Product Forms

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Product Forms

• Terri Germain
• McIntyre Group
• September 12, 2006
• Toronto Canada

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Product Forms

• Cleaning Products are sold as
• Liquids Solutions, Emulsions, Dispersions
• Bulk Liquids
• On a Substrate, i.e. Wipes
• Aerosols
• Solids
• Bulk Solid, as is or on a substrate
• Powders

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Liquids

• Water Based Solutions
• Laundry Detergents
• Hand Dishwash
• Handsoaps
• Hard Surface Cleaners
• Shampoos
• Emulsions
• Pine Oil Cleaners
• Waterless Hand Cleaners

• Dispersions
• Fabric Softeners
• Hand Cleaners with Pumice
• 2 in 1 Shampoos
• Hair Conditioners
• Autodish Detergents
• II Cleaners
• Non-Aqueous
• Specialty Products

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Liquid ManufacturingThings to Think About

• During Manufacturing
• Order of Addition
• Temperature sensitive
• pH sensitive
• Viscosity
• Mixing Time
• Mixing Temperature
• Shear
• Equipment Compatibility
• Rheology During Filling Process

• Post Manufacturing
• Container Compatibility
• Long Term Ambient Stability
• Color Change
• pH Change
• Viscosity Change
• Homogeneity
• High Temp Stability
• Cold Temp Stability
• Freeze/Thaw
• Evaporation
• UV Stability

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Mix Vessel for Liquids

• Clean!
• Flat or Conical Bottom
• Sample Tap
• Variable Mix Speed
• Multiple Blades (optional)
• Baffles (optional)
• External or Internal Heating Cooling (optional)
• Recirculation loop (optional)

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An Example

• Poor Processing of an LDL
• Water, Cold
• Alkanolamide
• Alkyl Ether Sulfate
• DDBSA
• NaOH 50
• Dye, Powder
• Fragrance

• Correct Processing of an LDL
• Water, Cold
• NaOH 50
• DDBSA
• Alkanolamide
• Alkyl Ether Sulfate
• Dye, Solution
• Fragrance, Predispersed

Gel!
Strong Acid just Hydrolyzed the Amide and AES!
Careful Soln will exotherm here
Could take a long time to dissolve
Fragrance could make soln hazy
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An Example

• Poor Processing of an LDL
• Water, Cold
• Alkanolamide
• Alkyl Ether Sulfate
• DDBSA
• NaOH 50
• Dye, Powder
• Fragrance

Gel!
Strong Acid just Hydrolyzed the Amide and AES!
Careful Soln will exotherm here
Could take a long time to dissolve
Fragrance could make soln hazy
8
An Example

• Poor Processing of an LDL
• Water, Cold
• Alkanolamide
• Alkyl Ether Sulfate
• DDBSA
• NaOH 50
• Dye, Powder
• Fragrance

• Correct Processing of an LDL
• Water, Cold
• NaOH 50
• DDBSA
• Alkanolamide
• Alkyl Ether Sulfate
• Dye, Solution
• Fragrance, Predispersed

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Emulsion and Dispersion LiquidsThings to Think
About

• Emulsions
• Order of Addition
• Oil Phase
• Water Phase
• Equipment Compatibility
• Mixing Time
• Shear
• Mixing Temperature
• Rheology During Filling Process
• Weeping / Syneresis

• Dispersions
• Order of Addition
• Equipment Compatibility
• Solids can polish equipment
• Mixing Time
• Shear
• Mixing Temperature
• Rheology During Filling Process

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Solids

• Bulk Solids
• Soap Bars
• Toilet Blocks
• Dryer Sheets
• Melt Points
• Softening Points
• Color Change
• Uniformity
• Weeping / Syneresis
• Cracking / Crumbling
• Dissolution Rates
• Rheology through Dissolution
• Water absorption

• Powders
• Laundry Detergents
• Hard Surface Cleaners
• AutoDish Detergent
• Particle Size Range
• Particle Density Range
• Compaction
• High Temp Stability
• Flow
• Melt Point
• Water Absorption
• Rheology through Dissolution
• Particle Friability

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Powder Manufacturing

• Dry Blending
• Simple mixing of dry ingredients
• Minimal amount of liquid ingredients can be used
• Spray Drying
• Drying of a high solids slurry
• Temperature sensitive ingredients need to added
  post process
• Agglomeration
• Dry and some liquid ingredients are mixed and
  then glued together

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Dry Blending
Powdered raw materials are blended together,
often with low levels of liquid surfactants
and/or solvents, until uniform.
V-Blender
Ribbon Blender
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Dry BlendedDetergents And Cleaners

• II and Consumer Laundry Detergents
• II and Consumer Auto Dishwash
• Powdered Carwash
• Metal Cleaners
• Hard Surface Cleaners

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Dry Blending

• Advantages
• Batch runs
• Ideal for varied product line
• Easy to operate and maintain
• Low capital costs and energy requirements

• Disadvantages
• High raw material costs
• Product segregation is common
• Bulk density is dependent on raw materials
• Low liquid surfactant capacity

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Spray Drying Process

• Powdered and liquid raw materials blended with
  water to make a slurry.
• The slurry is sprayed under high pressure
  (atomization).
• Small beads are formed under high temperature
  conditions.

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Spray Tower
Most common Spray Dried Products are Laundry
Detergents
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Spray Drying

• Advantages
• Very high thru-put capacity
• Continuous process, high reproducibility and
  efficiency
• Low raw material costs
• High surfactant loading possible
• Extremely uniform products/no segregation

• Disadvantages
• High capital costs and energy requirements
• Change over very expensive
• Formulation limitations due to high temperatures
• Low density product

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Agglomeration Process

• Powdered raw materials are mixed often with
  liquid surfactants and water.
• The mix is then sprayed with liquid sodium
  silicate, which binds the ingredients to form
  granules.

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Agglomeration

• Consumer Automatic Dishwash
• Consumer Laundry ("Ultra" type)

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Rotary DrumAgglomerator
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Agglomeration

• Advantages
• Moderate to high thru-put capacity
• Batch or continuous process
• Medium to high density products
• Use various particle size raw materials
• Low powder segregation

• Disadvantages
• More attrition (particle break-up) than spray
  drying
• More expensive raw materials than spray drying
• Liquid, surfactant loading capacity lower than
  spray drying
• Higher capital/operating costs(compared to dry
  blending)

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Detergent Powders

• Agglomerated Dry Blended Spray
  Dried

Photomicrographs (50x)
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Powder Manufacturing ProcessDensity/Sizing
Capability
1.2
1.0
0.8
Agglomeration
Density, g/cc
0.6
0.4
0.2
0.0
0
500
1000
1500
2000
2500
3000
Practical Size, Microns
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Wipes

• Low to moderate foam desired to control streaking
• Mild ingredients preferred
• Need to evaluate Substrate-Cleaner Compatibility
• e.g. Biocidal active release from substrate
• Chromatography of cleaner ingredients
• Watch for Mold Issues
• High humidity environment with lots of surface
  area

Not just a Liquid Product on a Substrate
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Aerosol

• Compatibility of Cleaning Solution and Propellant
• Can Compatibility with Formulation
• Lined or Unlined
• Type of Lining
• Anti-Corrosion Aids
• Vapor Phase
• Liquid phase
• Nozzle Compatibility
• Clogging
• Can Seal Integrity
• Puncture Leak Testing

Not just a Liquid Product in a Can
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Product Form Matters!