the invention to be more convenient and practical, especially when using a bank of moulds with different geometric and spatial layouts.
- Cutting and conveying of the solidified bars produced by the system of the invention can be carried out by conveying them in a direction which is different from the direction of the outlet of the mould e.g. in a direction perpendicular to the bar outlet from the mould.
- Molten soap was prepared in a jacketed vessel heated using hot water/steam, as shown in Figure-1.
- a batch of 30 kg soap was prepared.
- a 1.5 meter long horizontal mould of circular cross-section and of 48 mm diameter was provided with 4 stage cooling jackets each of about 30 cm long each.
- the casting operation was started by filling the mould over 0.5 meter towards the outlet of the mould with solidified soap composition.
- the soap melt was pumped through the mould using a gear pump.
- Hot water of 55°C was used in the 1 st cooling jacket, water of 25°C was used in the intermediate cooling jackets, and chilled water of 10 0 C was used in the final jacket near the outlet.
- Solid soap bars with acceptable properties were cast out continuously at a rate of ⁇ 7 kg/hr.
- Example-2
- Example-3 An experiment was carried out as per Example - 1 except that 100 kg soap was used. A 6 meter long horizontal mould of circular cross-section of 48 mm diameter was provided with 9 cooling jackets. Solid soap bars with acceptable properties were cast out continuously at a rate of around 35 kg/hr.
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- Chemical & Material Sciences (AREA)
- Life Sciences & Earth Sciences (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Wood Science & Technology (AREA)
- Organic Chemistry (AREA)
- Detergent Compositions (AREA)
Abstract
Description
Claims
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
BRPI0516058-8A BRPI0516058A (en) | 2004-10-14 | 2005-09-30 | system and method for continuous molding of fusion molded detergents or soaps |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
IN1100/MUM/2004 | 2004-10-14 | ||
IN1100MU2004 | 2004-10-14 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2006040035A1 true WO2006040035A1 (en) | 2006-04-20 |
Family
ID=35395880
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/EP2005/010641 WO2006040035A1 (en) | 2004-10-14 | 2005-09-30 | System and process for preparing shaped solid detergent |
Country Status (5)
Country | Link |
---|---|
CN (1) | CN101076581A (en) |
BR (1) | BRPI0516058A (en) |
MY (1) | MY148642A (en) |
WO (1) | WO2006040035A1 (en) |
ZA (1) | ZA200703017B (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20110278429A1 (en) * | 2003-11-25 | 2011-11-17 | Conopco, Inc., D/B/A Unilever | Process to prepare a shaped solid detergent |
WO2015074646A3 (en) * | 2013-11-25 | 2015-07-30 | Novatec Solar Gmbh | Storage assembly for receiving heat reservoir medium |
CN114836276A (en) * | 2022-05-06 | 2022-08-02 | 山东农业大学 | Processing device and processing method for production of sterilizing soap |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN106132656B (en) * | 2013-12-05 | 2017-11-10 | 荷兰联合利华有限公司 | For moving the apparatus and method of multiple products |
CN110591845B (en) * | 2019-09-19 | 2020-12-25 | 宿州市鑫尧健康科技有限公司 | Small simple soap manufacturing device |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3391725A (en) * | 1966-01-13 | 1968-07-09 | Concast Inc | Process and apparatus for cooling and supporting a continuous casting strand |
EP0138802A1 (en) * | 1983-10-13 | 1985-04-24 | VOEST-ALPINE Aktiengesellschaft | Horizontal continuous casting mould |
WO2003025110A1 (en) * | 2001-09-18 | 2003-03-27 | Unilever N.V. | Solid detergent composition |
WO2004009271A1 (en) * | 2002-07-22 | 2004-01-29 | Showa Denko K.K. | Continuous cast aluminum alloy rod and production method and apparatus thereof |
-
2005
- 2005-09-30 CN CNA2005800427608A patent/CN101076581A/en active Pending
- 2005-09-30 WO PCT/EP2005/010641 patent/WO2006040035A1/en active Application Filing
- 2005-09-30 ZA ZA200703017A patent/ZA200703017B/en unknown
- 2005-09-30 BR BRPI0516058-8A patent/BRPI0516058A/en not_active IP Right Cessation
- 2005-10-12 MY MYPI20054805A patent/MY148642A/en unknown
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3391725A (en) * | 1966-01-13 | 1968-07-09 | Concast Inc | Process and apparatus for cooling and supporting a continuous casting strand |
EP0138802A1 (en) * | 1983-10-13 | 1985-04-24 | VOEST-ALPINE Aktiengesellschaft | Horizontal continuous casting mould |
WO2003025110A1 (en) * | 2001-09-18 | 2003-03-27 | Unilever N.V. | Solid detergent composition |
WO2004009271A1 (en) * | 2002-07-22 | 2004-01-29 | Showa Denko K.K. | Continuous cast aluminum alloy rod and production method and apparatus thereof |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20110278429A1 (en) * | 2003-11-25 | 2011-11-17 | Conopco, Inc., D/B/A Unilever | Process to prepare a shaped solid detergent |
WO2015074646A3 (en) * | 2013-11-25 | 2015-07-30 | Novatec Solar Gmbh | Storage assembly for receiving heat reservoir medium |
CN114836276A (en) * | 2022-05-06 | 2022-08-02 | 山东农业大学 | Processing device and processing method for production of sterilizing soap |
Also Published As
Publication number | Publication date |
---|---|
ZA200703017B (en) | 2008-07-30 |
BRPI0516058A (en) | 2008-08-19 |
CN101076581A (en) | 2007-11-21 |
MY148642A (en) | 2013-05-15 |
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