WO2007133582A1 - Compositions de pains de savon comprenant de l'ester d'alkyle alpha sulfoné ou un acide gras sulfoné et un tensioactif synthétique et procédé de production desdites compositions - Google Patents

Compositions de pains de savon comprenant de l'ester d'alkyle alpha sulfoné ou un acide gras sulfoné et un tensioactif synthétique et procédé de production desdites compositions Download PDF

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Publication number
WO2007133582A1
WO2007133582A1 PCT/US2007/011180 US2007011180W WO2007133582A1 WO 2007133582 A1 WO2007133582 A1 WO 2007133582A1 US 2007011180 W US2007011180 W US 2007011180W WO 2007133582 A1 WO2007133582 A1 WO 2007133582A1
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Prior art keywords
soap
composition
weight
fatty acid
sulfate
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PCT/US2007/011180
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English (en)
Inventor
Carlos Ospinal
Branko Sajic
Xue Min Dong
Original Assignee
Stepan Company
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Publication date
Priority claimed from US11/430,715 external-priority patent/US20060241003A1/en
Priority claimed from US11/436,280 external-priority patent/US20070004611A1/en
Application filed by Stepan Company filed Critical Stepan Company
Publication of WO2007133582A1 publication Critical patent/WO2007133582A1/fr

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    • C—CHEMISTRY; METALLURGY
    • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
    • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
    • C11D10/00—Compositions of detergents, not provided for by one single preceding group
    • C11D10/04—Compositions of detergents, not provided for by one single preceding group based on mixtures of surface-active non-soap compounds and soap
    • C11D10/042—Compositions of detergents, not provided for by one single preceding group based on mixtures of surface-active non-soap compounds and soap based on anionic surface-active compounds and soap
    • 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
    • C11D10/00—Compositions of detergents, not provided for by one single preceding group
    • C11D10/04—Compositions of detergents, not provided for by one single preceding group based on mixtures of surface-active non-soap compounds and soap
    • 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
    • C11D17/006—Detergents in the form of bars or tablets containing mainly surfactants, but no builders, e.g. syndet bar
    • 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
    • C11D3/02—Inorganic compounds ; Elemental compounds
    • C11D3/04—Water-soluble compounds
    • C11D3/046—Salts
    • 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
    • C11D3/02—Inorganic compounds ; Elemental compounds
    • C11D3/04—Water-soluble compounds
    • C11D3/046—Salts
    • C11D3/048—Nitrates or nitrites
    • 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
    • C11D3/02—Inorganic compounds ; Elemental compounds
    • C11D3/04—Water-soluble compounds
    • C11D3/10—Carbonates ; Bicarbonates
    • 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
    • C11D3/16—Organic compounds
    • C11D3/20—Organic compounds containing oxygen
    • C11D3/2003—Alcohols; Phenols
    • C11D3/2041—Dihydric alcohols
    • C11D3/2044—Dihydric alcohols linear
    • 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
    • C11D3/16—Organic compounds
    • C11D3/20—Organic compounds containing oxygen
    • C11D3/2003—Alcohols; Phenols
    • C11D3/2065—Polyhydric alcohols
    • 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
    • C11D3/16—Organic compounds
    • C11D3/20—Organic compounds containing oxygen
    • C11D3/2068—Ethers
    • 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
    • C11D3/16—Organic compounds
    • C11D3/20—Organic compounds containing oxygen
    • C11D3/2075—Carboxylic acids-salts thereof
    • C11D3/2079—Monocarboxylic acids-salts thereof
    • 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
    • C11D3/16—Organic compounds
    • C11D3/37—Polymers
    • C11D3/3703—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C11D3/3707—Polyethers, e.g. polyalkyleneoxides
    • 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
    • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
    • C11D1/02—Anionic compounds
    • C11D1/04—Carboxylic acids or salts thereof
    • 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
    • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
    • C11D1/02—Anionic compounds
    • C11D1/12—Sulfonic acids or sulfuric acid esters; Salts thereof
    • C11D1/123—Sulfonic acids or sulfuric acid esters; Salts thereof derived from carboxylic acids, e.g. sulfosuccinates
    • 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
    • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
    • C11D1/02—Anionic compounds
    • C11D1/12—Sulfonic acids or sulfuric acid esters; Salts thereof
    • C11D1/14—Sulfonic acids or sulfuric acid esters; Salts thereof derived from aliphatic hydrocarbons or mono-alcohols
    • C11D1/143—Sulfonic acid esters
    • 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
    • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
    • C11D1/02—Anionic compounds
    • C11D1/12—Sulfonic acids or sulfuric acid esters; Salts thereof
    • C11D1/14—Sulfonic acids or sulfuric acid esters; Salts thereof derived from aliphatic hydrocarbons or mono-alcohols
    • C11D1/146—Sulfuric acid esters
    • 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
    • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
    • C11D1/02—Anionic compounds
    • C11D1/12—Sulfonic acids or sulfuric acid esters; Salts thereof
    • C11D1/28—Sulfonation products derived from fatty acids or their derivatives, e.g. esters, amides
    • 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
    • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
    • C11D1/02—Anionic compounds
    • C11D1/12—Sulfonic acids or sulfuric acid esters; Salts thereof
    • C11D1/29—Sulfates of polyoxyalkylene ethers
    • 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
    • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
    • C11D1/38—Cationic compounds
    • C11D1/52—Carboxylic amides, alkylolamides or imides or their condensation products with alkylene oxides
    • C11D1/523—Carboxylic alkylolamides, or dialkylolamides, or hydroxycarboxylic amides (R1-CO-NR2R3), where R1, R2 or R3 contain one hydroxy group per alkyl group
    • 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
    • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
    • C11D1/88—Ampholytes; Electroneutral compounds
    • C11D1/90—Betaines

Definitions

  • compositions comprising a soap, a fatty acid, a surfactant comprising sulfonated fatty acid, alpha sulfonated alkyl ester, or a mixture thereof, optionally a synthetic surfactant, an electrolyte and a polyhydric alcohol, wherein said compositions are suitable for formation into precursor cleansing/laundry bar pre-blends (i.e., "soap noodles"), finished personal cleansing bars, or finished laundry detergent bars.
  • precursor cleansing/laundry bar pre-blends i.e., "soap noodles
  • the present technology relates to compositions suitable for processing into solid or semi-solid personal cleansing and/or laundry detergent bars that contain ⁇ -sulfonated fatty acid alkyl ester and/or sulfonated fatty acid in combination with at least one synthetic anionic, amphoteric, zwitterionic, nonionic, or semi-polar surfactant.
  • the presently described technology additionally relates to an improved process for producing such precursor cleansing/laundry bar surfactant pre-blends or personal cleansing/laundry detergent bars.
  • Embodiments of the present compositions and processes exhibit improved processing characteristics and allow for formation of cleaning or detergent bars with improved hardness, improved resistance to marring, lowered wear-rate and decreased mush formation during consumer use. DESCRIPTION OF THE RELATED ART
  • Synthetic detergent bars frequently called “combo bars” (i.e., a bar having substantial amounts of soap) and/or “syndet bars” (i.e., a bar having very little or no soap) are well known to the art, along with natural "soap" bars for personal care use. Syndet bars often possess poor physical properties, e.g., they exhibit off odors, poor processability, stickiness, brittleness, bar mushiness, poor lather quality, lack of mildness or combinations thereof. Additionally, the problems of formulating synthetic detergent bars are not limited to the performance characteristics of the finished bars. Most synthetic bars which are made with certain mild surfactants are very difficult to fabricate. Processing conditions for such bars present relatively high technical challenges to commercial scale manufacturers, primarily due to the need of expensive special handling equipment.
  • Conventionally milled toilet soaps are made by a process which generally comprises (1) drying soap having a moisture content of from about 28% to about 30% down to a moisture content of about 7% to about 14%, (2) forming the dried soap into precursor "soap noodles," by passing it through a plodder, (3) mixing the various desired additives such as colorants, perfume, etc., into the soap noodles, (4) passing the mixture formed in (3) through a mill or series of mills ("milling" the soap) thereby forming ribbons of soap, (5) passing the milled soap mixture from (5) through another plodder to form a log of soap (i.e., "plodding” the soap to form a "billet"), and (6) cutting the log into segments (i.e., billets) and stamping the segments or "billets” into the desired bar shape.
  • the soap which is dried in step (1) can generally be made from saponification of fats or neutralization of free fatty acids. Because the drying is never completely uniform, the dried soap inevitably contains some particles which are over-dried and are harder than the remaining bulk of the dried soap. If the soap also contains free fatty acid, non-homogeneity of the free acid in the soap can also contribute to the presence of soap particles which, are harder than the remaining bulk of the dried soap.
  • the hard particles are generally from about 0.5 to about 10 mm in diameter. These particles remain in the soap through the first plodding step (2) and the mixing step (3).
  • the soap is "worked” and the over- dried particles are broken down into much smaller particles (generally less than about 0.25 mm in diameter) and are homogeneously distributed throughout the soap mass.
  • the finished bar may exhibit a rough or sandy feel during use, due to the slower dissolution rate of the relatively large over-dried soap particles, also called “hard specks.”
  • the over-dried soap cannot be detected during use, because it has been reduced to a much smaller particle size and is distributed uniformly throughout the soap mass. See British Pat. No. 512,551, to Fairweather, issued on September 19, 1939, incorporated herein by reference; and U.S. Patent No.
  • the chips processed into bars are produced from either a 40-50% aqueous slurry of the ingredients mixed at a temperature of from 38°C to 93°C, or from a mixture of the dry ingredients mixed at 100 0 C for a long period of time.
  • the bars are prepared from a liquid mixture of acyl isethionate, fatty acids, anionic syndet and soap mixed at a temperature of about 110 0 C to 113°C for about fifteen minutes.
  • the latter bars contain at least about 4% by weight of sodium isethionate as a processing aid.
  • U.S. Pat. No. 4,696,767, to Novakovic, issued on September 29, 1987 discloses a process for making mild toilet bars wherein a slurry of acyl isethionate, water and a polyol such as sorbitol is formed into a stable solution by heating at a temperature of from 100 0 C to 120 0 C at 4-10 p.s.i.g. The slurry is then mixed with neat soap and is heated to about 150 0 C under a pressure of 4 atmospheres before being spread through a vacuum drying and plodding step to provide flakes which yield a toilet bar without grit.
  • the presence of the polyol leads to increased water penetration in the soap dish as well as a bar of increased cost.
  • acyl isethionate in particulate form causes problems, such as lacrimation (i.e., the weeping of material out of the soap bar). Further, larger particles of acyl isethionate yield bars with grit.
  • compositions of the present technology are useful in as precursor cleansing/laundry bar surfactant pre-blends or "soap noodles," finished personal cleansing bars, or finished laundry detergent bars.
  • Soap compositions produced according to embodiments of the present technology generally exhibit improved processability.
  • Bars produced according to embodiments of the present technology generally also exhibit increased foaming properties, decreased smear properties, decreased marring properties, improved color stability, and/or impart superior feel and after-feel properties to skin.
  • the compositions may be translucent and/or can be processed into translucent personal cleansing and/or laundry detergent bars with the appropriate choice of additional components.
  • the compositions are preferably generally suitable for processing using standard extrusion and/or plodder equipment.
  • compositions according to the present technology comprise: a soap, preferably tallow and/or coconut soap; a surfactant comprising an alpha sulfonated alkyl ester, sulfonated fatty acid, and/or mixtures thereof; a Cg-C 22 fatty acid, an electrolyte (salt), a polyhydric alcohol, and water.
  • a soap preferably tallow and/or coconut soap
  • a surfactant comprising an alpha sulfonated alkyl ester, sulfonated fatty acid, and/or mixtures thereof
  • a Cg-C 22 fatty acid an electrolyte (salt), a polyhydric alcohol
  • Embodiments of the invention may additionally comprise one or more synthetic anionic, amphoteric, zwitterionic, nonionic, or semi-polar surfactants.
  • compositions are useful in preparing stamped, personal cleansing and/or laundry detergent bars which generally have improved processability, are mild to the skin, have improved smear and bar firmness properties, exhibit good lathering properties and/or reduced marring.
  • the compositions of the present technology may also be utilized to produce dish washing pastes, gels and body washes, along with other uses. Additionally, the invention provides improved processes for manufacturing precursor cleansing/laundry bar "soap noodles," personal cleansing bars and laundry detergent bars.
  • At least some preferred soap composition embodiments of the present technology comprise: from about 40% to about 94% by weight of at least one C6-C22 soap (preferably comprised of tallow and/or coconut soap) from about 1% to about 15% by weight of at least one C 6 -C 22 fatty acid; from about 1% to about 30% by weight of a mixture of (i) at least one alpha sulfonated alkyl ester, sulfonated fatty acid, or mixture thereof; and (ii) optionally at least one synthetic surfactant, that is preferably an anionic, amphoteric, zwitterior ⁇ c, nonionic, or semi-polar surfactant; between about 0.5% to about 2% by weight of at least one electrolyte (or salt) that is preferably sodium sulfate, sodium chloride, sodium carbonate, potassium sulfate, potassium chloride, potassium carbonate, calcium sulfate, calcium chloride, calcium carbonate, calcium nitrate, magnesium sulfate, magnesium
  • the alpha sulfonated alkyl ester, sulfonated fatty acid, or mixture thereof is preferably in an amount less than 12% by weight of the soap bar composition.
  • aqueous liquid mixtures or soap slurries (from which soap bar compositions of the present technology are derived) preferably exhibit or have a lamellar microstructure at about 70°C or less, alternatively at about 65 °C or less.
  • some slurries of the present technology exhibit or have a lamellar microstructure at a temperature between about 55°C and about 70 0 C, or between about 55°C and 65°C, including, for example, at about 56°C, at about 57°C, at about 58°C, at about 59°C, at about 6O 0 C, at about 61 0 C, at about 62°C, at about 63°C, at about 64°C, at about 65°C, at about 66°C, at about 6TC, at about 68°C, at about 69°C or at about 70°C.
  • a composition suitable for use in formulating personal hygiene or laundry detergent bars comprises: (a) from about 40% to about 94% by weight of a C6-C22 soap; (b) from about 1% to about 15% by weight of a C6-C22 fatty acid; (c) from about 1% to about 30% by weight of a surfactant mixture; (d) between about 0.5% to about 2% by weight of an electrolyte (e) between about 0.5% to about 6.0% by weight of a polyhydric alcohol; and (f) at least one synthetic surfactant.
  • the soap slurry from which such a composition is derived preferably exhibits a lamellar microstructure at about 70 0 C.
  • the electrolyte is preferably selected from the group consisting of sodium sulfate, sodium chloride, sodium carbonate, potassium sulfate, potassium chloride, potassium carbonate, calcium sulfate, calcium chloride, calcium carbonate, calcium nitrate, magnesium sulfate, magnesium chloride, magnesium carbonate, magnesium nitrate, mixtures thereof, and derivatives thereof.
  • the surfactant mixture preferably comprises (i) an alpha sulfonated alkyl ester, a sulfonated fatty acid, or a mixture thereof, in an amount less than 12% by weight of the composition, and (ii) at least one alkanolamide, alkylamidopropyl betaine, salt of alkyl sulfoacetate, di-salt of alkyl sulfosuccinate, or salt of alkyl lactylate, sodium alpha olefin sulfonate, salt of alkyl sulfate, or salt of alkylethoxy sulfate.
  • a soap bar composition is provided that is derived from an aqueous liquid soap mixture or soap slurry that exhibits a lamellar microstructure at about 70 0 C.
  • the soap bar composition comprises: (a) from about 40% to about 92% by weight of a C6-C22 soap; (b) from about 1% to about 15% by weight of a C6- C22 fatty acid; (c) from about 2% to less than 12% by weight of an alpha sulfonated alkyl ester, a sulfonated fatty acid, or a mixture thereof; (d) between about 0.5% to about 2% by weight of an electrolyte; (e) between about 0.5% to about 6.0% by weight of a polyhydric alcohol; and (f) between about 3% to about 22% water; and (g) optionally at least one synthetic surfactant.
  • the electrolyte is preferably selected from the group consisting of sodium sulfate, sodium chloride, sodium carbonate, potassium sulfate, potassium chloride, potassium carbonate, calcium sulfate, calcium chloride, calcium carbonate, calcium nitrate, magnesium sulfate, magnesium chloride, magnesium carbonate, magnesium nitrate, derivatives thereof, and mixtures thereof.
  • a composition suitable for use in formulating personal hygiene or laundry detergent bars comprises: (a) from about 56% to about 93% by weight of an aqueous slurry of tallow soap, coconut fatty acid soap, or a mixture thereof; (b) from about 1% to about 15% by weight of a C6-C22 fatty acid; (c) from about 5% to less than 12% by weight of an alpha sulfonated alkyl ester, sulfonated fatty acid or a mixture thereof; (d) between about 0.5% to about 2% by weight of an electrolyte; (e) between about 0.5% to about 5.0% by weight of a polyhydric alcohol selected from the group consisting of glycerin, polyglycerols, sorbitol, propylene glycol, derivatives thereof, and mixtures thereof; (f) optionally at least one synthetic surfactant.
  • a polyhydric alcohol selected from the group consisting of glycerin, polyglycerols, sorbitol,
  • the electrolyte is preferably selected from the group consisting of sodium sulfate, sodium chloride, sodium carbonate, potassium sulfate, potassium chloride, potassium carbonate, calcium sulfate, calcium chloride, calcium carbonate, calcium nitrate, magnesium sulfate, magnesium chloride, magnesium carbonate, magnesium nitrate, derivatives thereof, and mixtures thereof.
  • the composition suitable for use in formulating personal hygiene or laundry detergent bars is .preferably derived from an aqueous liquid soap mixture or soap slurry that exhibits a lamellar microstructure at about 70 0 C.
  • a soap bar composition comprises: (a) from about 55% to about 94% by weight of a C6-C22 soap; (b) from about 2% to about 5% by weight of a C6-C22 fatty acid; (c) from about 2% to less than 12% by weight of a mixture of alpha sulfonated alkyl ester and sulfonated fatty acid; (d) between about 0.8% to about 1.6% by weight of an electrolyte; (e) between about 1% to about 4% by weight of a polyhydric alcohol; (f) water; and (g) at least one synthetic surfactant; wherein the soap bar composition exhibits a lamellar microstructure at about 70 0 C in slurry.
  • the electrolyte is preferably selected from the group consisting of sodium sulfate, sodium chloride, sodium carbonate, potassium sulfate, potassium chloride, potassium carbonate, calcium sulfate, calcium chloride, calcium carbonate, calcium nitrate, magnesium sulfate, magnesium chloride, magnesium carbonate, magnesium nitrate, derivatives thereof, and mixtures thereof.
  • Other embodiments of the present technology relate to an improved process to produce precursor cleansing/laundry bar "soap noodles," and personal cleansing bars and/or laundry detergent bars derived from the soap bar compositions of the presently described technology.
  • such a process comprises the steps of (a) forming at a temperature of about 65°C to about 105 0 C an aqueous liquid mixture, which is preferably homogeneous or substantially homogeneous, comprising: an aqueous soap slurry comprising a C 6 -C 22 soap, the slurry having a free alkalinity of less than about 0.1%; a C 6 -C 22 fatty acid; an alpha sulfonated alkyl ester, a sulfonated fatty acid, or a mixture thereof; optionally a synthetic surfactant, which is preferably an anionic, amphoteric, zwitterionic, nonionic, or semi-polar surfactant; an electrolyte selected from sodium sulfate, sodium chloride, sodium carbonate, potassium sulfate, potassium chloride, potassium carbonate, calcium sulfate, calcium chloride, calcium carbonate, calcium nitrate, magnesium sulfate, magnesium chloride,
  • Processes of the present technology may include further steps, such as extruding the thickened mixture to form flaked solid or semi-solid particles, plodding the flaked solid or semi-solid particles to form plodded particles, and additional processing including a final extrusion step to form a billet.
  • the final extrusion step is performed at a temperature from about 35°C to about 45°C, and more preferably 35°C to about 38°C.
  • further processing steps may include, for example, cutting the billet to form a cut billet, and stamping the cut billet to yield a personal cleansing or a laundry detergent bar.
  • One embodiment of the present technology is a composition
  • a soap preferably tallow and/or coconut soap
  • surfactant comprising an alpha sulfonated alkyl ester, sulfonated fatty acid, and/or mixtures thereof; a C 6 -C 22 fatty acid, an electrolyte (salt), a polyhydric alcohol, and water.
  • embodiments optionally preferably comprise at least one synthetic surfactant.
  • Examples of acceptable synthetic surfactants include, but are not limited to anionic, amphoteric, zwitterionic, nonionic, or semi-polar surfactants.
  • Some embodiments of the present technology further include paraffin, and/or additional additives or surfactants.
  • compositions comprise: between about 40% to about 94% by weight of soap, the soap is preferably tallow soap, coconut soap, or a mixture thereof; between about 1% to about 15% by weight of a C 6 -Cj 2 fatty acid; from about 1% to about 30% by weight of a mixture of a surfactant comprising an alpha sulfonated alkyl ester, a sulfonated fatty acid, or mixtures thereof and an optional synthetic surfactant; between about 0.5% to about 2% of an electrolyte selected from the group consisting of sodium sulfate, sodium chloride, sodium carbonate, potassium sulfate, potassium chloride, potassium carbonate, calcium sulfate, calcium chloride, calcium carbonate, calcium nitrate, magnesium sulfate, magnesium chloride, magnesium carbonate, magnesium nitrate, derivatives thereof, mixtures thereof; alternatives thereof; and equivalents thereof; between about 0.5% to about 6% of a polyhydric alcohol;
  • the surfactant comprising alpha sulfonated alkyl ester, a sulfonated fatty acid, or mixtures thereof is preferably present in an amount less than 12% by weight of the composition.
  • soap bar compositions of the presently described technology preferably exhibit or have a lamellar microstructure at about 70 0 C when in an aqueous liquid mixture or slurry form.
  • the soap component of the presently described technology can be present in any amount from about 40% to about 94% by weight of the soap bar composition; including any amount from about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, or about 70% to about 94%, about 93%, about 92%, about 90%, about 85%, or about 80% and the like.
  • the fatty acid component utilized in the soap bar compositions of the presently described technology can be present in any amount, including but not limited to, from about 1% to about 15%, including any amount from about 1%, about 2%, about 3%, or about 5%, to about 10%, about 8%, about 7%, or about 6%.
  • the surfactant comprising alpha sulfonated alkyl ester, a sulfonated fatty acid, or mixtures thereof of the presently described technology can be present in any amount up to about less than 12% by weight of the composition, including but not limited to from about 2%, about 3%, about 3.5%, about 4%, or about 5%, to about 11%, about 10% or about 8%.
  • the synthetic surfactant component of the presently described technology can be present in' any amount up to about 18% by weight of the composition, including but not limited to from about 1%, about 2%, about 3%, or about 5%, to about 17%, about 16%, about 15%, about 12% or about 10%.
  • the electrolyte component of the presently described technology can be present in any amount,, including but not limited to, from about 0.5%, about 0.7%, about 0.8%, or about 1%, to about 1.4%, about 1.6%, or about 1.8%.
  • the polyhydric alcohol component of the presently described technology can be present in any amount, including but not limited to, from about 0.5%, 1%, or 2%, to about 4%, about 5%, or about 6%. Additional examples of component amounts that can be used in accordance with the present technology are provided in the discussion below. Soap:
  • compositions of the present technology preferably utilize at least one Cg-C 22 soap.
  • the soap has the following general chemical formula: wherein R 1 is a Q-C 22 hydrocarbyl group, an alkyl group, or combination thereof, n is 1 or 2, and L is a cation.
  • L is sodium, potassium, calcium, magnesium, ammonium, monoethanolammonium, diethanolammonium, triethanolammonium, or a mixture thereof.
  • the soap is present as an aqueous slurry.
  • the soap preferably comprises between about 40% to about 94% by weight of the initial mixture and/or thickened mixture, before or after drying or dehydration of the soap mixture.
  • the soap can also be present in an amount from about 40% to about 92%, or from about 55% to about 94%, by weight of the soap bar composition. More preferably, the soap is present in an amount between about 65% to about 80% by weight of the composition. In some embodiments, the composition may comprise from about 56% to about 93% by weight of an aqueous soap slurry. It should be understood that the amount of soap put into a soap bar composition may vary depending upon the amount of other components to be added to the soap bar composition. The soap preferably comprises between about 65% to about 80% in a finished soap bar.
  • the soap is preferably added to the initial soap bar composition in the form of an aqueous slurry.
  • the aqueous slurry is about 70% solids.
  • the other components of the soap bar composition are mixed with the soap slurry to form an initial mixture.
  • the primary source of the water content of the initial mixture is usually the water in this aqueous slurry, though additional water may be added if desired.
  • Soap bar compositions of the present technology may have from about 3% to about 22%, more preferably from about 3% to about 16%, by weight of water at any point during processing.
  • most of the water is preferably removed from the initial mixture before forming a finished soap bar.
  • water comprises between about 3% to about 16% of a finished soap bar.
  • the soap is a tallow or coconut soap, or mixture thereof.
  • the soap comprises between about 60% to about 95% by weight of the soap of tallow soap and between about 5% to about 40% by weight of the soap of coconut soap.
  • the soap comprises between about 60% to about 90% tallow soap and between about 10% to about 40% coconut soap.
  • Fatty acids of the present technology are preferably present from about 1% to about 15% by weight, and more preferably, between about 1% to about 7%.
  • the fatty acid is preferably a Cg-C 22 fatty acid.
  • the fatty acid preferably contains a hydrocarbyl group, an alkyl group, or combination thereof. More preferably, the fatty acid is a C 12 -C 20 fatty acid.
  • the fatty acid has the formula:
  • R 2 is a C O -C 22 hydrocarbyl group, an alkyl group, or a combination thereof.
  • R 2 is a Ci 2 -C 2O hydrocarbyl group, or a combination of a C 12 -C2 0 hydrocarbyl group and an alkyl group.
  • the (free) fatty acids generally used in accordance with the present technology correspond with the fatty acids used to make conventional soaps.
  • the fatty acid material which is desirably incorporated into the invention includes, for example, material ranging in hydrocarbon chain length of from about 6 to about 22 carbons, essentially saturated. These fatty acids can be highly purified individual chain lengths and/or crude mixtures such as those derived from fats and oils.
  • the industry term "triple pressed stearic acid" comprises about 45 parts stearic and 55 parts palmitic acids. Additionally, the term stearic acid is used in the context of the soap industry to refer to a fatty acid mixture which is predominately stearic acid and shall be the meaning as used herein.
  • compositions and the methods of producing such compositions according to the present technology can include soaps derived from hydrocarbon chain lengths of from about 6 to about 22 carbons (including carboxyl carbon) and, in some embodiments, are saturated.
  • the soap is the sodium salt, but other soluble soap can be used. Potassium, calcium, magnesium, monoethanolammonium, diethanolammonium, triethanolammonium, and mixtures thereof, are deemed acceptable.
  • the soaps can be prepared by the in situ saponification or ion exchange with halide salt of the corresponding fatty acids, but they may also be introduced as pre-formed soaps.
  • compositions and processes preferably utilize an alpha sulfonated alkyl ester, alpha sulfonated fatty acid, or mixture thereof.
  • the alpha sulfonated alkyl ester preferably has the following general formula:
  • R 3 is a C 6 -C22 hydrocarbyl group, an alkyl group, or combination thereof
  • R 4 is a straight or branched chain Ci-C 6 hydrocarbyl group, an alkyl group, or combination thereof
  • n is 1 or 2
  • M is hydrogen, sodium, potassium, calcium, magnesium, ammonium, monoethanolammonium, diethanolammonium, triethanolammonium, a mixture thereof, a derivative thereof, an alternative thereof, or an equivalent thereof.
  • the sulfonated fatty acid preferably has the general formula:
  • R 5 is a C 6 -C 22 hydrocarbyl group, an alkyl group, or combination thereof, n is 1 or 2 and wherein N is hydrogen, sodium, potassium, calcium, magnesium, ammonium, monoethanolammonium, diethanolammonium, triethanolammonium, a mixture thereof, a derivative thereof, an alternative thereof, or an equivalent thereof.
  • Embodiments of the present technology may disclose one or the other of such anionic surfactants, or a mixture of the two. Either a single such anionic surfactant or mixture of both types of anionic surfactants may also be utilized in combination with a synthetic anionic, amphoteric, zwitterionic, nonionic, or semi-polar surfactant, as discussed below, hi some embodiments alpha sulfonated alkyl esters and sulfonated fatty acids are present in a ratio of from about 0:1 to about 1:0.
  • compositions of the presently described technology and the methods of producing such compositions preferably contain (or utilize) from about 1% to about 30% by weight of a surfactant mixture wherein the primary surfactant comprises an alpha sulfonated alkyl ester and/or sulfonated fatty acid.
  • the primary surfactant is preferably present in an amount less than 12% by weight of the soap bar composition.
  • the alpha sulfonated alkyl esters used are typically prepared by sulfonating an alkyl ester of a fatty acid with a sulfonating agent such as SO 3 , followed by neutralization with a base, such as sodium hydroxide, potassium hydroxide, calcium hydroxide, magnesium oxide, monoethanolamine, diethanolamine or triethanolamine, or a mixture thereof.
  • a base such as sodium hydroxide, potassium hydroxide, calcium hydroxide, magnesium oxide, monoethanolamine, diethanolamine or triethanolamine, or a mixture thereof.
  • the alpha sulfonated alkyl esters normally contain a minor amount, typically not exceeding 33% by weight, of an alpha sulfonated fatty acid, i.e., di-salt, which results from hydrolysis of the ester.
  • the alpha sulfonated alkyl ester and alpha sulfonated fatty acid may be provided to the composition or utilized in the process of the presently described technology as a blend of components which naturally result from the sulfonation of an alkyl ester of a fatty acid, or as individual components.
  • minor impurities such as sodium sulfate, unsulfonated methyl esters (ME), and unsulfonated fatty acids (FA) may also be present in the mixtures according to the present technology.
  • the alpha sulfonated alky] esters i.e., alkyl ester sulfonate surfactants
  • Suitable starting materials include, among others, natural fatty substances as derived from tallow, palm oil, etc.
  • the ⁇ -sulfonated alkyl ester is a sulfonated methyl ester, desirably as further described herein.
  • Preferred embodiments may contain either an alpha sulfonated alkyl ester separately, a sulfonated fatty acid separately, or a mixture of the two.
  • Either component or a mixture of the components may be provided in any form, although preferably provided as an aqueous mixture (e.g., slurry).
  • compositions and the methods of producing such compositions of the presently described technology generally contain (or utilize) about 0.5% to about 2%, or more preferably between about 0.8% to about 1.6%, by weight of an electrolyte.
  • an electrolyte may be any salt capable of acting as crisping agent or builder to arrive at a final bar formulation.
  • the electrolyte is sodium sulfate, sodium chloride, sodium carbonate, potassium sulfate, potassium chloride, potassium carbonate, calcium sulfate, calcium chloride, calcium carbonate, calcium nitrate, magnesium sulfate, magnesium chloride, or magnesium carbonate, magnesium nitrate, mixtures thereof, derivatives thereof, alternatives thereof, or equivalents thereof.
  • the salt is magnesium chloride, sodium chloride or a mixture thereof.
  • the salt is sodium chloride.
  • Polyhydric alcohols of the present technology may be polyols generally defined as a non-volatile di- or higher polyhydric alcohol, a sugar or a polyethylene glycol.
  • the polyhydric alcohol is glycerin, polyglycerols, sorbitol, glycols, mixtures thereof, derivatives thereof, alternatives thereof, or equivalents thereof.
  • Particular examples can include, without limitation, glycerine, propylene glycol, glycerol, sorbitol, sucrose and 200-400 molecular weight polyethylene glycol, dipropylene glycol, polypropylene glycols 2000, 4000, polyoxyethylene polyoxypropylene glycols, polyoxypropylene polyoxyethylene glycols, glycerol, sorbitol, ethoxylated sorbitol, hydroxypropyl sorbitol, polyethylene glycol 200-6000, methoxy polyethylene glycols 350, 550, 750, 2000, 5000, poly[ethylene oxide] homopolymers (100,000-5,000,000), polyalkylene glycols and derivatives, hexylene glycol (2-methyl-2,4-pentanediol), 1,3- butylene glycol, 1,2,6-hexanetriol, ethohexadiol USP (2-ethyl-l,3-hexanedio
  • the useful polyols of the present technology are generally liquid water-soluble aliphatic polyols or polyethylene glycols or polypropylene glycols.
  • the polyol may be saturated or contain ethylenic linkages; it must have at least two alcohol groups attached to separate carbon atoms in the chain, and must be water soluble and liquid at room temperature. If desired, the compound may have an alcohol group attached to each carbon atom in the chain.
  • the compounds which are effective are, for example, ethylene glycol, propylene glycol, glycerine and mixtures thereof.
  • the polyol is glycerine.
  • Water-soluble polyethylene glycols, water-soluble polypropylene glycols useful in accordance with the technology of the present invention are those products produced by the condensation of ethylene glycol molecules or propylene glycol molecules to form high molecular weight ethers having terminal hydroxyl groups.
  • the polyethylene glycol compounds may range from diethylene glycol to those having molecular weights as high as about 800, and, in some embodiments, about 100 to 700, in other embodiments, 100 to 600.
  • polyethylene glycols having molecular weights up to 800 are liquid and completely soluble in water. As the molecular weight of the polyethylene glycol increases beyond 800, they become solid and less water-soluble. Such solids may be used as plasticizers herein when malleable at 35°C to about 46°C.
  • the polypropylene glycol compounds may range from dipropylene glycol to polypropylene glycols having molecular weights of about 2000, and, in some embodiments, less than 1500, in other embodiments, less than 1000. These are normally liquid at room temperature and are readily soluble in water.
  • the present technology also optionally preferably comprises at least one synthetic surfactant in combination with the alpha sulfonated alkyl ester, sulfonated fatty acid, or mixture thereof.
  • the synthetic surfactant is present in an amount such that the mixture of total surfactant is between about 1% to about 30% by weight of the total composition. More preferably, the synthetic surfactant is present in an amount between about 5% to about 15% by weight of the total composition.
  • Synthetic surfactants are preferably anionic, amphoteric, zwitterionic, nonionic, or semi-polar surfactants.
  • Preferred synthetic surfactants include, for example, alkanolamides, alkylamidopropyl betaines, alkylamidopropyl hydroxysultaines, salts of alkylamphoacetate, salts of alkyl sulfoacetate, di-salts of alkyethoxy sulfosuccinate, di-salts of alkyl sulfosuccinate, alkylamide monoethanolamine, alkylamidopropylamine oxide, salts of alpha olefin sulfonate, salts of alkyl sulfate, salts of alkylyl isethionate, salts of alkylethoxy sulfate, salts of alkyliminodipropionate, salts of alkyl sarcosinate, salts of alkyeth
  • the alkanolamide is present in an amount up to about 10% by weight of the composition, more preferably between about 1% to about 10%, and most preferably between about 2% to about 5%.
  • Contemplated synthetic surfactants further include, but are not limited to the following: cocoamidopropyl betaine, laurylamidopropyl betaine, cocoamidopropyl hydroxysultaine, sodium cocoamphoacetate, sodium lauryl sulfoacetate, sodium laureth sulfoacetate, disodium laureth sulfosuccinate, disodium lauryl sulfosuccinate, cocoamide monoethanolamine, cocoamidopropylamine oxide, laurylamidopropylamine oxide, lauryl/myristylamidopropylamine oxide, sodium alpha olefin sulfonate, sodium lauryl sulfate, sodium cocoyl isethionate, sodium lauryl ether sulfate, potassium lauryl sulfate, magnesium lauryl sulfate, sodium lauriminodipropionate, sodium lauryl sarcosinate, sodium laure
  • the synthetic surfactant is cocoamidopropyl betaine, sodium lauryl sulfoacetate, disodium laureth sulfosuccinate, acyl lactylate, sodium alpha olefin sulfonate, potassium lauryl sulfate, sodium coco sulfate or sodium laureth sulfate.
  • the synthetic surfactant is cocoamidopropyl betaine.
  • compositions and the methods of producing such compositions also optionally may further comprise (or utilize) additional ingredients, surfactants, pH adjusters, emollients, moisturizers, viscosity agents, buffers, and the like as disclosed in published PCT Application WO 03/063819, to Ospinal et al., published on August 7, 2003, incorporated by reference herein.
  • some additives may include from about 0.5% to about 10% by weight of a sucrogylceride, a functional metallic soap, a succinamate, a sulfosuccinamate, a mono-, di-, or trigylceride, chitosan, or a mixture thereof.
  • the compositions and the methods of producing such compositions may further comprise (or utilize) from about 0.1% to about 10% by weight of fragrance, emollients, moisturizers, viscosity control agents, as well as additional agents appropriate for incorporation into a composition of the invention and which are known to those skilled in the art.
  • acyl isethionates such as for example, sodium acyl (cocoyl) isethionate (SCI).
  • suitable anionic surfactants include, among others, the sodium, potassium, magnesium, calcium, ammonium, monoethanolammonium (MEA), diethanolammonium (DEA), triethanolammonium (TEA), or alkyl amine salts, or mixtures thereof, of sulfonic acids, polysulfonic acids, sulfonic acids of oils, paraffin sulfonic acids, lignin sulfonic acids, petroleum sulfonic acids, tall oil acids, olefin sulfonic acids, hydroxyolefin sulfonic acids, polyolefin sulfonic acids, polyhydroxy polyolefin sulfonic acids, perfluorinated carboxylic acids, alkoxylated carboxylic acid sulfonic acids,
  • Suitable nonionic surfactants include those generally disclosed in U.S. Pat.
  • nonionic surfactants may include, for example, those selected from the group comprising polyoxyethyleneated alkylphenols, polyoxyethyleneated straight chain alcohols, polyoxyethyleneated branched chain alcohols, polyoxyethyleneated polyoxypropylene glycols, polyoxyethyleneated mercaptans, fatty acid esters, glyceryl fatty acid esters, polyglyceryl fatty acid esters, propylene glycol esters, sorbitol esters, polyoxyethyleneated sorbitol esters, polyoxyethylene glycol esters, polyoxyethyleneated fatty acid esters, primary alkanolamides, ethoxylated primary alkanolamides, secondary alkanolamides, ethoxylated secondary alkanolamides, tertiary acetylenic glycols, polyoxyethyleneated silicones
  • compositions and the methods of producing such compositions herein may be formulated and carried out such that they will have a pH of between about 4.0 and about 10.0, and, in some embodiments, between about 5 and about 9.5.
  • Techniques for controlling pH at recommended usage levels include the use of buffers, alkali, acids, etc., and are well known to those skilled in the art.
  • Optional pH adjusting agents can include, but are not limited to citric acid, succinic acid, phosphoric acid, sodium hydroxide, sodium carbonate, and the like.
  • auxiliary surfactants are selected from the group comprising amides, amine oxides, betaines, sultaines and C 8 -C 1S fatty alcohols, hydrating cationic polymer, suitable plasticizers, non-volatile, nonionic silicone conditioning agents, polyalkyl or polyaryl siloxanes, and pearlescent/suspending agents, detergent builders, anti-bacterial agents, fluorescers, dyes or pigments, polymers, perfumes, cellulase enzymes, softening clays, smectite-type softening clays, polymeric clays, flocculating agents, dye transfer inhibitors, optical brighteners, skin feel enhancers including aluminosilicate and non- aluminosilicate odor-controlling materials, chitan, triglycerides, glycerine, succinamates, sucroglycerides
  • compositions of the presently described technology may be transparent and/or produce a transparent personal cleansing or laundry detergent bar upon proper processing and/or selection of optional ingredients and components detailed herein. Additionally, the compositions may be used to produce a transparent dish washing gel, paste or solution, or further applications or forms which will be apparent to one skilled in the art. Whether transparent or nontransparent, the compositions may exist as solid flakes, or as a gel. [0062] Further, the compositions and the methods of producing such compositions of the present technology may optionally contain (or utilize) about 1.0% to about 15.0% by weight of a wax, in some embodiments, for example, paraffin, having a melting point of from about 54°C to about 180 0 C.
  • a wax in some embodiments, for example, paraffin, having a melting point of from about 54°C to about 180 0 C.
  • the waxes can include without limitation beeswax, spermaceti, carnauba, bayberry, candelilla, montan, ozokerite, ceresin, paraffin, synthetic waxes such as Fisher-Tropsch waxes, microcrystalline wax, derivatives thereof, or mixtures thereof.
  • the wax ingredient is used in the compositions of the present technology to impart skin mildness, plasticity, firmness, and processability. Wax also provides a glossy look and smooth feel to the final product.
  • At least one additional component of the compositions of the present technology can be a wax, and in some embodiments, paraffin wax having a melting point of from about 54°C to about 82°C, in other embodiments from about 60 0 C to about 74°C, and in yet other embodiments from about 61°C to about 71°C.
  • "High melt” paraffin is a paraffin that has a melting point from about 66°C to about 71 0 C.
  • Low melt paraffin is a paraffin that has a melting point from about 54°C to about 60 0 C.
  • the paraffin wax is a fully refined petroleum wax which is odorless and tasteless and meets FDA requirements for use as coatings for food and food packages.
  • Such paraffins are readily available commercially.
  • a suitable paraffin can be obtained, for example, from The National Wax Co. under the trade name 6975. Processing:
  • Such a process preferably comprises first forming at a temperature of about
  • an aqueous liquid mixture which is homogeneous or substantially homogeneous, comprising: an aqueous soap slurry comprising a C 6 -C 22 soap; a C 6 -C 22 fatty acid; a surfactant mixture; an electrolyte selected from the group consisting of sodium sulfate, sodium chloride, sodium carbonate, potassium sulfate, potassium chloride, potassium carbonate, calcium sulfate, calcium chloride, calcium carbonate, calcium nitrate, magnesium sulfate, magnesium chloride, magnesium carbonate, magnesium nitrate, mixtures thereof, derivatives thereof, alternatives thereof, and equivalents thereof; a polyhydric alcohol; and water.
  • Preferred surfactant mixtures comprise a mixture of either a sulfonated fatty acid or an alpha sulfonated alkyl ester, plus another synthetic surfactant. Most preferably, both sulfonated fatty acid and alpha sulfonated alkyl ester are utilized in combination with another synthetic surfactant.
  • the aqueous soap slurry comprising a C6-C22 soap preferably has a free alkalinity of less than about 0.1%. It is also preferred that the water content be in an amount from about 30% to about 36% by weight of the aqueous liquid mixture. Additionally, it is preferred that the aqueous liquid mixture has or exhibits a lamellar microstructure at about 70 0 C.
  • the process preferably involves drying the aqueous liquid mixture by removing water to form a thickened mixture.
  • the thickened mixture may comprise amounts of the components of the homogeneous aqueous liquid mixture in any amount in accordance with the soap bar compositions described above.
  • the thickened mixture comprises from about 40% to about 94%, more preferably from about 60% to about 75%, by weight of the C 6 -C 22 soap; from about 1% to about 15%, more preferably from about 1% to about 7%, by weight of the C 6 -C 22 fatty acid; from about 1% to about 30% by weight of a mixture of surfactants; between about 0.5% to about 2% by weight of the electrolyte; between about 0.5% to about 6.0%, more preferably between about 1% to about 4%, by weight of the polyhydric alcohol; and between about 3% to about 22%, more preferably between about 3% to about 16%, and most preferably between about 9% and about 12%, by weight of water.
  • Preferred surfactant mixtures comprise an alpha sulfonated alkyl ester, a sulfonated fatty acid, or a mixture thereof in an amount from about 2%, more preferably from about 5%, to less than 12% by weight of the overall composition, and optionally a synthetic surfactant.
  • Removal of the water from the initial liquid mixture is preferably accomplished by scraped wall vacuum evaporation drying under reduced pressure or heated drum drying at ambient pressure. In a preferred embodiment, about 55% to about 85% by weight of the water is removed from the initial liquid mixture; and most preferably, about 60% to about 80% by weight of the water is removed from the initial liquid mixture.
  • Some examples of determining water removal by drying include final thickened mixtures comprising between about 1.74% of the final thickened mixture (Example: approximately 70% solids of an aqueous slurry comprising 58% of the initial mixture, with 90% water removed) to about 26.5% of the final mixture (Example: approximately 70% solids of an aqueous slurry comprising 93% of the initial mixture, with 5% water removed).
  • Processes of the present technology may include further steps, such as extruding the thickened mixture to form flaked solid or semi-solid particles, plodding the flaked solid or semi-solid particles to form plodded particles, and additional processing including a final extrusion step to form a billet.
  • the final extrusion step is performed at a temperature from about 35°C to about 45°C, and more preferably 35°C to about 38°C.
  • further processing steps may include, for example, cutting the billet to form a cut billet, and stamping the cut billet to yield a personal cleansing or a laundry detergent bar.
  • the processes of the present technology described herein generally overcome many of the shortcomings of the aforementioned heretofore known processes. For example, the present technology yields homogeneous or substantially homogeneous soap noodles which results in bars with minimal grit or hard specks.
  • the processes are also carried out at temperatures at or below about 105 0 C in the atmospheric mixing stage (i.e., forming the homogeneous aqueous liquid mixture) so as to conserve energy and minimize hydrolysis of the alpha sulfonated alkyl ester, and the process utilizes standard bar processing equipment.
  • soap bars resulting from the improved process have the desired hardness, water permeability, low grit, enhanced slip, reduced hard specks, and an absence of marring (even when dried to exceptionally low moisture levels, and with aging on the shelf for several months).
  • compositions of the present technology are extremely useful in soap bar and laundry bar. applications, other applications for these compositions are possible.
  • the compositions of the presently described technology may be useable in or as liquid, paste or gel dish washing compositions, hand soaps including waterless hand cleaners, multi-purpose cleaners, body washes, further laundry detergent compositions such as laundry powder, pre- spotter or stain sticks, textile treatment compositions including triethanolamine (TEA) soaps for dry cleaning, shampoos including those for humans, pets, and carpets, car wash, soap scouring pads and scrubbing pads, toilet tank drop ins and/or cleaners, personal care creams and lotions, and the like.
  • TAA triethanolamine
  • Coco Fatty Acid Emery 627 (a tradename from Emery Corporation, a division of He ⁇ kel) and coconut fatty acids that can be substituted for Emery 627
  • ALPHA-STEP® MC-48 average about 5:1 to about 10:1 mixture of sulfonated stripped coco methyl esters and stripped coco fatty acids available from Stepan Company
  • NINOL® CMP or LMP CMP - coco monethanolamine amide available from Stepan
  • Pristerene 4981 Stearic Acid (from Unichema); approximate iodine value of 1.0 maximum; mixture of about 65% C 18 fatty acid, about 28% fatty acid and about 2% myristic fatty acid
  • ALPHA STEP® BSS-45 average about 1.3 to about 1.8:1 mixture of alpha sulfonated stripped coco methyl esters and stripped coco fatty acids with actives of about 43% to about 45% available from Stepan Company
  • ALPHA-STEP® PC-48 coco 10:1 SME to SFA ratio available from Stepan Company
  • ALPHA-STEP ® PS-65 palm stearin 10:1 SME to SFA ratio available from Stepan Company
  • Stepanol® MG magnesium lauryl sulfate available from Stepan Company
  • Example 1 Procedure for Making Cleaning Bar
  • Neat soap is melted in a steam jacketed crutcher (about 140 0 F to about 200 0 F)
  • Additives such as stearic acid and/or coco fatty acids, mixtures thereof (about 1 to about
  • the wet soap is air-dried or vacuum-dried to reduce the moisture level to below about
  • the temperature of the plodder is maintained at about 90 0 F to about 100 0 F using a water circulation system.
  • the acid is neutralized by the dropwise addition of sodium hydroxide (50% solution) until a pH of about 6.5 is achieved, all the while maintaining the temperature below about 45°C using a water/ice bath.
  • the final product is analyzed by titration with 0.02N hyamine, and found to comprise 35.82% SME (mono-salt) and 1.36 SFA (di-salt), with the SME:SFA ratio being 26.3:1.
  • Example 6 Preparation of Samples Containing Various Amounts of SME and SFA 10079]
  • samples containing differing amounts of SFA and SME e.g., total amounts of each or either present in the initial liquid mixture, and optionally present with respect to varying amounts of total SFA and SME actives
  • samples containing differing amounts of SFA and SME can be obtained, for instance, by varying the hydrolysis of SME to SFA (e.g., by varying hydrolysis conditions, and/or amount of methanol applied for hydrolysis).
  • mixtures can be combined, and/or varying amounts of either pure (or relatively pure) SME or SFA can be added to adjust the concentration of a particular mixture.
  • One skilled in the art will recognize how to obtain the particular ratios referenced herein (if not otherwise disclosed) as well as further ratios and formulations encompassed by the scope of the presently described technology and appended claims.
  • Table 1 provides two soap bar formulations without alpha sulfonated alkyl ester or sulfonated fatty acid (Formulation A), or without polyhydric alcohol (Formulation B) 5 used herein as control formulations.
  • An additional control formulation is provided in Table 7.
  • Tables 2-7 provide examples of formulations of skin cleansing bars according to the present technology, indicating weight percent of components in finished cleansing bars.
  • NINOL® LMP LMP: Lauryl Monoethanolamide
  • NINOL® CMP CMP: Coconut Monoethanolamide
  • Salt is 1: 1 sodium chloride:magnesiuin sulfate Table 6
  • Tables 8-18 provide examples of formulations of skin cleansing bars with added synthetic surfactant, indicating weight percent of components in finished cleansing bars. Table 8
  • Mono/di ratio paste, and 3.93% of NINOL® CMP or LMP are added to a crutcher in the indicated order. Mix the product at about 85 0 C to about 9O 0 C. [0084] Vacuum Drying Step. The crutcher mix is then vacuum dried at approximately 50 mm Hg absolute pressure to reduce the moisture content of the mix to about 10% and to plod this soap into noodles.
  • a conventional plodder is set up with the barrel temperature at about 35 0 C and the nose temperature at about 42 0 C.
  • the plodder used is a dual stage twin screw plodder that allows for a vacuum of about 40 to about 65 mm Hg between the two stages.
  • the soap log extruded from the plodder is typically round, and is cut into individual plugs. These plugs are then stamped on a conventional soap stamping apparatus to yield the finished toilet soap bar.
  • Marring is the damage incurred by impact to a soap bar during handling and shipping. It is a well-known characteristic by which consumers rate a bar. Bar soap manufacturers prefer a soap formulation with low mar characteristics to reduce consumer rejection should the bars incur any damage or rough handling during shipping.
  • the bars of the present technology show little damage when dropped compared to conventional soap bars. As an illustration of this, soap bars prepared according to the present technology are subjected to a test that quantitatively compares different bars by their marring characteristics. [0090] Each sample is weighed and then dropped from a specific height to mar the bars. It was determined that exactly 7 feet would provide an extreme enough impact to clearly determine the marring characteristics of the bars.
  • the bars would be dropped in a way that the small end of the bar would strike the ground to provide the most visible damage possible (striking perpendicular to the extrusion of the bars).
  • the bars are then analyzed for their level of damage in the form of a dry-impact bar cracking scale. Using this scale the mar value of the bar is determined through ranking of the visible damage to the bar.
  • the bar mar test method was analyzed for reproducibility. Samples are tested in triplicate to ensure reproducibility and determine the standard deviation. The average standard deviation of the mar values for the samples is 0.39, showing a high reproducible rate within a range of 1 on the dry-impact cracking scale. [0092] The test method is used to determine the marring characteristics of several trial bars made according to the presently described technology, and several conventional commercial bars. Each bar is dropped from a height of 7 feet and the damage measured to calculate the total marring value of each sample.
  • soap bar compositions containing alpha sulfonated alkyl ester, sulfonated fatty acid, or mixtures thereof, in addition to polyhydric alcohol and electrolyte are easier to process than conventional soap compositions.
  • soap bar compositions of the present technology are readily pumpable using standard soap bar production equipment, as compared to compositions prepared in the absence of alpha sulfonted alkyl ester, sulfonated fatty acid, or mixtures thereof, polyhydric alcohol and electrolyte.
  • initial soap slurry compositions according to the present technology generally exhibit lower viscosity at lower temperature.
  • aqueous liquid mixtures or soap slurries of the present technology are homogeneous or substantially homogeneous, and have a viscosity of between about 2000 cps to about 9000 cps at the temperature at which they are formed.
  • such aqueous liquid mixtures or slurries of the present technology have a viscosity of between about 2000 cps to about 6000 cps at the temperature at which they are formed.
  • formulations according to the present technology generally exhibit constant viscosity more quickly in shear tests.
  • Table 21 illustrates the lowered viscosity of certain exemplary formulations of the present technology, compared to control samples without sulfonated fatty acid (SFA) and/or sulfonated alkyl ester (SME), or without polyhydric alcohol. Viscosity was measured in a continuous ramp test at constant shear rate of 2 1/s and at 70 0 C with an AR-2000 rheometer from TA Instruments of New Castle, Delaware. A 4 cm plate-plate geometry was used for these tests. After shearing for 100 seconds and 300 seconds, the viscosity was recorded. Table 10 shows the viscosity results.
  • the soap bar composition exhibits a lamellar microstructure at about 70 0 C in slurry, or at less than about 70 0 C in slurry.
  • compositions of the present technology exhibit a phase transition temperature from hexagonal to lamellar at about 65 0 C, or at less than about 65°C, in slurry.
  • Various embodiments of soap slurries of the present technology can exhibit a lamellar microstructure at a temperature between about 55°C and about 70 0 C, such as, for example, at about 70 0 C, about 68°C, about 65°C, about 64°C, about 63°C, about 62°C, about 60 0 C, about 58°C, about 57°C, or about 55°C.
  • Table 22 illustrates the phase morphology of several embodiments of the present technology, compared to control samples without alpha sulfonated alkyl ester and/or sulfonated fatty acid (SME/SFA), or polyhydric alcohol.
  • Tested embodiments of the presently disclosed technology exhibited a primarily lamellar microstructure at approximately 70 0 C, compared to control formulations without SME/SFA or polyhydric alcohol, which exhibited a primarily hexagonal microstructure at about 70 0 C.
  • Hexagonal microstructures have high viscosity and yield stress, and are known to be more difficult to process.
  • control formulations exhibited phase transition temperatures between about 75°C to about 90 0 C, while the formulations according to the present technology exhibited phase transition temperatures between about 57°C to about 65°C. These tests also indicate a synergistic relationship in compositions utilizing or containing both SME/SFA and polyhydric alcohol - namely, compositions containing both SME/SFA and polyhydric alcohol exhibit more desirable viscosity and microstructure than compositions containing only one.
  • Table 22 Microstructure of SME Soap Slurries
  • the improved rheological and microstructural properties of the present compositions also may result in improved physical characteristics of a finished soap bar.
  • a lamellar structure water binds with the polar groups of surfactants and form in a sheet type highly ordered structured water phase. The water is .distributed more evenly and is available uniformly as its structure recovery under shear is fast. This results into much better drying properties of lamellar soap melt. Due to uniform moisture distribution in the soap melt/slurry, there will be very few dry and moist spots in extruded bars. During storage or use these bars, they may not lose or absorb different amount of water causing the bar to develop cracks at the point of moisture gradient difference.
  • the bar produced from a lamellar soap melt/slurry will have much more uniform evaporation of water over time and would display characteristics of much better elasticity.
  • the preferred compositions can evenly distribute the bound water, making such water not easily available for evaporation under storage temperatures. As a result, very little crystallinity occurs in the finished bar, making it less susceptible to marring. This is another positive and desirable attribute of SME soap bar technology.

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Abstract

L'invention concerne une composition appropriée pour être utilisée dans des pains de savon d'hygiène personnelle ou détergents, ainsi que des procédés de production de ladite composition. La composition comprend un tensio-actif comprenant un acide gras sulfoné, un ester d'alkyle alpha sulfoné, ou un mélange de ces derniers, et elle comprend également, éventuellement, un tensio-actif synthétique. La composition et les procédés permettent un traitement efficace et permettent la formation de pains d'hygiène ou détergents présentant une dureté améliorée, une résistance améliorée au tachage, une aptitude au traitement contre le tachage améliorée, un taux d'usure inférieur et une formation de pâte diminuée lors de l'utilisation par un consommateur.
PCT/US2007/011180 2006-05-09 2007-05-09 Compositions de pains de savon comprenant de l'ester d'alkyle alpha sulfoné ou un acide gras sulfoné et un tensioactif synthétique et procédé de production desdites compositions WO2007133582A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US11/430,715 US20060241003A1 (en) 2002-01-31 2006-05-09 Soap bar compositions comprising alpha sulfonated alkyl ester and polyhydric alcohol and process for producing the same
US11/430,715 2006-05-09
US11/436,280 2006-05-18
US11/436,280 US20070004611A1 (en) 2002-01-31 2006-05-18 Soap bar compositions comprising alpha sulfonated alkyl ester or sulfonated fatty acid and synthetic surfactant and process for producing the same

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020225005A1 (fr) 2019-05-07 2020-11-12 Basf Se Compositions tensioactives aqueuses et pains de savon

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2003063819A1 (fr) * 2002-01-31 2003-08-07 Stepan Company Compositions de pains de savon comprenant des alkylesters d'acides gras alpha-sulfones et des polyols, et procedes de production desdites compositions
US20050153853A1 (en) * 2002-01-31 2005-07-14 Stepan Company Soap bar compositions comprising alpha sulfonated alkyl ester or sulfonated fatty acid and synthetic surfactant and processes for producing same

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2003063819A1 (fr) * 2002-01-31 2003-08-07 Stepan Company Compositions de pains de savon comprenant des alkylesters d'acides gras alpha-sulfones et des polyols, et procedes de production desdites compositions
US20050153853A1 (en) * 2002-01-31 2005-07-14 Stepan Company Soap bar compositions comprising alpha sulfonated alkyl ester or sulfonated fatty acid and synthetic surfactant and processes for producing same
WO2006062665A1 (fr) * 2004-12-08 2006-06-15 Stepan Company Pains de savon comprenant un alkyl ester sulfone ou un acide gras sulfone

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020225005A1 (fr) 2019-05-07 2020-11-12 Basf Se Compositions tensioactives aqueuses et pains de savon

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