MXPA99010529A - Process and apparatus for the production of a detergent composition - Google Patents

Abstract

A process for forming detergent bars by injection moulding in which a pressure is applied to a partially structured detergent composition to deliver it to a mould. The detergent composition can be delivered to the mould in a substantially semi-solid state, at a temperature below 70°C and at a pressure at the point of injection of greater than 20 psi. Apparatus for forming detergent bars according the invention are also described.

Description

PROCESS AND APPARATUS FOR THE PRODUCTION OF A COMPOSITION OF DETERGENT TECHNICAL FIELD The present invention relates to a process and apparatus for forming bar detergent and bar detergents formed therein. In the detergents in bar they can be of the type for personal washing or of factory.

BACKGROUND AND PREVIOUS TECHNIQUE Bar detergents are manufactured with eneime on by one of two methods: (i) ground followed by extrusion ("work in pauses" ") and stamping (sometimes referred to as the" ground "process), or (ii) casting.) In the milling process, a preformed solid composition comprising all The components of the bar are usually treated in steps, that is, they extend through a nozzle to form a continuous "rod" that is cut into small pieces of predetermined length, commonly referred to as "ingots." "ingots" are then fed to a stamping machine, or alternatively, they are printed on surfaces, for example, using a die of the same dimensions as the surface of the bar which is struck with force such as with a hammer or It can be given in the form of a roller or simply cut in. - There are many disadvantages associated with the bar-making detergent milling method.A problem encountered in the stamping process is die blocking, in which the quantity The residual detergent left in the die halves accumulates during continuous use of the dice. The blockage of the dice can lead to a poor release "or that there is no release of the bars from the surface of the die and / or visible imperfections on the surface of the bar.Extrusion and stamping also require that the extruded ingot has a "Substantially" rigid form to process conditions Blocking die and "soft" ingots can be caused by soft detergent compositions, for example, compositions containing a large proportion of ingredients that are liquid at the processing conditions and / or they can be the result of forces of shear and extension to which the detergent composition is subjected by the grinding process, for example, extrusion and / or stamping.Therefore, grinding is only suitable for the formulations that They are made of plastic and are not soft or do not become soft or sticky due to the degradation of shear at operating temperatures. of the manufacturing equipment, normally in the ambient range of ± 30 ° C. The grinding bars also tend to have an oriented structure, aligned along the extrusion axis. They also tend to form separation planes within the bar, which weaken the bar and, with repeated wetting and drying of the bar in use, can lead to cracking with moisture along the planes. Wet cracking is highly undesirable having an unpleasant appearance and leading to fracture of the bar. The other conventional method for the manufacture of the detergents in "bar is the casting.In the casting, the detergent compositions in a state that is mobile with heat and easily pourable" are introduced into the upper part of a closed cavity (it is say, a mold) of the desired configuration - and the temperature of the composition is reduced until it solidifies. The bar can then be removed by opening the mold. In order to be able to strain, the detergent formation must be mobile and easily pourable at high temperatures employed. Certain formulations of detergent are viscous or semi-liquid liquids at really high temperatures commercially and therefore not. lead to casting. In addition, in the casting process, the detergent portion tends to expand slowly and unevenly. This can lead to orientations - and segregation of unwanted structural ingredients. Frequently "some kind of active cooling system is employed in order to achieve acceptable processing times." Although a "cooling system" is employed, cooling is still generally not uniform through the detergent composition in the mold. A major problem with the casting process is that the detergent compositions in the molds tend to shrink as they cool. This is highly undesirable since the mold is intended to impart a different shape on the bar and / or a logo of some kind.The shrinkage may take the form of crevices, wrinkles or voids, or a depression at the filling point. Therefore, there is a need for a process "and" apparatus to form detergent compositions in bars of good quality (ie, bars, for example, good appearance and physical characteristics), which overcomes the problems idents and the disadvantages associated with the grinding process and that also avoids the problems associated with "the side." U.S. Patent No. 2987484 (Procter &; Gamble) describes a closed-die casting process in which a mixture of synthetic detergent-free soap fluid and a binder vehicle is rapidly injected through a small orifice in a substantially closed die, the fluid mixture is capable of solidifying in a way that maintains the configuration. The process involves heating the composition to a temperature in the range of 70 ° C to 150 ° C, so that the molten composition is in the injectable state with fluid. In all the examples, the temperature is in the range of 82-150 ° C. The melt is circulated through a continuous injection circuit comprising a crusher in which the fluid mixture is mixed and heated, a pipe in the form of loops with the crusher, an interchange of heat in the pipeline. to establish the melting temperature and a pump to maintain the injection circulation pressure. The viscosity of the hot melt at the injection conditions is 2-50 Pa.s. It is described that it depends on the intensity of the shear and the temperature and a function of the composition, however, no effort regimes are given. In a melt that has a viscosity in the range of 2-50 Pa.s, the injection conditions are described as being thick enough so that it does not spread in the mold, traps air or "comes out through the mold air vents while it is thin enough 'to allow complete filling of the mold before solidifying any composition therein and to avoid excessive injection pressures. The appropriate injection pressures vary from about -6.89-137.8 kPa (1-20 psi) approximately, but are preferably in the range of "13.8-68.9 kPa (2-10 psi). injection is between 34.4-35.12 kPa (5-8 psi) .The pressures * which are very high are described as causing dispersion in the mold and therefore increase the density of the melt. * United States Patent 2987 ~ 484 also teaches, and is an essential aspect of the claims, that for the working process, the fluid mixture must be cooled through an energetic phase (isotropic liquid) plus crystals. fluid of detergents in the pure or medium phases (anisotropic liquid) are not suitable for molding in closed cubes, due to the excessive viscosity of these phases and the tendency to form undesirable complexes in these phases. United States 2987 484 states that successful closed die casting needs to avoid cooling through the pure and medium phases (column 4, lines 8 to 27). U.S. Patent No. 2989484 is described as overcoming the problems associated with conventional methods of barmaking and in particular those associated with grinding. However, the described solution has several inherent convenient features, most of which are common for the casting processes and formation of closed structures. It is very energy intensive, the "energy is required to heat the compositions" detergents at high temperatures to which the fluid mixture is injected and subsequently cooling the molds in order to reduce solidification times to levels In addition, by injecting the compositions as fluids at high temperatures, the process leads to problems with the collection of the bars as they solidify.This also does not address the problem of segregation of ingredients since the detergent composition is cooled in The mold The detergent composition in the apparatus is perviously subjected to shear stress being pumped through pipes or through a mixer into the crusher.The conventional processes of the manufacture of bar detergent operate either by structuring the detergent composition completely. with the mold, requiring an input of high initial heat energy (for example, casting), or the structure The detergent composition is completely out of the mold / bar configuration means resulting in the processing of a rigid solid material prior to molding (eg, extrusion and stamping). The last type of the process subjects the structured material to high shear energy (for example, in stamping). In an attempt to overcome the drawbacks of such processes, and in particular those of milling processes and structure formation, the process described in U.S. Patent 2987484 does not deviate from this general pattern, it is a high introduction. Energy in terms of the relatively high temperatures used From this perspective, US Patent 2987484 provides only an alternative casting process in which the detergent material is injected instead of being poured into a mold. The inventors of the present have found that the problems present in the methods of the prior art can be overcome by operating a processing window by which the structure partially develops outside and partially inside the mold. In this way, any alteration shear stress effect in the process only acts on a partially developed structure and sufficient structure can be formed in the mold to produce good quality bars. In this way, the structuring of the detergent composition is damaged to a much lesser degree during the formation of bars and higher injection pressures can be tolerated, without altering the partial structure.

BRIEF DESCRIPTION OF THE INVENTION Partially structuring a detergent composition before supplying it to a mold in an injection molding process, bars of good quality can be obtained and the problems of shrinkage, oriented structure and segregation of ingredients are significantly reduced. In addition, production benefits such as "shorter bar release times can also be achieved." Therefore, according to a first aspect, the first invention provides a process for forming detergent into bars comprising applying pressure to a detergent composition. for supplying the detergent composition to a characterized mold, wherein the detergent composition is at least partly structured when it enters the mold Preferably, the continuous phase of the detergent composition is such that it is at least partially structured. , the detergent compositions are considered as being less partially structured if they contain molecular structure which will affect the viscosity properties of the detergent composition.Additionally or alternatively, the detergent compositions can be considered to be at least partially structured if they contain a structuring agent. which increases the viscosity of the detergent composition. Preferably, the detergent composition is in a semi-solid state when it is supplied to the detergent. In a second aspect, the present invention provides a process for forming detergent into sticks comprising the application of pressure to a detergent composition for delivery. - the detergent composition to a mold, characterized in that the pressure at the point at which the detergent composition enters the mold is greater than 137.8 kPa (20 psi) during at least part of the time in which the detergent composition enters the mold. To the mold In a third aspect, the present invention provides a process for forming bar detergent which comprises applying pressure to the detergent composition for delivering a detergent composition to a mold characterized in that the detergent composition is at a temperature below 70 ° C. When it enters the mold, the detergent composition is supplied to the mold at a lower temperature than that described in the prior art. The process is less energy intensive and the bars are cooled to a temperature at which they are strong enough to exit the mold more quickly. The inventors of the present invention have designed apparatus for forming bar detergent by injection molding. More particularly, the inventors of the present have provided a means for feeding the detergent composition to the medium for applying pressure. Therefore, the present invention provides an apparatus for cleaning detergent into sticks comprising a means for applying pressure to a detergent composition for the purpose of supplying the detergent composition to a mold and a substantially separate medium adapted for feeding. "the detergent composition to the means to apply pressure. The detergent composition can be introduced into the means for feeding in any suitable state, so that, for example, it is in the form of fluid, semi-solid or particulate. We have found that a particularly effective means of feeding detergent compositions, including compositions supplied in a fluid state, in an "injection molding process" is provided by means of screw extruders. preferably comprise a feeder in the form of a screw In another aspect, the present invention provides detergent in bars obtainable by the process of the present invention We have found that the process of the invention is suitable for incorporating additive or additive agents. beneficial agents that are immiscible with the detergent composition Accordingly, the present invention provides detergent in sticks that can be obtained by the process of the present invention comprising a detergent composition and immiscible components with the detergent composition., where the immiscible component is present in non-spherical domains. In a further aspect, the present invention provides a method for incorporating an additive or benefit agent into a bar detergent, comprising the addition of additive or benefit agent to a detergent composition which is at least partially structured and which applies a pressure to the detergent composition containing the additive or benefit agent so as to supply it to a mold. In a preferred embodiment, the additive or beneficial agent is immiscible with the detergent composition. Unless more generally specified, references herein to the invention or to any preferred aspect apply to all aspects of the invention.

DETAILED DESCRIPTION OF THE INVENTION "Bar detergent" is understood to mean a tablet, cake or bar which at the level of agent "of active surface, which comprises soap, active of synthetic detergent or a mixture thereof, at least is 5% by weight based on the bar The bar detergent may also comprise beneficial agents for imparting or maintaining skin-friendly properties For example, wetting agents may be included The detergent compositions may comprise homogeneous components or mixtures of components, or may comprise suspended or dispersed material in a continuous phase - The detergent compositions that will be delivered to the mold may have any shape capable of being supplied to the mold For example, the composition may be in a substantially fluid form (eg, molten , molten dispersion, liquid), substantially semi-solid or substantially in solid form, while the position is plastic enough to allow the pressure application means to supply it to a mold as will be understood by a person skilled in the art.

Construction The detergent composition should be compared to a detergent composition that is at the same temperature as the detergent composition under consideration and substantially has the same composition, except that it does not have a structure and / or structuring agent present, while it can assure viscosity increases or does not increase. The structure can be provided, for example, by the formation of liquid crystals, an agent for forming polymeric structures or clay, or a sufficient volume of a dispersed solid component that will affect the viscosity. A solid component can provide a structure whereby to form a network wn the detergent composition or through the physical / physical interaction of the solid particles weach other or wthe continuous phase. Wrespect to the detergent compositions and in particular the detergent compositions in a substantially fluid or liquid state, there are two general and separate classes of compositions, those wstructurally isotropic phases and those wstructurally anhydrous phases. Those phase states that are structurally isotropic are liquid phases, cubic liquid crystals and cubic crystal phases. The other phases are structurally an i s or t r o p a s. Structured liquids can be "internally structured" whereby the structure is formed by the primary ingredients, preferably by the surfactant material (ie, anisotropic phases or having liquid crystals) and / or "externally structured" so that provides a three-dimensional matrix structure using secondary additives, for example, polymers (eg, carbopols), clay, silica, and / or silicate material (including lumino si l in situ formed). Such secondary additives may be present at a level of 1-10% by weight of the detergent composition. The existence of internal structure in the detergent composition may be due to the components used, their concentration, the temperature of the composition and the shear stress to which the composition is exposed or exposed.

In general, the degree of ordering of the systems containing a surfactant increases wthe increase of the concentrations of surfactant and / or electrolytes. At very low concentrations of surfactant and / or electrolytes, the surfactant may exist as a molecular solution or as a solution of spherical micelles, both solutions being isotropic, that is, not being structured. Wthe addition of the surfactant and / or additional electrolytes structures of surfactant material can be formed. Various forms of such structures exist, for example, bilayers. They are referred to by various terms such as micelles in bars, anisotropic surfactant phase, "flat lamellar structures, lamellar droplets, and liquid crystalline phases (most of which are anisotropic, but can be isotropic). Several examples of fluid compositions that are internally structured of surfactant material are given in HA Barnes, "Detergents", Ch.2 in K. alters (Ed), "Rheometry: Industrial Applications", J. Wiley &; Sons, Letchworth 1980. Workers often use different terminologies to designate structures that are really the same, for example, the lamellar drops are called spherolites in EP-A-0151884. The presence of structuring, ordering or anisotropy The internal structure can usually be revealed by the profile of the material / viscosity / shear stress of the composition in a manner known to the person skilled in the art.Often, the presence of the molecular structure gives rise to to a non-Newtonian fluid behavior The presence and identity of a system for forming surfactant structures in a detergent composition can be determined by means known to those skilled in the art, for example, optical techniques, various rheometric measurements, X-ray or neutron diffraction and sometimes electron microscopy As is known to those skilled in the art, the structure of Molecular scaffolding can be detected by the use of polarized light microscopy. The f is ~ is isotropic has no effect on polarized light, but the structural phases will have an effect on the polarized light and can be bi-cooling. An isotropic liquid might not be expected to show any kind of periodicity in X-ray diffraction microphages or neutrons, whereas the molecular structure may originate periodicity of first, second or even third order in a way in which it will be known to the expert. Preferably, the detergent composition is in a semi-solid state when supplied to the mold. It can be considered that a detergent composition is in a semi-solid state if it is present in a sufficient structure in the composition so that it no longer behaves as a simple liquid, as would be understood by the person skilled in the art. Contrary to the prior art, we have found that it is possible to obtain detergent in sticks having good physical properties by cooling a detergent composition of, or through a pure and / or medium liquid crystal phase. In addition, we have found that it is not essential for the detergent composition to be cooled through a portion of black liquids and crystals phase in order to achieve successful rod formation by an injection molding process.

Accordingly, the detergent composition entering the mold is preferably cooled from and / or through a phase of liquid crystals. The process and apparatus of the present invention therefore provide a means to produce good quality bar detergent from detergent formulations which do not by themselves lead to the methods of grinding and pouring, manufacturing, eg, formulations, in particular , foundations for personal washing, which have a high concentration of ingredients in a liquid state at ambient conditions, formulations "having a solid structure sensitive to shear and formulations that are very viscous to be cast." One of the benefits provided by the present invention is a reduction in the problems associated with the shrinkage of the bar with the mold as the bar cools, this results in greater accuracy in the replication of the surface contours and the shape of the cavity. the reproduction of the good logo can be obtained.

In order to overcome the problems associated with a prior art process, the detergent compositions in the present invention are usually more viscous than prior art compositions. Consequently, the pressure required to supply a detergent composition to a mold is greater.

Pressure The pressure applied to the detergent composition in contact with the pressure application means is referred to herein as the "applied pressure" and is referred to as "applying" and "applying" pressure to a detergent composition that refers to the applied pressure. Since the detergent composition can be relatively viscous, the pressure experienced by the composition can be added significantly more than the flow path. * "Injection pressure" is the pressure on the composition of the detergent at the entry point of the product. The inventors have discovered that higher pressures than those of the prior art can be used to deliver a detergent composition to a mold without compromising. the final molecular structure of the bar detergent. As in the second aspect of the invention, the use of injection pressures in excess of 137.8 kPa (20 psi) may allow relatively viscous compositions to be fed into a mold. The applied pressures may be in the order of 68.9-344.5 kPa (10-50 psi). However, the higher pressures applied, for example, up to 6890 kPa (1000 psi) can be used to supply relatively viscous detergent compositions to the mold (eg, semi-solids) the applied pressure will normally not exceed 5167.5 kPa (750 psi) and more normally it will not exceed 3446 kPa (500 psi). Excessive shear stress can be avoided at such pressures by controlling process parameters such as temperature, flow rate and apparatus design. The injection pressure is usually greater than 137.8 kPa (20 psi), preferably greater than 202.56 kPa (29.4 psi) and even more preferably greater than 344.5 kPa (50 psi). Because the detergent compositions which are being injection molded are at least partially structured and / or at relatively low temperatures, the injection pressures significantly higher than those reported in US Pat. No. 2,987,784 can be employed. For example, the detergent composition can have a substantially semi-solid form. Injection pressures greater than 1378 kPa (200 psi), greater than 2756 kPa (400) and even higher at 4823 kPa (700 psi), can be used. We have found that the problems associated with the shrinkage of the bars in the mold can be reduced, if there is a need to do so, by providing additional detergent composition to the mold, as the mold volume cools or becomes solid. To achieve this, a "maintenance pressure" is placed on the detergent composition in the mold. - In this way, the total volume in the mold can be maintained and can further improve the reproduction of the configuration. In addition, the use of a "maintenance pressure" minimizes the weld lines (ie the interfaces between the front sides of the flow of detergent material within the mold) and improves the definition of the logo.

Therefore, it is possible to obtain detergent in bars with reduced shrinkage and having good physical properties by applying a pressure to a detergent composition to supply the detergent composition to a mold and continuing to apply the pressure on the detergent composition for a time after it is applied. has filled the mold. The pressure created in the mold by continuing to apply pressure to a detergent composition that enters a mold after the mold has been filled is referred to herein as * "holding pressure". The detergent compositions can be subjected to a high maintenance pressure, inside the mold. For example, such "pressures can be up to 6890 kPa (1000 psi)." All pressure figures are calibres in kPa (psig), that is, the level above or below atmospheric pressure. "Maintenance pressure" is developed by the continuous application of pressure to a detergent composition after the mold has been filled is referred to herein as the "holding time." The holding time varies depending on the properties of the detergent composition. For example, compositions that are being supplied in a molten state and at high temperatures may require a longer holding time than compositions that deliver to a mold in a semi-solid state and / or at a lower temperature. Typically, the holding time is less than 2 minutes, preferably less than 1 minute, more preferably less than 30 seconds, and more preferably less than 10 seconds. The maintenance time can be very short, for example less than 1 second. mpe ur The inventors have discovered that detergent compositions at lower temperatures than those normally employed by the prior art can supply lower pressure to a mold without compromising the final molecular structure of the stick detergent. When the presence of structure in a detergent composition that will be delivered to the mold can be clearly identified, it may be acceptable for the detergent composition to be at a temperature of 100 ° C or more as it enters the mold, however, as in the third aspect of In the invention, a detergent composition can be supplied to a mold under pressure to a mold at a temperature below 70 ° C when the mold enters. Excessive shear can be avoided at such temperatures by controlling the process parameters such as flow rate and apparatus design. Detergent compositions usually do not have a single melting point, but instead pass in a solid form, to a semi-solid form and then to a fluid (or melt) as the temperature increases. Any practical detergent composition in the form of stick will be in a substantially solid state at storage temperature and / or ambient or normal use, which are usually in the range of up to 30-40 ° C. Accordingly, the detergent composition preferably enters the mold at a temperature above the ambient, for example, preferably above 30 ° C, more preferably above 40 ° C.

Of course, the lower the temperature, the lower the energy required to heat the composition of the room temperature, the faster the bars cool down and the lower the shrinkage tendency of the bars. It is a particular advantage of the present invention that the detergent composition can enter the mold at a lower temperature than in a simple casting technique. When the solid detergent compositions are heated, less heat (i.e., energy) may be required as the operating temperatures may be lower. When the liquid detergent cools, no heating will be required at all. The present invention therefore offers economy in operation. Usually, "The detergent composition can be at a temperature of 60 ° C or lower. The present invention is particularly suitable for detergent compositions that are subjected to s up and down, ie the thermal energy can be removed out of the mold without the formation of the final bar structure. Injection Molding Apparatus Injection molding is a process that is particularly used today in the molding of synthetic polymeric thermoplastic articles, particularly thermoplastic articles having thin cross sections and complex shapes. In essence, an injection molding apparatus for a plastic material comprises a substantially closed mold and a means for supplying a plastic material under high pressure in the substantially closed mold. Preferably, there are means for raising the temperature of the plastic material to a temperature where the material can flow under pressure. The process of the present invention can be carried out using such known injection molding apparatus, with or without any means of heating the feed. Preferred modifications according to the present invention are described below. The detergent compositions of the present invention can be injection molded or are an apparatus comprising a means for applying pressure to the detergent composition so as to drive the detergent composition into a mold. A "means for applying pressure" is defined as a device capable of containing a material and of applying pressure to such material in a manner that forces it into a mold. Suitable types of selfconducting apparatuses for driving the detergent composition into a mold include displacement pump type arrangements such as, for example, piston pump (which may include extruder e "s), gear pump and lobe pump. A suitable apparatus is a simple plunger extruder in contact with a mold. Such an apparatus typically comprises a reservoir or barrel for the detergent composition, a piston for applying pressure to the material in the reservoir and an outlet port in which the detergent composition is driven, directly and indirectly in a mold. The single plunger extruder apparatus is particularly suitable for the injection mold of the detergent composition, for example a semi-solid form. The injection molding apparatus as described above can be used for the process of the invention.

In a preferred embodiment, the detergent composition is preferably structured at least partially when supplied to the mold. Preferably, the detergent composition is in the semi-solid form when it is supplied to the mold. Of course, the present invention also provides detergent compositions for injection molding in a substantially fluid form. Some detergent compositions may be made permanently sticky if they are molded by injection under the wrong conditions. That is, some solid detergent compositions have a complex molecular structure that can be altered if the solid is exposed to excessive shear stress. The molecular structure may not be restored after such shear stress so that the detergent composition will remain in an unusable sticky state. Consequently, it is convenient to ensure that such detergent compositions are not exposed to excessive shear stress during the supply of mole.

In order to control the shear stress in which the detergent composition is subjected, the nature of the detergent composition by itself needs to be taken into account, in particular its viscosity and molecular structure at various temperatures. To control the shear stress, one can control the process parameters such as temperature, pressure applied to the composition, flow rate of the detergent composition in the apparatus and the configuration of the apparatus. Configurations such as flexions, constrictions and rapid movement of severe parts can subject the detergent composition to shear stress. It has been found that by supplying the detergent composition * at a temperature appropriate to the mold, the structure sensitive to shear structure may not be completely formed and the structure of the composition according to room temperature is not lost. Any suitable method can be used to control the temperature of the detergent composition that is injected into the mold. A suitable temperature can be supplied to supply the mold and does not require alteration to its temperature. Alternatively and preferably, the temperature of the detergent composition is altered before or while it is fed into the mold using heating or cooling means to raise or lower the temperature of the composition as appropriate. Preferably, the state of the detergent composition is altered before or while feeding. For example, it can pass from a liquid phase to a semi-solid state. Alternatively, it can pass from a solid state to a "semi-solid state." Any suitable cooling or heating means can be applied to the injection molding apparatus, in which the detergent composition is contained / passed during the "injection molding process". Suitable heating and cooling means are well known to the person skilled in the art. For example, a suitable cooling medium in a cooling jacket containing a cooling medium, and suitable heating means include, for example, electric heating jackets, which contain a heating medium or heat exchangers of various types. shapes.

A high temperature can be maintained near the point at which the detergent composition is fed into the mold, so as to avoid blocking. to solidification. A plurality of controllable heating means or cooling means can be avoided at different positions in the apparatus. A stepped temperature profile can then be provided in the flow direction of the detergent composition. For example, the temperature may be increased or decreased in the stages. Detergent compositions often enter the form of solid particles (eg pellets) which are then extruded and stamped in a mill process, or melted and cast in a casting process. The known injection molding apparatus used in the plastics industry typically uses plastic particulate starting material that flows easily from a hopper. In contrast, the detergent compositions in the form of particles can be tacky and flows relatively little. Therefore, special means may be required in order to ensure good feeding of the detergent composition to the apparatus.

The inventors have also observed that some detergent compositions are produced and supplied in a high temperature molten state. The means therefore for feeding the liquid detergent composition to the means for applying pressure to the detergent composition are going to be required. Accordingly, the present invention provides an apparatus for forming bar detergent comprising means for applying pressure to a detergent composition for the purpose of supplying the detergent composition to a mold and a substantially separate medium adapted to feed the detergent composition to the means for Apply pressure to the detergent composition. The feed means are substantially separated in that no part of the feed means has an important role in applying pressure to the detergent composition. Of course, the feeding means suitably are in fluid relation with the means for applying pressure to the detergent composition, whereby the detergent composition can be easily fed into the means for applying pressure.

Examples of suitable feeding means include a conveyor, a container with a tapered lower section, a stirrer, a plunger feeder, a screw feeder or any number thereof in any combination. In a preferred embodiment, the detergent composition is supplied to the feed means in a substantially solid (eg, particulate) or semi-solid form. The "particulate form" forms pellets, flakes, nodules, granules, and "pieces" stick as is well known in the art.When a detergent composition is supplied in a substantially solid form, a heating medium may be required to heat the material. in the apparatus (e.g., in the reservoir in the case of a plunger extruder apparatus) so that it becomes and / or remains flowable under pressure.If the detergent composition is provided in a substantially fluid form, then it can be employed A cooling zone in place of, or in addition to, a heating zone If the molten feed is supplied at a temperature above 70 ° C, it is preferably cooled before being supplied to the mold.Of course, it is understood that the detergent compositions can be introduced into the mold at a temperature greater than 100 ° C. In addition, a heating apparatus can be used to maintain such a high temperature. It is a preferred aspect of the feeding means "which is capable of supplying a continuous feed of the detergent feed." Means for feeding the detergent material may feed the composition to the means for applying pressure or to an area preceding the media. for applying pressure such as a heating or cooling zone In a preferred embodiment, the means for feeding the detergent material feeds the composition into an accumulation zone that provides an interface between the continuous operation of the feeder and the discontinuous injection cycle " of the medium of application of pressure. The means for controlling the temperature of the detergent composition can be provided at any position in the injection molding apparatus. For example, such heating or cooling means may be provided in the means for applying pressure, in the feed means "or in a" separate zone, or in any combination therein. In a separate heating zone to be positioned as, for example, between the means for feeding detergent material and means for applying pressure. The present invention provides the use of extruders of. screw as part of the "injection molding apparatus, either as the feed means," pressure application means or both. In a reciprocal injection moulder, the means to apply pressure to the prepared material (for example, heat-thermal) is provided by the screw itself. normally, the screw is movable along its axis away from the mold. As the flowable material is distributed in the accumulation zone at the end of the screw barrel, the pressure generated in it allows the screw to be pushed backwards in order to apply the pressure to the accumulated molten material (the shot "), the screw is forced (usu- ally using hydraulic pressure) forward in the direction of the accumulation zone, thereby placing pressure on the material therein, which moves through a nozzle in the mold. A specially designed screw tip valve prevents the material from flowing backwards into the screw fins. The means for applying pressure to the detergent composition can compress the tip of a screw extruder, as described above for the known injection molding apparatus. Alternatively, the separate means for supplying detergent under pressure can be used as shown below. Preferably, the means for feeding the detergent composition comprises a feeder in the form of a screw feeder. It is found that it gives a particularly uniform feed. The geometry of the screw can be designed to adapt to the formulation that is being processed. The rotational speed of the screw or screws is controlled to provide an acceptable flow rate of the material to the accumulation zone or means for applying pressure, without applying unacceptable shear stress to the detergent. There are particular problems with the detergent compositions with the fluid. The unique screw extruders are based on the transport flow for transport and therefore transport fluids that need to be specifically designed with a closed and / or inclined free space so that gravity helps the fJL ow forward of the material. Accordingly, it is preferred that it has two parallel finned screws forming "an internal mesh, preferably of true impurity, the positively advancing lines for propelling forward the detergent composition.

The screws can rotate in opposite directions (counter rotation), but preferably co-rotate to reduce the reverse pressure flow. Such double-screw extruders with fins forming internal meshes for supplying liquids or solids are known to those skilled in the art. It may be preferable that a displaceable screw is not used to apply pressure to the detergent composition in order to supply the mold. In its location, a pressure chamber can be provided in "where the material can accumulate, comprising at least one wall defined by a piston that can be moved to increase or decrease the volume of the pressure chamber, and In a preferred embodiment, the screw extruder, in addition to feeding the mold material by injection into the means for applying pressure, also performs the function of pr econdi onate, material to a desired physical state for injection, providing e-1 screw extruder with one or more heating and / or cooling zones and by selecting, for example, appropriate screws, screw alignment and screw speed, the feed material in the The extruder can be intimately mixed and structured to any length that is required for the injection molding process, in particular being used and looking for the characteristics of the product. example, a preferred embodiment of the present invention is that a material is injected in a substantially semi-solid state. In addition, the feeding means, preferably a screw extruder, may contain intermediate ports for degassing and / or for adding additional ingredients. Additives, such as, for example, dyes and fragrances and other beneficial agents can also be added through tl or s intermediate ports along the entire length of the screw feed. Using a screw feed with a temperature profile, it is possible to add ingredients and / or additives, and / or beneficial agents to the volume flow of material in the feeder at a specific temperature. In addition, the material in the screw feed can be mixed and / or structured to a greater or lesser degree as it moves into the screw feed depending on the equipment and process parameters employed. It is therefore possible to add ingredients and / or additives and / or beneficial agents to the volume flow of the material when it is at a chosen level of "viscosity and / or mixing and / or structuring." In addition, it is also possible that soap formation (eg, saponification) or detergent surfactant formation if soap (eg, neutralization of anionic surfactant acid precursors) within the screw extruder, more particularly the first part of the screw extruder. gas (eg, air) can be added to the detergent composition to be injection molded in order to produce, for example, reduced density or flotation bars Preferably, the gas will be added at the stage of the screw extruder ib.

Injection nozzle The means for applying pressure to the detergent composition can be connected to the mold by a simple passage, or a passage having non-return means or connections for bypass ducts, in order to allow the rapid extraction of the pressurization means. after the mold is filled and for the uniform operation of the apparatus. In a preferred embodiment, however, the detergent composition is fed through a nozzle whose length is at a significant proportion (at least half, preferably at least three quarters) of the length of the internal volume of the mold. It has been found that there may be problems in simple filling with jetting or "snaking" of the material into the mold. Providing a nozzle that extends substantially to the far end of the mold, it has been found that a good filling is possible. Preferably, the nozzle and the mold move in relation to one another, while the detergent composition is supplied. The mold can be moved relative to the means for applying pressure and / or the nozzle can be moved relative to the mold while the detergent composition is being supplied. The rate at which the nozzle and the mold move in relation to one another preferably is equal to the rate of the detergent supply, so that the nozzle remains just below the surface of the detergent composition in the mold. It has been found that a good filling is particularly given. In a preferred embodiment, the nozzle moves with respect to the mold. The nozzle can be heated or pre-heated, for example in order to avoid any solidification of the detergent composition (deposit) in the nozzle, and thus inhibit the uniform supply of the composition to the mole. diameter of the injection nozzle for use with the means for supplying the detergent composition, under pressure is small Preferably, the diameter is in the range of 1 to 20 mm, preferably 5 to 10 mm, more preferably approximately mm in diameter and it has a circular section.

Mold The mold of the present invention can be constructed of any suitable material, for example, rigid material with good mechanical strength. Where rapid cooling is desired, a material with high thermal conductivity may be preferred. Preferably, a mold can comprise a material selected from metals and their alloys (for example, aluminum, brass and other copper alloys, steel including carbon and stainless steel), compressed forms of metals or mixed metal materials, non-metallic materials. such as ceramics, "mixed materials and plastics made of porous, or spongy, forms. The "molds may comprise rigid and non-rigid materials, for example, non-rigid plastics may be used.The mold may be part of the entire package of the detergent product in stick.In this aspect, the package may be of a rigid nature or may be be non-rigid, for example, a plastic wrap. " For example, the inner liner of a rigid mold may comprise a "wrapping plastic" for the product of the stick detergent, so that the wrapped rod is released from the mold. The mold may also comprise an expandable liner within a cavity defined by the mold, the liner expanding to fill the cavity as the detergent composition is delivered to the mold. Such liners and casings can be released with the bar being integral parts of the packaging product or they can be removed once the bars are released, for example, they can only be used to facilitate the release of the bars from the mold. The mold can be precooled or preheated to the supply of the detergent composition to the mold. The internal surface of the mold can be pre-heated at a temperature, for example, in excess of the delivery temperature and / or the melting temperature of the composition. Such pre-heating of the mold has been found to provide a more uniform, glossier finish to the bars. After supplying the detergent, the mold can be cooled to produce a rapid solidification of the detergent. Any suitable chiller can be used, for example, air, water, ice, solid carbon dioxide or combinations thereof, depending on the cooling rate and the final temperature set. Preferably, at least part of the outer face of the mold is provided with a means for improving the cooling efficiency of the mold after injection. In the preferred embodiments of the invention, such means comprise fins or ribs for air cooling or sleeves for circulation of the cooled liquid. The mold suitably comprises at least two rigid complementary dies adapted to be adjusted with one another and supporting the injection pressure and maintenance, each die corresponding to a respective portion of the desired shape of the molded article, the dies when they are in coupling together with the contact portion of its edges defining a cavity corresponding to the total shape of the molded article. The use of multi-part molds comprising at least two parts of dies allows the manufacture of highly diversified three-dimensional shapes; For example, circular, oval, square, rectangular, concave or any other shape that you want. In a mold comprising at least two die parts, at least one of the dice may be provided with a sealing means along the contact portion of the edge thereof. More preferably, the sealing means comprise an elastomeric gasket. The mold is provided with an internal surface, the side and shape of which may vary depending on the "final product form." The internal surface of the mold may be partially or completely coated with a material having good release characteristics, such as low surface energy or other properties as described for example in WO97 / 20028.Examples of such materials include luoroplastic materials and f 1 or r or 1 i, silicones and other elastomers. The thickness of the coating is preferably less than 1 mm, more preferably less than 50 microns.The internal surface of the mold may be flat, concave or convex or in any other way as desired.The shape may be such that it adapts the shrinkage. of the bar without removing its final bar appearance, for example, very convex surfaces can be used.The internal surface of the mold optionally is provided with mirror images of inscriptions or logos or desired figures on the surface of the molded article, either as projections or depressions To ensure easy separation of the olde article without distortion or damage to the inscription in the article, the inscription may be designed so that the edge of the mirror image of the inscription is not exactly perpendicular to the surface of the die, but which is properly leveled, to avoid further distortion or damage to the inscription or logo or figure, the Rolling on the surface of the inner die "should be free of protuberances and imperfections and preferably be polished carefully. Leakage of material from the molds comprising the die parts can be avoided by having the bonded surfaces of the paired dies tightly, for example, by overlapping them or by supplying them with a package. In the case of high viscosity materials, the contact of faces 1 to 1 is sufficient The two dice are held together by the use of nuts and bolts or by some kind of clamping mechanism, for example a hydraulic mechanism Alternatively, the external surfaces of the die parts can slide on inclined planes in a separate housing means that allows the mold to support lateral forces. " It is important that a good seal is achieved when using high applications and pressure maintenance. Usually, . the mold has a"gate", this is the opening in the mold through which the detergent composition can be supplied to the mold cavity. In this respect, the gate opens on one side of the mold cavity and on another side it can be directly or directly coupled. indirectly for the means of applying pressure. The detergent composition can be supplied from the pressure application means via a slide channel (or burrs). In this regard, it may be beneficial to heat or cool the slide channel. The detergent composition can be supplied to the mold cavity directly without any slider channel. For example, it can be supplied directly through a nozzle. The mold may comprise a "neck", a short channel separated from the mold cavity by the gate. The detergent composition can be supplied through the mold neck. Alternatively, a nozzle can enter the mold cavity via the neck and the gate in order to supply the detergent composition. In a mold comprising portions of the die, the gate and / or neck may be fully present in a part of the die or may be formed on the coupling of two or more parts of the die. The gate opens on one side to the cavity and on the other side is adapted to be coupled, suitably by means of a nozzle that enters the mold via a neck, to the pressure applying means. The mold can be of such a design that it can be closed once it is complete or once the material in the mold has solidified to the extent that an outer shell is formed. By making the mold hermetic, the effects of shrinkage are controlled. In a preferred embodiment, the gate remains open while a pressure continues to be applied by the pressure application means. The mold can be closed in the gate while the material inside the mold is still under pressure. The process can be carried out in a continuous manner having a plurality of molds circulating through a feeding station where the detergent composition is injected under pressure in each mold and subsequently passed through the cooling steps to solidify. to the additional material and demold it before recycling again. In a mold comprising die parts, the die parts can be designed so that there is a differential level of adhesion of the solidified stick detergents. This allows flexibility in methods of releasing the bars from the molds as the dice slide. The differential adhesion of the solidified bars to the dice can be achieved, for example, by coating certain parts of the die as described above and not others, or by using coatings with different release characteristics.

Ventilation In injection molding processes it is generally necessary to provide a means for ventilation, ie, air removal from the mold, as the mold is filled. Ventilation of the mold is a technique employed in various known injection molding processes, for example, in the "thermoplastic industry, and such a technique can also be suitably employed in the present invention as will be understood by those skilled in the art. In the present invention, ventilation of the mold can be achieved simply by providing a means of ventilation such as, for example, a small hole or tilt in the mold, ventilation can be formed by two or more parts of the mold die entering together. , ventilation can be an integral part of a mold or die.Vanulation can be closed by the detergent composition by filling the mold that is being solidified at that point.Alternatively, a small amount of detergent material can leave the mold through ventilation, this material is subsequently removed.It is also possible to have a means of ventilation that can be opened and closed, being open during the filling of the mold and closed once the mold has been filled. It is also possible to facilitate the flow of air from the molding by adopting suitable shapes for the mold and logo. The present invention also provides ventilation by means of incorporation of a porous material in the mold. The porous material herein includes any material that is porous or permeable and having pores in the range of 2 to 500 microns in diameter.Preferably, the pores are in the range of 5 to 50 microns, substantially 10. at 20 microns. __ The porous material may constitute a part or all of a mold or part of a die, for example, it may be that only the logo comprises porous material, materials that comprise porous material can be used to form bars. of detergent compositions supplied in molten and non-molten states The porous material suitable for use in the molds as ventilation means is Metapor F100 AL, an air-permeable, microporous aluminum, available from Portee, North America, a division of Portee's NEST Technologies , Ltd., a Swiss company Another porous die material may be Porcerax II, a porous steel available from Mold Steel, Inc., of Erlanger, KY, USA. The release of the bar - may also be facilitated by pressurization, eg, a porous die 'after the mold has been filled and the detergent composition solidified to an appropriate degree. In a further embodiment, the present invention proves that the air present in the mold is removed by vacuum or partial vacuum during, or more preferably, before filling. In a preferred embodiment of the present invention, the nozzle is adapted with means to allow air to escape from the mold as the nozzle supplies material to the material. The preferred means are channels running parallel to the length of the nozzle. Such channels extend over most of the length of the nozzle, although preferably they do not extend -to the tip of the mouthpiece. When the nozzle is supplied with the detergent composition within the mold cavity, air can flow along its channels out of the mold. In a preferred embodiment, the nozzle is withdrawn from the mold cavity, as the cavity is filled. When the nozzle reaches the tip where it is discharged substantially with the mold gate, the non-grooved portion of the tip of the nozzle provides an effective air seal. This allows a maintenance pressure to be applied as required.

Bar Formulations Detergent compositions suitable for injection molding include the following ingredients: (A) 10-60% by weight of a synthetic soap-free detergent (B) of 0-60% by weight of a water-soluble structure that has a melting point in the range of 40-100 ° C, (C) 5-60% by weight of a water-insoluble structure, which has a melting point in the range of 40-100 ° C, (D) 1-25% by weight of water, (E) 1-20% by weight of the total composition of one or more amphoteric surfactants and / or iserionic ozone, (F) 0-20% by weight of the total composition of one or more surfactants, non-ionic, (G) 0-60% by weight soap, (H) Other optical ingredients, such as described in the following, (I) 0-10% by weight of total electrolytes. Synthetic detergents suitable for use in the process of the present invention include anionic surfactants such as Cs-C22 aliphatic sulfonates, aromatic sulfonates, (for example, alkyl benzene sulphonates), alkyl sulfates (eg, sulfates) C12-C? alkyl), alkyl ether sulfates (for example, alkyl glyceryl sulfates) Suitable aliphatic sulfonates include, for example, primary alkane sulphonate, primary alkane disulfonate, alkene sulfonate, sulfonate of hydrous oxide 1 ca or sulfonate ether of 1 to 1 g 1 g of sodium (AGS) Other anionic surfactants that may also be used include alkyl sulphonates (including mono- and dialkyl, for example, C6-C22 sulphonates), alkyl and acyl taurates, alkyl and acyl sarcosinates, sulfoacetates, alkyl phosphates, alkyl phosphate esters, esters of alkoxyalkyl phosphate, acyl lactates, monoalkyl succinates and maleates, sulfoacetates. Other surfactants that can be used are acyl isethionates (for example, Ca-C 8). These esters are prepared by reaction between the alkali metal isethionate with mixed aliphatic fatty acids having 6 to 18 carbon atoms and an iodine value of less than 20. At least 75% of the mixed fatty acids of 12 to 18 atoms of carbon and up to 25% have from 6 to 10 carbon atoms. The acyl isethionate may be an alkoxylated isethionate such as that described in Ilardi et al., U.S. Patent No. 5393466, incorporated herein by reference in the present application. The "anionic surfactants used are preferably smooth, that is, a surface-active agent that does not damage the stratum corneum, the outer layer of the skin." Hard surfactants such as primary alkane sulfonate or alkyl benzene sulfonate will generally be The suitable water soluble structurants include moderately high molecular weight polyethylene oxides of suitable melting point (for example, from 40 to 100 ° C, preferably from 50 to 90 ° C) and in particular polyethylene glycols or mixtures The polyethylenes (PEG) glycols used can have a molecular weight in the range of 2,000 to 25,000.They also include water-soluble starches.The suitable insoluble structurants are generally a long-chain liquid fatty acid (C8-). C24) unsaturated or branched or ester derived therefrom, and / or unsaturated and / or branched long chain liquid alcohol or ethers derived therefrom. n be a saturated short chain fatty acid such as capric acid or caprylic acid. Examples of liquid fatty acids that can be used are oleic acid, isostearic acid, linoleic acid, linolenic acid, ricinoleic acid, elaidic acid, acid r i qui dóni co, myristoleic acid and palmitoleic acid. The ester derivatives include propylene glycol isostearate, propylene glycol oleate, glyceryl isostearate, glyceryl oleate, and di i s or e s t a a r a t o o p o 1 i g 1 i c e r i 1 o. Examples of alcohols include alcohol oleyl alcohol i s or s t e a r i 1 i c o. Examples of ether derivatives include isosteareth or oleth carboxylic acid or isosteareth or olethyl alcohol. Suitable zwitterionic surfactants for use in the formulations are exemplified by those which can be broadly described as derivatives of quaternary ammonium, phosphonium and sulfonium compounds, in which the aliphatic alkalies can be a branched chain and wherein one of the aliphatic substituents contains from about 8 to about 18 carbon atoms and one contains an anionic group, for example, carboxy, sulfonate, sulfate, phosphate, or phosphonate. Amphoteric detergents that can be used in this invention include at least one acid. This may be a carboxylic or sulfonic acid group. They include quaternary nitrogen and therefore are quaternary amino acids. They should generally include an alkyl or alkenyl group of 7 to 18 carbon atoms. Suitable amphoteric detergents include simple betaines or sulfobetaines. The amphoacetates and di a n d o c t t t s are also intended to be covered in possible zwitterionic and / or amphoteric compounds that can be used. In addition to one or more of the amphoteric and / or zwitterionic surfactants, there are surfactants which can optionally comprise a nonionic surfactant at a level of up to 20% by weight. The nonionic that can be used includes in particular the reaction products of the compounds having a hydrophobic group and a reactive hydrogen atom, for example aliphatic alcohols, acids, amides or alkyl phenols with alkylene oxides, especially ethylene oxide and either alone or with propylene oxide. The specific non-ionic detergent compounds are condensates of phenols of a 1 qui 1 o - ethylene oxide (Cs-C22), the condensation products of linear or branched alcohols, primary or secondarily aliphatic (Cs-Cis) with ethylene oxide and products made with the condensation of ethylene oxides with the reaction production of propylene oxide and ethylenediamine. Other so-called non-ionic detergent compounds include long chain * tertiary amino oxides, long chain tertiary phosphine oxides and dialalkyl sulfoxides. The non-ionic can also be a sugar amide, such as a polysaccharide amide. Specifically, the surfactant may be one of the active ingredients described in U.S. Patent No. 5389279 to Au et al., Which is incorporated herein by reference or may be one of the sugar amides. described in Kelkenberg Patent No. 5009814, incorporated herein in the application by reference. Other surfactants that can be used are described in U.S. Patent No. 3723325 to Jr., and non-ionic alkyl polysaccharide surfactants as described in U.S. Patent No. 4565647 to Llenado, both of which are incorporated herein by reference. they are incorporated here in the application by reference. The nonionic surfactant can also be a chemically modified water-soluble polymer with a hydrophobic portion or portions, for example, the block copolymer EO-PO, hydrophobically modified PEG such as POE (200) -g 1 i 1-Stearate can be included in the formulations claimed in the present invention The formulations can optionally contain up to 60% soap made by processes to form normal soap, eg saponification products of natural material such as bait, coconut oil, palm oil, rice bran oil, fish oil or any other suitable source of long chain fatty acids can be used. The soap can be pure soap or medium-phase soap. In addition, the compositions of the invention may include optional ingredients in the following way: Organic solvents, such as propylene glycol ethanol; auxiliary thickeners, such as carboxymethylcellulose, magnesium-aluminum silicate, hydrocarbon, methylcellulose, carbopoles, glucamides, or Antil | F) from Rhone Poulenc; perfumes; secondary agents, such as tetrasodium tertiary (EDTA), EHDP O- mixtures in an amount of 0.01 to 1%, preferably 0.01 to 0.05%; and dyeing, opacifying and peeling agents such as zinc stearate, magnesium stearate, Ti02, EGMS (ethylene glycol monostearate) or Lytron 621 (Styrene / acrylate copolymer), all of which are useful for improving the appearance or cosmetic properties of the product The compositions may further comprise antimicrobials such as 2-hydroxy-4,2 ', 4'-trichlorodiphenyl ether (DP300), preservatives such as dimethyloldimethylhydate (Glydant XL1000), parabens, sorbic acid, etc. The compositions may also comprise coconut acyl mono or diethanol amides such as reinforcements and strongly ionizing salts such as sodium chloride and sodium sulfate may also be used advantageously Such electrolyte is preferably present at a level between 0 and % by weight, preferably less than 4% by weight. Oxidants such as, for example, butylated hydroxy toluene (BHT) can be advantageously used in amounts of 0.01% or higher if appropriate. The cationic conditioners that can be used include conditioners of the type Quatrisoft LM -200 Polyquaternium-24, Merquat Plus 3330 -. 3330 - Polyquaternium 39; and the Jaguar181 type conditioners. Polyethylene glycol conditioners that can be used include Polyox WSR-205 PEG 14M; Polyox WSR-N-60K PEG 45M, Polyo WSR-N-750 PEG 7M and PEG with molecular weight ranging from 300 to 10,000 Daltons, such as those marketed under the trade name CARBOWAX SENTRY by Union Carbide. Thickeners that may be used include Amerchol Polymer HM 1500 (Nonoxynil hydroxyethyl cellulose); glucam DOE 120 (PEG 120 Methyl glucose dioleate); Re odermIR | (PEG-modified glyceryl cocoate, palmate or ceboate) from Rewo Chemicals; Antil (R) 141 (from Goldschmidt).

Clays and paraffin wax. Another optional ingredient that can be added to deflocculating polymers such as those taught in U.S. Patent No. 5147576 to Montague, incorporated herein by reference, is another ingredient that may be included. such as polyoxyethylene beads, walnut shells and apricot seeds The detergent compositions of the present invention can include normal known additives such as perfumes and colorants.

Additives and Beneficial Agents In order to improve the properties perceived by the consumer of the bars, it may be desirable to incorporate beneficial agents and / or other additives into the formulation. Skin beneficial agents are defined as products that are included in a detergent composition that will be deposited on the skin when the detergent composition is applied and which will impart or maintain desirable properties to the skin. It is particularly preferred that the detergent compositions given in the present invention comprise beneficial agents such as, for example, wetting components. Normally, such beneficial ingredients are substantially immiscible with the detergent composition and it is desired that they be present in discrete zone forms. When the detergent composition is in a fluid state as in a casting process, any difference in density between the beneficial ingredients and the fluid detergent mixture can lead to phase operations in the non-agitated system such as may exist in a casting after the molding. The beneficial agent can exist in a single-phase component or with some of the ingredients of the formulation. One of the problems associated with the beneficial agents is that they are washed by the foaming surfactants before they are deposited on the skin. One way to avoid this is to disperse the beneficial agents heterogeneously in the bar, for example, as zones, allowing the direct transfer of the beneficial agent, as the bar is rubbed on the skin. It is widely accepted that more beneficial agent is deposited on the skin "when the beneficial agent disperses heterogeneously.In addition, in order to give an optimal deposit to the skin during the washing process, it may be convenient to control the size of the occupied areas By the beneficial ingredient in the finished bar product In a fluid system, it is difficult to stabilize the droplets of a specific size.Such areas can be from 1 to 5 mm in size.Preferably, the zones have a size of 15. at 500 microns for example as set forth in WO 96/0229.More preferably, the zones have a size in the range of 50 to 200 microns.

The inventors have found that the process of the invention is particularly suitable for the incorporation of beneficial agents for mixing detergents and in particular when the detergent composition is in a semi-solid state. Preferably, the beneficial agent is added to the detergent composition in the medium to feed the detergent composition. When the means for feeding the detergent composition comprises a feeder in the form of a screw, the beneficial agent can be added in any suitable manner along the screw feeder. Using the equipment of the present invention, when there is a temperature profile in the equipment it is possible to choose the temperature at which the beneficial agent is added. Therefore, it is possible to introduce the beneficial ingredient into a chosen viscosity volume flow. By using equipment and appropriate processing parameters, it is also possible to introduce the beneficial agent into a volume flow of material having a chosen volume of mixing and structuring. It is also possible to control the shear stress (mixing) experienced by the materials after they have been combined, which can be used to manipulate the size of the areas of the beneficial agent. The inventors have found that the beneficial agent by the process of the present invention can be of the final detergent composition of the non-spherical stick. In general, it is found that the domains are enlarged. Bars produced containing substances such as for example beneficial agents that are substantially miscible with the detergent composition will be two-phase systems. One phase may simply comprise the beneficial agent, while the other phase comprises the detergent composition. Alternatively, the beneficial agent can interact with one or more components of the detergent composition to form a phase containing the separate beneficial agent. Accordingly, in another aspect, the present invention provides a stick detergent that can be obtained by the process of the present invention, comprising a detergent composition and immiscible components with the detergent compositions, such as beneficial agent, wherein the immiscible component is present. in non-spherical domains. Other ingredients such as perfume or dyes can be introduced in the same way.

The beneficial agents include components that moisturize, condition or protect the skin. Suitable beneficial agents include humectant components such as, for example, emo 1 i in t e s / a ce i t e s. By emollient oil is meant a substance that softens the skin and keeps it soft by slowing down the decrease of its water content and / or its protrusion.

Preferred beneficial agents include: Silicone oils, gums and modifications thereof, such as linear and cyclic polymers; amino, alkyl, alkylaryl and aryl silicone oils. The silicone oil used can have a viscosity in the range of 1 to 100,000 centistokes. Fats and oils that include natural fats and oils such as jojoba oil, soy, rice bran, avocado, almond, olive, sesame, persic, castor, coconut, mink, araquis, corn, cottonseed, palm kernel, rapeseed, safflower and sunflower seeds; cocoa butter, bait of beef, lard; hardening oils obtained by hydrogenation of the oils mentioned above; and synthetic mono, di and triglycerides, such as ~ myristic acid glyceride and 2-ethylhexanoic acid glyceride; Waxes such as carnauba, whale sperm, beeswax, lanolin and its derivatives; Extracts of hydrophobic plants; H i d r o_c arbours such as liquid paraffins, petrolatum, microcrystalline wax, ceresin, squalene and mineral oil; Higher alcohols and fatty acids such as behenic, palmitic and stearic acids, lauryl, cetyl, stearyl, oleyl, behenyl, cholesterol and 2-hexadecanol alcohols, esters such as cetyl octanoate, cetyl lactate, myristyl lacatate, cetyl palmitate, butyl m-stearate, butyl stearate, decyl oieate, cholesterol isostearate, myristyl myristate, glyceryl laurate, glyceryl ricinoleate, glyceryl stearate, alkyl lactate, alkyl citrate, alkyl tartrate, isostearate alkyl, hexyl laurate, isobutyl palmitate, isocetyl stearate, isopropyl isostearate, isopropyl laurate, isopropyl linoleate, isopropyl myristate, isopropyl palmitate, isopropyl stearate, adipate, isopropyl, propylene glycol monolaurate, propylene glycol ricinoleate , propylene glycol stearate, and propylene glycol isostearate; - - - Essential oils such as fish oils, oil mint tea, jasmine, camphor, white cedar, bitter orange peel, ryu, turpentine, cinnamon, bergamot, citrus unshiu, calamus, pine, lavender, laurel, clove, hiba, eucalyptus, lemon, chicken milk, thymus, pepper , rose, mugwort, menthol, cineol, eugeniol, citral, cintronella, borneol, linalool, geraniol, narcissus, camphor, thymol, spirantol, pinene, limonene and terpenoids; Lipids - such as cholesterol esters, ceramides, sucrose and sibutocarbons as described in EP-A-556 957; Vitamins such as vitamin A and E, and vitamin alkylesters, including those esters of vitamin C; Sunscreens such as octyl methoxyl cinnamate * (Parsol MCX) and butyl methoxy benoylmethane (Parsol 1789); Phospholipids; and Mixtures of any of the above components.

It should be understood that where the emollient can function as a structure, it should not be doubly included so that, for example, if the structurant is 15% oleyl alcohol, no more than 5% oleyl alcohol can be added, as " emollient "since the emollient (whether functioning as an emollient or structuring agent) should not comprise more than 20%, preferably not more than 15% by weight of the composition. The emo 1 i e n t e / a c e i t e is generally used in an amount of about 1 to 20%, preferably 1 to 15% by weight of the composition. Generally, no more than 20% of the weight of a composition should be understood. The present invention will also be described in the manner of the following appended drawings.

Brief Description of the Drawings Figure 1 shows an apparatus for use in the method of the invention (side view of the extruder with a single reciprocating screw). Figure 2 shows an additional apparatus according to the present invention (plan view, of the twin screw extruder).

Figure 3 shows an additional apparatus according to the present invention (side view, double screw extruder with low shear in-line injection head, degassing zones "and solid food filler machine.) Figure 4 shows a view from the end of the apparatus of Figure 2 (apparatus for moving the mold during-filling) Figure 5 shows the apparatus for use in the method of the invention (plan view, single plunger extruder). internal construction of one side of the mold according to the invention, Figure 7 shows the external construction of a mold, Figure 8 shows a further embodiment of a mold, Figure 9 shows a schematic illustration of a detergent molding system.

DETAILED DESCRIPTION OF THE DRAWINGS Figure 1 shows an apparatus for injection molding to maintain this detergent material for the purpose of being used in the present invention, generally designated (1) (Sandretto Series 7 HE 135 injection molder). comprises conventional means (2) for feeding the particulate solid detergent composition The medium shown is generally known as a packaging container and comprises a piston (3) which produces a loose mass of the particulate detergent material. particles flow from a packaging container to a screw feeding apparatus The screw feeding apparatus comprises a barrel (4) having an internal cylindrical bore (5) Within the barrel (4) there is a single screw (6) (screw made by molding a paste with a diameter of 50 mm) The means (not shown) are provided to rotate the screw (6) continuously.The screw is rotated to a speed from 80 to 100 rpm. The rotation of the screw (6) causes the detergent composition to flow in the direction shown in the solid head arrows. Heating means (7) independently controllable in the form of ducts for liquid are provided surrounding the barrel (4). The heating means (7) elevate the urine t of the detergent composition to a level which can be supplied under pressure without becoming sticky.The temperature profile along the barrel (4) is staggered. The furthest end of the barrel (4) of the hole (5) is reduced in diameter to a nozzle (8), to which a mold (9) of aluminum can be fastened in two parts having a mold cavity configured in the shape of one of the bar counter (the fastening means are not shown) During the operation, the screw (6) can move inside the barrel (4), to leave the accumulation zone (10) in the hole (5) cylindrical At the end thereof In operation, the detergent composition can be prepared as sticky particles (average diameter in the region of 1 to 10 mm) using equipment already known in the art, such as cooling rolls, bar extruders with nozzle plates. , etc. The detergent composition in particícu the fed in the packaging container (2) so it is fed into the screw feeder. The screw (6) is rotated continuously to transport the detergent material along the hole (5). During transport, the temperature of the detergent material is raised by the heating means (7) so that, at the injection point, it is between room temperature and 70 ° C. The means (not shown) are provided to move the feed screw (6) along the axis of the cylindrical hole (5). During operation, the flowable detergent composition at elevated temperature is fed in an area (10). As the detergent composition accumulates in this area ", force the screw (6) out of the nozzle (8) so that the volume "of the space * (10) increases." "When a sufficient volume has accumulated in the space (10), the screw (6) ) "is driven by hydraulic means (not shown) towards the nozzle (8) whereby pressure is applied to the detergent composition at elevated temperature so that it is supplied through a nozzle in the mold (9). A check valve (not shown) is provided to prevent the back flow along the screw. Once the mold is full, pressure is maintained on the mold as it cools "if required." This allows the volume of the mold detergent to be maintained by and shrink upon cooling.The mold can then be removed from the unit and cooling if necessary before opening The mold cooling means can be used to accelerate the cooling of the composition of people in the mold, eg, solid carbon dioxide, ice / water bath or water. Cooling may be used to pre-chill the molds or to cool them down prior to demolding.Figure 2 shows a side view of one embodiment of the present invention.It is generally designated (11) The apparatus (11) is preferably for feeding the detergent composition, which is supplied in liquid form, however, the device (11) can be used to feed detergent compositions supplied in solid form if provided with suitable feeding means. A duct 12 is provided to receive a feed of liquid detergent composition, of a separate step in the manufacturing process, for example. The duct (12) is connected to an extruder (13). In the extruder (13) there are two co-rotating feed screws (14), (15) forming intermediate mesh, each with a single fin. At the end of the screws, a set of medium shear mixing elements is provided, comprising three three-lobed spatulas (26) and three "fusion discs" (27) to provide the return pressure and some mixing. The temperature control means (16) are provided in the jacketed zones around the barrel of the extruder (13). The temperature control means comprise channels for the liquid cooler, and electric units for heating. The temperature control means in zone A of the extruder are maintained at a low temperature, for example, 30 ° C, to improve the formation of the composition 'Solid detergent in order to seal the end of the arrows of the screws (14), (15). The temperature control means in the marked area B are at a high temperature to maintain the detergent composition in the molten state in order to prevent blockages at the feeding point. The means (L 6) of temperature control in the marked region C (i.e., the remainder of the extruder length) are for conditioning the detergent composition gradually to the desired temperature.

A connecting valve (17) is tested by means of which the detergent composition is fed to an injection head (18) comprising two injection chambers (19). The injection chambers (19) comprise cylinders with retractable pistons (20). The injection head (18) has a nozzle (21) which will be described in relation to the following Figure 4. The connection (17), injection head (18) and injection chambers (19) are provided with electric heaters (not shown) for temperature control. In operation, a molten feed of detergent composition at a temperature in the range of 90 to 95 ° C is fed into the feed cavity 13 and driven by the co-rotating screws in the direction of the solid head arrow. through the connection (17) to the injection chambers (19) At this point, the temperature is below 70 ° C. During the first phase of operation, the detergent material accumulates in the injection chambers, the pistons (20) are displaced simultaneously When an adequate volume of detergent composition has accumulated, the pistons (20) are actuated by hydraulic pressure (not shown) whereby the pressure is applied to the detergent composition which is forced to Through the nozzle (21) to a mold that will be described later, Figure 3 shows a side view of one embodiment of the present invention, Generally, it is designated (28) The apparatus comprises an extruder, with two screws. The co-rotating feed-ins form internal mesh, each with a single fin, as described in Figure 2. The general configuration of the two internal mesh screws can be chosen to suit the particular application. At the end of the screws, a set of medium shear and kneading mixing elements are also provided as described in Figure 2. The "mixing and kneading elements can be placed behind the transport screw elements of various separations. The temperature control means, comprising the channels for the liquid cooler and the electric heating means, are provided by the jacketed zones around the barrel of the extruder (as in Figure 2) .The apparatus can accept liquid, semi-solid or liquid materials. solids such as feed, depending on the chosen feed arrangement The particulate detergent material is fed into zone D of the extruder via a solid feeder (29) The fluid materials are fed into zone E of the extruder by a medium (30) Liquid feed A degassing port (31) is fed into the extruder zone H. In the J ° zone of the extruder, a solid feed means (32) for supplying solid attachments to the extruder is illustrated. In zone K, a duct (33) is shown for the introduction of liquid additives or a pump (not shown). Since the areas of the former can be interchanged, it should be understood that solids, liquids and additives feeds can be introduced at any position along the length of the screw, one of a number of feeds can be supplied for one product. At the outlet of the extruder, a three-way valve (34) for sampling and recycling is used.When this valve is in the straight-through position, the conditioned material from the extruder passes to the accumulator (36) comprising a chamber. Cylindrical (37) and piston (38) The position of the piston (38) "" and "the cylinder (37) varies according to the flow of material in and out of the accumulator. A pneumatic pressure behind a piston keeps the material in the accumulator at a constant pressure, and therefore provides a buffer between the continuous flow of the extruder and the intermittent demands of the injection head (39). The three-way valve (34) and the accumulator (36) are provided with controlled temperature jackets. The "injection head is placed perpendicular" to the extruder with its vertical axis. It is provided with a means for temperature control (not shown). The injection head (39) comprises a hydraulic actuator (40), a spindle (41) c or n e cr. An actuator chamber, an inlet chamber (42), an injection chamber (43), a nonreturn ring check valve (44) and an injection valve (45) are also shown. ) and the mold (9) The nozzle and the mold can be pre-fitted before the injection if required.In the charge mode, the injection valve (45) is closed.The pressure above the valve The ring retainer is larger than the bottom one and the v ula moves to its lower seat.

In this position, the material can flow through the ring check valve, between the injection spindle and the cylinder wall. As the injection spindle moves hydraulically upwards by the movement of the actuator, the prepared material flows into the injection chamber. The loading process is complete when the spindle is completely filled. The diameter of the spindle is reduced to a minimum (within the restrictions of mechanical strength) to give a maximum area of flow, and therefore to exert shear stress of minimum elongation on the flow material. When the pressure below the valve exceeds the previous one, the valve moves to its upper seat and isolates the injection chamber from the inlet chamber. At this point, the camera is charged by injection. This passive valve system removes the need for an inlet control valve and provides first flow of inlet and outlet material to the mold. In the injection mode, the injection valve (45) is opened, the cylinder is hydraulically driven down and the pressure of the injection chamber rises above the intake chamber. This closes the ring check valve. As the spindle moves down with the actuator, the material flows from the injection chamber through the open injection valve and into the mold via the nozzle (46). The volume of material supplied to the mold is determined by the shock of the hydraulic actuator. The speed of the material as it is supplied in the mold is determined by the hydraulic pressure. The applied pressure is measured at an appropriate position within the injection head (39). When the apparatus is used according to Figure 3, the applied pressure is measured through the actuator. In addition, the pressure at a point just before the nozzle is also measured. This is recorded as the "injection pressure" as referred to in Tables 3 to 5. Figure 4 shows an end view of the apparatus of Figure 2. However, the nozzle and the mold configuration are equally applicable to the apparatus of FIG. Figure 3. The nozzle (46) can be seen at the top, together with the injection chambers (19) and pistons (20).

-Also the mold is visible (9). A nozzle extension (47) extends into the mold cavity (48) of the mold (9) through a hole in the upper part. The mold (9) is mounted on a plate (49) that moves up and down by a system (5 * 0) hydraulically or manually. In use, when the pistons (20) are activated to supply the detergent composition under pressure from the injection cylinders, the detergent composition flows through the bore (46) and the nozzle extension (47) into the cavity of the pump. of the mold (48). The advancing relation of the pistons (20) joins the retraction rate of the plate (49). As a result, the mold (9) that falls as the mold cavity (48) is filled with the detergent composition. The detergent composition flowing under pressure tends to fill the lower part of the mold cavity. The rate of retraction of the plate (49) is adjusted so that the nozzle extension tip (47) is always just below the surface of the detergent composition in the mold cavity (48). This gives a good "filling quality" Alternatively, a good filling quality is obtained by moving the nozzle (46) in place of the plate (49) The nozzle moves to the base of the mold cavity (48) and it rises from the mold as the mold cavity is filled with the detergent composition In a preferred embodiment, the nozzle is splined by providing it with a series of vertical slots (51) of a depth of about 1 mm. The top of the nozzle is approximately 10 mm from the tip.When the nozzle is inside the mold, the air can be taken out of the mold via the flutes.When the nozzle is removed, the mold is sealed by the nozzle, allowing the pressure to be maintained inside the mold. Figure 5 shows a simple plunger extruder apparatus for use in the method of the invention. A sample or barrel reservoir (52) has an installation (53) for heating and maintains the temperature of the sample by varying from the ambient (TA) temperature to 100 ° C. A plug (54) is provided together with a drive mechanism and a speed controller (55). A transmitter (56) pressure indicator is provided in the lower part of the tank.

One end of the slide (57) is screwed onto the bottom of the tank. The outer end of the slide is connected to a gate (58) on the mold (59) using threaded bolts. A vacuum pump is connected to the capillary outlet (60) to evacuate the mold before filling. Figure 6 shows a die (61) of the mold made of aluminum. The die is provided with a cavity (62) of volume of approximately 60 ml. The outer surface of the cavity is convex and is provided with projections that provide a mirror image of the desired inscription (63) on the surface of the injection molding bar.The inner surface of the cavity is coated with PTFE, 35 microns thick (64) When the two dice are joined the cavity formed, which corresponds to the end form of the tablet molded by injection is opened via a gate (65) 7"This gate connects the feed tank" to Through a slide into the cavity, leakage of the material from the mold is prevented by providing a packing (66) along the surfaces of the dice. A capillary (67) of diameter 1.5 mm connects the mold to a vacuum pump. The end of the capillary that is far from the cavity is threaded (68) and connected to a valve, which in turn is connected to a vacuum pump. The closure of the valve helps to obtain high injection pressures inside the mold after evacuation, from the mold. The die is provided with holes (69) for bolting the two dice. Figure 7 shows the external surfaces of a mold comprising two dies in Figure 5 attached, the dices are provided with 1 etas / co sti 11 as (70) to improve the cooling efficiency Figure 8 illustrates the modality Further of a mold of the invention wherein the external surfaces of the dice (71) are tilted in such a way that the die dies can slide on the internal inclined surfaces of the housing (72) to withstand the injection pressures. 9 illustrates the detergent molding system according to the invention comprising a feed reservoir (73) and a plurality of the molds (74) mounted on the conveyor (75) whereby the process of the invention is carried out by the circulation of each mold through the reservoir where the detergent formulation is injected into the mold under pressure and is subsequently taken through the cooling steps to complete the solidification. and demoulding (76) before recycling again. The present invention will be further described by way of the following non-limiting examples: USES Example 1 A recirculated screw injection molding unit according to Figure 1, sold as "SANDRETTO Series 7 HP135" having three temperature controlled zones is used.The machine was adapted with a screw and barrel of the dough composite with diameter of 50 mm The feeding means are comprised of a conventional packaging container, or a manual feeder as appropriate for the material.A rotary rotation regime of 80 to 100 rpm was used. The mold (9) comprises a pair of aluminum molded parts defining a bar configuration, these were like those used with the latest in detergent stamping ~ in bars, modified by the addition of a feed orifice sized to have the nozzle and small holes at appropriate places in the mold to allow air to be vented during filling.Detergent formulations A, B and C were " molded by injection. Formula A is as follows: active weight% Directly Reviewed Fatty Isethionate 27.00 Acid mixture for commercial use 17.00 Cocoamidop r op i lbe t ai na 5.00 Bad todext quarrel 10.00 Sodium Stearate 6.00 PEG 8000 21.62 PEG 300 _ ~ 2.05" PEG 1450 4.95 Water 4.50 Sodium Isethionate 2.16 Minor additives (preservatives, perfume, coloring, etc.) 1.72 TOTAL "" "'100.00 Formulation B comprised Lux UK commercially available, ground, white soap, dated September 1996. Formulation C comprised a commercially available ground-up Dove beauty bar dated June 1996.

A detergent composition was fed into the packaged container in the form of small particles (grain size of about 1 to 10 mm). Such particulate material can be obtained by cutting commercially available bars or using rolls or extruder bar equipment or commercially available strip or cooling roller. In the same experiment, the detergent composition was manually fed into the unit. The injection molding apparatus was then used to inject the detergent composition into the mold. The detergent compositions were in a semi-solid state when they entered the mold. The molds were previously cooled in ice / water and dried before filling. After a few minutes at ambient conditions, the mold was removed from the molder by injection and opened. The properties of the bar were evaluated in terms of ease of mold release and surface appearance. The results are shown in Table 1 below. It can be seen that the injection molding apparatus of Figure 1 is suitable for manufacturing bar detergent which is freed from the mold after a short period and has surface appearance from satisfactory to excellent.

Example 2 An apparatus according to Figure 2 comprising a BETOL co-rotating twin screw extruder with 40 mm diameter screws and eight temperature control zones was used. The temperatures of the connecting valve 17 and the injection head assembly (18, 19, 20) are also. controlled. A novel piston-type injection unit according to the present invention was adapted at the end of the screw extruder. The detergent compositions as shown in the foregoing were prepared in molten form and fed to the extruder using a Bran and Luebbe measuring pump. The molten feed was at a temperature of 90 to 95 ° C. It was kept in a hot agitation feed container. During the filling of the mold it was moved either manually, or hydraulically using a molding movement mechanism according to the Figure 4 of the present application.

The formulations D and E were injected molded, Formulation D was as follows: Active weight% Directly esterified Fatty Iethionate 38.0 Propylene glycol 21.5 Sodium stearate 12.2 Sodium palmitate 12.2 Water "16.1 TOT AL 100.0 Formulation E was as follows: Active weight% Isethionate Directly esterified 27.8 Sodium stearate 14.6 Propylene glycol 17.8 Stearic acid "12.8 PEG 800.0 9.7 Cocoamidopropylbetaine 4.9 Paraffin wax 2.9 Sodium Iethionate 0.4 Water 5.6 Minor additives (preservatives, perfume, color, etc.) 2.5 TOTAL 100.0 The apparatus was used to form a bar detergent over a range of temperatures that were subsequently freed from the molds and revised for mold release properties and surface quality. The results are shown in Table 2. It is clear that detergent can be manufactured in good quality bars using the apparatus of Figure 2.

TABLE 1 Notes on Tables 1 and "2 * 1 The temperature zones are 1, 2 (feed), 3, 4, 5, 6, 7, 8 (mixing elements), 9 (valve connection and injection head) 10 (cylinders). * 2 Mold cooling was achieved by contact with solid carbon dioxide (for temperatures in the -5 ° C region) ice / water bath (for temperatures up to 10 ° C) and water or ambient air (for temperatures in excess of 10 ° C).

Example 3 An apparatus comprising BETOL co-rotating twin-screw extruder with screws of diameter "40 mm, eight emperature control zones and a low-shear in-line injection head were used as described in FIG. Figure 3. The detergent composition E was prepared in molten form (95 ° C) and kept in a hot, stirred feed vessel, then heated in zone E of the extruder using a Bran &amp measurement pump.; Luebbe The detergent composition B was fed at room temperature in the D zone as 4 mm diameter strips using a Ktron feeder. The maximum injection pressure and type of maintenance were recorded. The results are given in Table 3. The detergent compositions were in a semi-solid state when they entered the mold. In all operations, the mold was at ambient temperature, before filling and cooling were performed by packing solid C02 around the outside of the mold during the specific time period plus a mold maintenance at room temperature for another 5 hours. minutes These operations illustrate that the surface quality of the bars can be improved by the use of a maintenance pressure after filling, if. compromise the release of the bars to the mold.

TABLE 3 Notes in Table 3 * 1 The temperature zones are 1, 2 (supply), 3, 4, 5, 6, 7, 8 (mixing elements), 9 (valve connection and accumulator) and 10 (supply head). injection) .

Example 4 The detergent formulation E was molded by simultaneous injection to a beneficial agent. Using the equipment of Figure 3, two silicone oils (viscosity of 100 and 60000 centistokes) were introduced into the twin screw extruder in separate experiments. the flow regime of silicone oil was controlled by a Seepex pump so that an approximate concentration of 2% -15% w / w of silicone oil is given in the final bar. For some operations dye was added to the silicone oil stream, so that its presence in the bar could be verified visually during the experimentation. The detergent compositions were in a semi-solid state when they entered the mold. The formed bars were released from the molds as easily as their counterparts without oil, ba or similar conditions. The mold was at room temperature before filling and cooling was performed as described in Example 3. The high resolution proton NMR was used to determine the distribution of silicone oil in sticks. The "invention of NMR was carried out on samples taken from six different sites on the bar (3 in and 3 on the surface.) The results are shown in Taba 4. Subsequent microscopic analyzes indicated that silicone oil was present in The bars in areas configured irregu 1 instead of droplets.An average volume guide of the area was obtained by heating a sample, allowing the oil to flow in droplets, dividing its diameter. This varied with the viscosity of the oil (lower viscosity, smaller zones) and the mixed regime in the dosing region (helical fins of flat long zones) than the elements of ama sa do / me zc 1 a do) indicating that zone size control was possible.

TABLE 4 Example 5 Using the equipment of Figure 3, Formulation F bars were formed by injection molding: Formulation F was as follows:% by weight active Isethionate fat directly esterified 7.60 Sodium stearate. 4.75 SLES-3EO 11.87 Fatty acids 4.26 PEG 8000 9.49 Co-co-infusions 11.87 Glycerol monostearate 20.64 Glycerol monolaurate 20.64 Water 3.79 Sunflower oil 4.75 Minor additives up to 100% TOTAL 100.0 Detergent compositions were in a semi-solid state when they entered the mold. The temperature of the molds in the filling was amb i e n t a 1.

TABLE 5 Example 6 An extruder rod is shown in the Figure for injection molding of two representative personal wash detergent formulations G and H.

Formulation G as follows:% active weight Soap * "76.7 -« Water - 22.0 Ti02. 0.3 Per smoke 1.0 TOTAL 100.0 Formulation H as follows: active weight Sodium cocoyl isethionate 49.5 Stearic acid 20.0 Coconut fatty acid 3.0 Sodium ionatetoate 4.7 Al qui lbence nsu 1 lineal fato (LAS 2.0 Sodium chloride 0.4 Soap * * 8.3 Sodium stearate 3.0 Perfume 1.3 Miscellaneous 0.7 Water 7.1 TOTAL 100.0 * Distribution of sodium The long chain of the soap load is given in Table 3. ** The 82/18 mixture of sodium ceboate and sodium cocoate.

TABLE 6: Distribution of the long load of soap grease in the G uide.

The detergent composition is filled in the reservoir and the reservoir was heated until the feedstock obtained the desired temperature. The dice were assembled and the slide was connected to the gate of the injection mold. The other end of the slide was screwed into the bottom of the tank. The slide and the mold were heated and maintained at the desired temperature using a blanket type heater. The temperature on the outer surface of the mold was measured using a Fe / k thermocouple of washer type. Once the feed temperature and the mold temperature reached desired values, a vacuum pump was connected to the threaded portion of the outlet capillary (60) of the mold and the mold was evacuated prior to filling. A moisture trap was provided in the vacuum pump line in order to prevent moisture from entering the vacuum pump oil. A vacuum gauge in the vacuum pump line measured the vacuum in the mold cavity. The piston (54) was then turned on and the hot feed was injected into the mold at a controlled rate, the speed being displayed on an instrumentation panel in mm / min. The pressure rating of the piston apparatus rated at 5064 kPa (735 psi) and once the pressure exceeded this value, the auto-off system of the instrument automatically stopped the piston. The pressure, measured by the indication transmitter (56) was displayed on the instrumentation panel in units of millivolts over a range of 0-1013 mV, co-predicted at 0-5064 kPa (0-735 _ psi) , through the injection molding unit. An online computer recorded the transmitter pressure output in millivolts with a time function. After the mold was filled and the piston was turned off, the mold still connected to the slide was detached from the tank and allowed to cool. The two dice of the mold were opened and the detergents were expelled on hardened bars. Mold cooling was performed under conditions of forced air cooling with air and at approximately 27 ° C and at an air velocity of approximately 3.6 ms. The feed entering the mold had a partially semi-solid structured shape, containing liquid crystalline phases. Table 7 shows the preferred operating conditions for injection mold of these formulation.

Table 7: Optimal Operating Conditions It was found that tablets with good surface finish and print quality of the acceptable logo could be obtained using the process treated before the invention. A comparison of the final properties of the user of the formulation H molded against a worked and extruded bar detergent with conventional co-control effort was performed. The injection molding and the control rods "were of the same weight (approximately 75 g) and in a similar way (r e qt angu 1 a r). Table 8 shows the end user properties such as usage regime, consistency, foaming and cracking of the two rods. The wear regime was comparable for the two tablets.The volume of foam formation for the injection molded bar was higher than that of the control.The consistency regime was poor for the injection molded bar. cracking for both bars.

TABLE 8: Evaluation of the formulation (I-M) for the injection by molding G vis-a-vis a control worked and extruded with conventional shear

Claims (25)

1. Process for forming detergent into sticks comprising applying pressure to a detergent composition for the purpose of supplying the detergent composition to a mold, characterized in that the detergent run is at least partially structured when it enters the mold.

2. Process for forming detergent into bars comprising applying pressure to a detergent composition, in order to supply the detergent composition to a mold, characterized in that the pressure at the point of introduction into the mold is greater than 137.8 kPa (20 psi) during at least part of the time in which the detergent composition enters the mold. "~

3. Process for forming detergent in bars comprising applying pressure to the detergent composicron in order to supply the detergent composition to a mold, characterized in that the detergent composition is at least at a temperature below 70 ° C when it enters the detergent composition. from .

4. Process according to any preceding claim, characterized in that the detergent composition entering the mold is cooled from and / or through a liquid crystal phase.

5. Process according to any preceding claim, characterized in that the detergent composition is in substantially semi-solid form when it enters the mold.

6. Process according to any preceding claim, wherein the detergent composition is at a temperature between 40 ° and 70 ° when it enters the mold.

7. Process according to any preceding claim, in which the detergent composition is heated while or before feeding to the mold.

8. Process according to any preceding claim, wherein the detergent composition is cooled while, or before, feeding into the mold.

9. Process according to any preceding claim, wherein the detergent composition is mixed with components such as beneficial agent before entering the mold.

10. Process according to claim 9, wherein the mixing is carried out in a screw extruder.

11. Process for forming detergent in bars according to any preceding claim, characterized in that the pressure on the Detergent composition continues to be applied for a period after the model has been filled.

12. Process for forming detergent into bars, according to any preceding claim, characterized in that the mold is heated before the detergent composition enters the mold.

13. Process to form -detergent in bars according to any preceding claim, characterized in that the mold is evacuated before the detergent composition enters the mold.

14. Apparatus for forming detergent into bars, comprising: a) a mold for receiving a detergent composition; b) a reservoir for supplying a detergent composition to the mold; and c) a means for supplying the detergent composition to the mold, the means being capable of supplying the detergent composition at a pressure, at the point of entry into the mold, in excess of 137.8 kPa (20 psi).

15. Apparatus according to claim 14, adapted to carry out the process in a continuous form having a plurality of mold circulating through a feeding station wherein the detergent composition is supplied under pressure to each mold, the detergent composition in each mold subsequently going through the cooling steps and demolding before the molds are recycled again.

16. Apparatus for forming bar detergent, comprising means for applying pressure to a detergent composition, for the purpose of supplying the detergent composition to a mold and a separate medium substantially adapted to feed the detergent composition to the means for applying pressure.

17. Apparatus according to claim 16, characterized in that the feeding means comprise a screw feeder means.

18. Apparatus according to claim 17, wherein the screw feeder comprises two parallel screws with fins forming intermediate meshes.

19. Apparatus according to any of claims 14 to 18, which further comprises a means for adjusting the temperature of the detergent composition.

20. Apparatus according to any of claims 16 to 19, wherein the means for feeding the detergent composition further comprises means for mixing the detergent composition with beneficial agent or other additives.

21. Apparatus according to any one of claims 14 to 20, wherein the detergent composition is fed from the means for applying pressure to the detergent composition to a nozzle whose length is a significant proportion of the length of the internal volume of the mold, the The nozzle and the mold are able to move in relation to one another while the detergent composition is entering the mold.

22. Apparatus according to claim 21, characterized in that the nozzle is grooved.

23. Bar detergent obtainable by the process of any of claims 1 to 13.

24. Bar detergent obtainable by the process of any of claims 1 to 13, which comprises a detergent composition and immiscible components with detergent compositions wherein the immiscible component is present in non-spherical domains.

25. Method for incorporating an additive or beneficial agent into a stick detergent, which comprises adding the additive or benefit agent to a detergent composition which is at least partially structured and which applies pressure to the detergent composition containing the additive or benefit agent so that he will supply it to a mold.