DE69605893T2 - Process for bringing filled packaging together - Google Patents

Description

Field of the invention

The present invention relates to a method for the joint accommodation of filled packages or packs in a secondary packaging.

Background of the invention

A wide variety of primary packaging has been described which are suitable for the packaging of any type of solid, granular or liquid substance, such as detergents. It is a constant major concern of manufacturers to provide packaged products which are convenient to handle and especially to store. Especially during storage, it is usually preferred to further pack the primary packaging in secondary packaging. The secondary packaging has the function of simply protecting the primary packaging from external influences during storage and transport.

More than one filled primary package is usually combined into a packaging arrangement formed by an outer wrap. The outer wrap is usually made of (corrugated) cardboard material. This outer wrap can protect the primary packages against most external influences. In addition, the outer wrap can support the load from the stacked primary packages, thereby avoiding the primary packages bearing the load of the arrangement, if desired. However, the manufacturing costs of such an outer wrap are relatively high. Therefore, packaging manufacturers need to reduce the costs of the packaging required for handling, storing and transporting filled primary packages. Furthermore, packaging manufacturers need to easily pack the primary packages into secondary packages.

Another possibility is to bundle filled primary packages into flexible secondary packages that are unable to support the load of a stacked arrangement of other bundles. However, these flexible secondary packages fit too tightly or too loosely around the filled primary packages. If the flexible secondary package fits too tightly around the filled primary packages, the primary packages can be deformed by the tension force exerted by the tight bundling of the secondary package. The filled primary packages, particularly filled flexible bags, can be deformed in such a way that the primary packages provide a less stable surface for stacking further bundles of primary packages. On the other hand, if the flexible secondary package is bundled too loosely around the filled primary packages contained therein, the primary packages move freely around the secondary package or rotate within it. This uncontrolled movement of the primary packages in of the secondary packaging can result in an external shape of the bundle that can no longer provide a stable surface for stacking further bundles of primary packaging.

A flexible secondary package containing a bundle of primary packages is described in US Patent 4,353,196 which describes a method according to the preamble of appended claim 1, wherein the secondary package has a sealed closure.

It is therefore an object of the invention to provide a method of accommodating filled primary packages in a secondary package which is cost effective, allows for easy packing and which is tight enough to prevent any uncontrolled movement of the primary packages within the secondary package without any deformation of the external shape of the primary package, while at the same time facilitating opening of the secondary package.

Summary of the invention

The present invention is a method for co-accommodating filled packages in a secondary package, the method being the method described in claim 1.

Short description of the drawings

Figure 1 is a perspective view of a portion of the packaging machine showing the method of co-locating filled packages in a secondary package according to the present invention.

Figure 2 illustrates the method for measuring the powder cake strength of a granular or powder detergent.

Detailed description of the invention

Any kind of solid, granular or liquid product is filled into a primary packaging. The primary packaging is a packaging suitable for containing a specific product. Primary packaging can include bottles, cartons or flexible pouches. Preferably, the primary packaging according to the present invention consists of a material selected from the group consisting of: fabric, metal, paper, (corrugated) cardboard material, plastic materials and a combination thereof. As plastic materials, polyolefins such as polyethylene (= PE), or (oriented) polyethylene terephthalate, or (oriented) polypropylene or a combination thereof can be used. If the primary packaging is a bottle, the primary packaging is preferably made of plastic and is manufactured by blow molding and/or injection molding. If the primary packaging is a carton, the carton is made of cardboard and is manufactured by erecting a molded part of the cardboard.

If the primary packaging consists of a multi-layer material, for example a flexible pouch, the intermediate layers may be a perfume barrier layer, a gas barrier layer, an oxygen barrier layer, a moisture barrier layer or a combination thereof. Preferably, the intermediate layer consists of a material selected from the following group, which comprises: aluminum foil, ethyl vinyl alcohol copolymer (EVOH), a lacquer coating and a combination thereof. Possible lacquer coatings are, for example, Flexoplastol® 2KB-Lack 9A 918 920 or Flexoplastol® 2KB-Lack 9A 919 920, commercially available from BASF Lacke + Farben AG, Stuttgart.

The primary packages comprising multilayers can be obtained by laminating or extruding the layers together. The lamination of layers means that different layers are bonded together in a solid state, i.e. the different layers are not fused together as in the extrusion process. In the lamination process, lower temperatures are used with respect to the extrusion. As a preferred option, a tie layer can be used on at least one side of the intermediate layers to strengthen the adhesion between the intermediate layers and the other layers. This tie layer preferably consists of adhesive. A preferred adhesive is a polyurethane-based adhesive. By polyurethane-based adhesives is meant all polyurethane-based adhesives known to those skilled in the art. In particular, solvent-based (including water) and solvent-free adhesive systems are usable for the purpose of the present invention. This tie layer can also be applied to both sides of the intermediate layer and/or the other layers.

Preferably, when the primary packaging is a flexible pouch, the flexible pouch is an upright or free-standing pouch. This flexible upright pouch can be formed in various possible ways. One possibility is a folded pouch. This type of pouch is described, for example, in EP-A-620 156, DE-A-25 20 084, DE-A-39 26 728 and US-3 659 775. These documents further describe the forming and filling processes of these pouches. Another possibility is a pouch with a widened bottom base, as described, for example, in EP-A-0 626 319 and/or EP-A-0 681 970. The same documents also describe the corresponding forming and filling processes of these pouches.

When the primary package is a flexible pouch, the flexible pouch preferably has an air-free portion. This means that the flexible pouch is not completely filled with the substance contained therein and the remaining portion of the volume of the pouch is under a partial or substantially complete vacuum. This vacuum is maintained starting with an unfilled, flat pouch during the filling and sealing operation. The air-free portion is preferably folded to form a nearly flat surface. This nearly flat surface is large enough to support the base of another pouch stacked on top of it. The air-free portion folded to a nearly flat surface is preferably secured with appropriate means. These securing means can, for example, be selected from the group consisting of: bandages, adhesive tapes, straps or tightening bands, plastic film tapes, shrinkable plastic films bands and any combination thereof. These fastening means are placed partially or completely around the pouch, the air-free part being held in a folded, nearly flat surface, thereby preventing unfolding of this nearly flat surface. This folding of the air-free part and the fastening means are further described and explained in EP-A-0 681 970, which is hereby incorporated by reference for further reference.

The primary packaging may contain any type of solid, granular or liquid substance. Preferably, the substance is a detergent. When the substance is a detergent in granular form contained in a flexible sachet, the granular or powder detergent preferably has a powder cake strength of less than or equal to 200 g/cm2. The "powder cake strength" is the force required to de-clump a caked detergent and is measured according to the method described below. "Caking" in the following means that the granular or powder detergent sticks together to form clumps or is clumped together when subjected to a compressive force such as a load from above. The caking may occur such that the detergent clumps into an insoluble block. The "caking" of a detergent may affect the washing properties of the detergent itself.

The so-called "cake strength" is a measure of the caking of a granular or powder detergent. The "cake strength" is defined as the force required to de-clump a caked detergent. This means that the smaller the cake strength value, the less caked the detergent is. For example, a cake strength of 0 g/cm2 means that the detergent is not caked. The cake strength of a granular or powder detergent varies with the composition or manufacturing process of the detergent itself. Therefore, especially when flexible pouches are filled with a granular or powder detergent that is prone to cake formation and the filled flexible pouches must bear a load, such as in a filled flexible pouch arrangement, it is important to ensure that the detergent has a cake strength below a certain value. The powder cake strength of a granular or powder detergent is measured and determined in the following manner.

The apparatus for measuring powder cake strength is shown in Fig. 2 and comprises a cylinder (110), a sleeve (111), a lid (112), a locking pin (114), a weight (115) and a force gauge (not shown). The cylinder further comprises a hole (118) into which the locking pin can be inserted. The cylinder stands on its closed lower surface (119) and the cylinder is filled with detergent through the opposite open upper end (120). First, the locking pin (114) is inserted into the hole (118) and then the sleeve (111) is pushed over the outermost surface of the cylinder until the sleeve sits on the locking pin. This keeps the upper end (121) of the sleeve higher positioned as the upper end (120) of the cylinder. The open volume between the upper end of the cylinder and the upper end of the sleeve has the following dimensions: diameter 6.35 cm and height 3 cm. This volume is filled with a detergent up to the upper end of the sleeve and leveled with the upper end of the sleeve.

The lid (112) is now placed on the sleeve (111). Preferably the lid is made of a very light material but strong enough to bear a load and capable of compressing the detergent. A preferred material is Perspex® (from ICI). The weight (115) is now placed on the lid. The total weight of the lid (112) together with the weight (115) is 5 kg. The lid is further secured to the sleeve to prevent the lid from moving. Securing the lid to the sleeve is achieved by stretching an elastic band around suitable lugs (122) on the lid and the cylinder. After the weight has been placed on the lid, the locking pin is removed from the hole (118). In this way the weight compresses the detergent located between the lid (112) and the top end (120) of the cylinder. The weight is left in place for two minutes. Then the weight is removed from the top of the lid. All elastic bands are also removed.

The sleeve (111) is now gently pushed down towards the closed end (119). Consequently, the detergent located between the cover (112) and the upper end (120) of the cylinder is no longer restricted by any side walls. In principle, this detergent can flow freely from this area. However, the free flow of the detergent located in this area depends on the caking of this detergent during compression by the weight (115). In fact, partial caking of the detergent in this area can hinder the free flow of the detergent. It has been found that by applying a force to the detergent located in this area, the possibly caking detergent de-clumps so that the detergent can flow away freely again. The force required to detect this free flow of the detergent from this area is the powder cake strength according to the present measuring method. The powder cake strength is measured by a force gauge placed on the center of the lid (112). By progressively pressing the force gauge on the lid, an increasing force is applied to the detergent. The force at which the detergent collapses and flows freely from the area between the lid and the open end of the cylinder is considered to be the powder cake strength of the detergent. These measurements of powder cake strength are made at about 20ºC and in the range of 45% to 70% relative humidity.

The detergent composition

The term "detergent composition" herein refers to laundry detergent compositions and machine dishwashing detergent compositions as well as laundry washing additive compositions.

The detergent preferably has a powder cake strength of less than or equal to 200 g/cm². In particular, the powder cake strength of the granular or powder detergent with a density of up to 600 g/l is not more than 200 g/cm². The powder cake strength of granular or powder detergent with a density of more than 600 g/l is preferably up to 100 g/cm², more preferably less than 90 g/cm², even more preferably less than 80 g/cm², more preferably less than 60 g/cm², most preferably less than 50 g/cm². As previously stated, the powder cake strength is the strength required to de-clump a caked detergent.

Anionic surfactants

In the preferred embodiment herein, where the detergent compositions described herein are laundry detergent compositions, the compositions typically contain one or more anionic surfactants as described below.

Alkyl sulfate surfactant

Alkyl sulfate surfactants described herein are water soluble salts or acids of the formula ROSO₃M, wherein R is preferably a C₁₀-C₂₄ hydrocarbon, preferably an alkyl or hydroxyalkyl having a C₁₀-C₂₀ alkyl moiety, more preferably a C₁₂-C₁₈ alkyl or hydroxyalkyl, and M is H or a cation, e.g. B. an alkali metal cation (e.g., sodium, potassium, lithium), or ammonium or substituted ammonium (e.g., methyl, dimethyl, and trimethylammonium cations and quaternary ammonium cations such as tetramethylammonium and dimethylpiperdinium cations and quaternary ammonium cations derived from alkylamines such as ethylamine, diethylamine, triethylamine and mixtures thereof, and the like). Typically, C₁₂₋₁₆ alkyl chains are preferred for lower wash temperatures (e.g., below about 50°C) and C₁₆₋₁₈ alkyl chains are preferred for higher wash temperatures (e.g., above about 50°C).

Alkyl-alkoxylated sulfate surfactant

Alkyl alkoxylated sulfate surfactants described herein are water-soluble salts or acids of the formula RO(A)mSO₃M, wherein R is an unsubstituted C₁₀-C₂₄ alkyl or hydroxyalkyl group having a C₁₀-C₂₄ alkyl moiety, preferably a C₁₂-C₂₀ alkyl or hydroxyalkyl, more preferably a C₁₂-C₁₈ alkyl or hydroxyalkyl, A is an ethoxy or propoxy moiety, m is greater than zero, typically between about 0.5 and about 6, more preferably between about 0.5 and about 5, and MH is or a cation which is, for example, a metal cation (e.g., sodium, potassium, lithium, calcium, magnesium, etc.), ammonium or substituted ammonium cation. Alkyl ethoxylated sulfates as well as alkyl propoxylated sulfates are contemplated herein. Specific examples of substituted ammonium cations include methyl, dimethyl, trimethylammonium and quaternary ammonium cations such as tetramethylammonium, dimethylpiperdinium and cations derived from alkanolamines such as ethylamine, diethylamine, triethylamine, mixtures thereof and the like. Exemplary surfactants are C₁₂-C₁�8-alkyl polyethoxylate(1,0)-sulfates, C₁₂-C₁�8-E(1,0)M), C₁₂-C₁₃-alkyl polyethoxylate(2,25)-sulfate, C₁₂-C₁�8-E(2,25)M), C₁₂-C₁�8-alkyl polyethoxylate(3,0)-sulfate, C₁₂-C₁�8-E(3,0) and C₁₂-C₁₃- Alkyl polyethoxylate (4,0) sulfate, C₁₂-C₁₈-E(4,0)M), wherein M is suitably selected from sodium and potassium.

Other anionic surfactants

Other anionic surfactants useful for cleaning purposes may also be included in the laundry detergent compositions with or without the species described above. These may be salts (including, for example, sodium, potassium, ammonium and substituted ammonium salts such as mono-, di- and triethanolamine salts) of soap, linear C9-C20 alkylbenzene sulfonates, primary or secondary C8-C22 alkane sulfonates, C8-C24 olefin sulfonates, sulfonated polycarboxylic acids prepared by sulfonation of the pyrolyzed product of alkaline earth metal citrates, e.g. B. as described in British Patent Specification No. 1 082 179, C8-C24 alkyl polyglycol ether sulfates (containing up to 10 moles of ethylene oxide); alkyl ester sulfonates, such as C14-C16 methyl ester sulfonates; Acylglycerol sulfonates, fatty oleylglycerol sulfates, alkylphenol ethylene oxide ether sulfates, paraffin sulfonates, alkyl phosphates, isethionates such as the acylisethionates, N-acyl taurates, alkyl succinamates and sulfosuccinamates, monoesters of sulfosuccinamate (particularly saturated and unsaturated C₁₂₋₁₈ monoesters), diesters of sulfosuccinate (particularly saturated and unsaturated C₆-C₁₄ diesters), acyl sarcosinates, sulfates of alkyl polysaccharides such as the sulfates of alkyl polyglucoside (the nonionic non-sulfated compounds being described below), branched primary alkyl sulfates, alkyl polyethoxycarboxylates such as those of the formula RO(CH₂CH₂O)kCH₂COO-M⁺, where R is C₈-C₂₂ alkyl, k is an integer from 0 to 10 and M is a soluble salt-forming cation. Resin acids and hydrogenated resin acids are also useful, such as rosin, hydrogenated rosin, and resin acids and hydrogenated resin acids present in or derived from tallow oil. Further examples are given in "Surface Active Agents and Detergents" (Volumes I and II by Schwartz, Perry and Berch). A variety of such surfactants are also generally described in US Patent 3,929,678, issued Dec. 30, 1975 to Laughlin et al., at column 23, line 58, through column 29, line 23 (incorporated herein by reference).

Preferred surfactants for use in the compositions described herein are the alkyl sulfates, alkyl alkoxylated sulfates, and mixtures thereof.

When included therein, the laundry detergent compositions typically comprise from about 1% to about 40%, preferably from about 3% to about 20%, by weight of such anionic surfactants.

Non-ionic surfactants

The present laundry detergent compositions also preferably comprise a nonionic surfactant.

While any nonionic surfactant can normally be used, two families of nonionic substances have been found to be particularly useful. These are nonionic surfactants based on alkoxylated (especially ethoxylated) alcohols, and those nonionic surfactants based on amidation products of fatty acid esters and N-alkylpolyhydroxyamine. The amidation products of the esters and the amines are generally referred to herein as polyhydroxy fatty acid amides. Particularly useful are mixtures comprising two or more nonionic surfactants wherein at least one nonionic surfactant is selected from each of the groups of alkoxylated alcohols and the polyhydroxy fatty acid amides.

Suitable nonionic surfactants include compounds prepared by the condensation of alkylene oxide groups (hydrophilic in nature) with an organic hydrophobic compound, which may be aliphatic or alkyl aromatic in nature. The length of the polyoxyalkylene group condensed with a specific hydrophobic group can be readily adjusted to give a water-soluble compound with the desired degree of balance between hydrophilic and hydrophobic elements.

Particularly preferred are nonionic surfactants such as the polyethylene oxide condensates of alkylphenols, e.g. the condensation products of alkylphenols with an alkyl group having about 6 to 16 carbon atoms in either straight chain or branched chain configuration, with about 4 to 25 moles of ethylene oxide per mole of alkylphenol.

Preferred nonionics are the water-soluble condensation products of aliphatic alcohols having 8 to 22 carbon atoms in either straight-chain or branched-chain configuration, with an average of up to 25 moles of ethylene oxide per mole of alcohol. Especially preferred are the condensation products of alcohols having an alkyl group having about 9 to 15 carbon atoms with about 2 to 10 moles of ethylene oxide per mole of alcohol; and condensation products of propylene glycol with ethylene oxide. Most preferred are condensation products of alcohols having an alkyl group having about 12 to 15 carbon atoms with an average of about 3 to 7 moles of ethylene oxide per mole of alcohol, preferably 3 to 5.

The nonionic surfactant system herein may also include a polyhydroxy fatty acid amide component.

Polyhydroxy fatty acid amides can be prepared by reacting a fatty acid ester and an N-alkyl polyhydroxyamine. The preferred amine for use in the present invention is N-(R1)-CH2(CH2OH)4-CH2-OH and the preferred ester is a C12-C20 fatty acid methyl ester. Most preferred is the reaction product of N-methylglucamine with C12-C20 fatty acid methyl ester.

Processes for the preparation of polyhydroxy fatty acid amides have been described in WO 92 6073, published on April 16, 1992. This application describes the preparation of polyhydroxy fatty acid amides in the presence of solvents. In a highly preferred embodiment of the invention, N-methylglucamine is reacted with a C12-C20 methyl ester. This also states that the formulator of the granular detergent compositions may find it convenient to carry out the amidation reaction in the presence of solvents comprising alkoxylated, particularly ethoxylated (EO 3-8) C12-C14 alcohols (page 15, lines 22-27). This directly provides nonionic surfactant systems preferred in the present invention, such as those comprising N-methylglucamide and C12-C14 alcohols having an average of 3 ethoxylate groups per molecule.

Nonionic surfactant systems and granular detergents prepared from such systems have been described in WO 92 6160, published April 16, 1992. This application describes (Example 15) a granular detergent composition prepared by fine dispersion mixing in an Eirich RV02 mixer comprising N-methylglucamide (10%) and nonionic surfactant (10%).

Both of these applications describe nonionic surfactant systems together with suitable manufacturing processes for their synthesis which were considered suitable.

The polyhydroxy fatty acid amide may be present in the compositions of the present invention in a proportion of from 0 to 50% by weight of the detergent component or composition, preferably from 5 to 40% by weight, more preferably from 10 to 30% by weight.

Also useful as the nonionic surfactant of the surfactant systems of the present invention are the alkyl polysaccharides described in U.S. Patent 4,565,647, Llenado, issued Jan. 21, 1986, having a hydrophobic group containing from about 6 to about 30 carbon atoms, preferably from about 10 to about 16 carbon atoms, and a polysaccharide, e.g., polyglycoside, a hydrophilic group containing from about 1.3 to about 10, preferably from about 1.3 to about 3, most preferably from about 1.3 to about 2.7, saccharide units. Any reducing saccharide containing 5 or 6 carbon atoms can be used, e.g., 1,2,3,4,5,6,6,7, saccharide units. B. Glucose, galactose and galactosyl units can be substituted for the glucosyl units (optionally the hydrophobic group is attached at the 2-, 3-, 4-, etc. position, thus obtaining a glucose or galactose as opposed to a glucoside or galactoside). The intersaccharide bonds can be located e.g. between the 1-position of the additional saccharide units and the 2-, 3-, 4- and/or 6-positions on the preceding saccharide units.

The preferred alkyl polyglycosides have the formula

R²O(CnH2nO)t(glycosyl)x

wherein R2 is selected from the group consisting of alkyl, alkylphenyl, hydroxyalkyl, hydroxyalkylphenyl and mixtures thereof in which the alkyl groups contain from about 10 to about 18, preferably from about 12 to about 14, carbon atoms; n is 2 or 3, preferably 2; t is 0 to about 10, preferably from about 1.3 to about 3, most preferably from about 1.3 to about 2.7. The glycosyl is preferably derived from glucose. To prepare these compounds, the alcohol or alkylpolyethoxy alcohol is first formed and then reacted with glucose or a source of glucose to form the glucoside (attachment to the 1-position). The additional glycosyl units can then be linked between their 1-position and the preceding glycosyl units to the 2-, 3-, 4- and/or 6-position, preferably predominantly to the 2-position.

Other surfactants

The laundry detergent compositions may also contain cationic, ampholytic, zwitterionic and semipolar surfactants as well as nonionic surfactants other than those already described herein, including the semipolar nonionic amine oxides described below.

Cationic detergent surfactants suitable for use in the laundry detergent compositions are those having a long chain hydrocarbon group. Examples of such cationic surfactants include the ammonium surfactants such as alkyldi- or trimethylammonium compounds and the surfactants of the formula:

[R²(OR³)y][R⁴(OR³)y]₂R⁵N+X-

wherein R2 is an alkyl or alkylbenzyl group having from about 8 to about 18 carbon atoms in the alkyl chain, each R3 is selected from the group consisting of -CH2CH2-, -CH2CH(CH3)-, -CH2CH(CH2OH)-, -CH2CH2-CH2-, and mixtures thereof; each R4 is selected from the group consisting of C1-C4 alkyl, C1-C4 hydroxyalkyl, benzyl ring structures formed by joining the two R4 groups, -CH2COH- COHCOR6CHOHCH2OH, wherein R6 is is any hexose or hexose polymer having a molecular weight of less than about 1000, and hydrogen when y is not 0; R5 is the same as R4 or is an alkyl chain wherein the total number of carbon atoms of R2 plus R5 is not more than about 18; each y is 0 to about 10 and the sum of the y values is 0 to about 15; and x is any compatible anion.

Other cationic surfactants useful herein are also described in U.S. Patent 4,228,044, Cambre, issued Oct. 14, 1980.

When included therein, the laundry detergent compositions of the present invention typically comprise from 0 to about 25%, preferably from about 3 to about 15%, by weight of such cationic surfactants.

Ampholytic surfactants are also suitable for use in the laundry detergent compositions of the present invention. These surfactants can be broadly described as aliphatic derivatives of secondary or tertiary amines, or aliphatic derivatives of heterocyclic secondary and tertiary amines, in which the aliphatic moiety can be straight chain or branched chain. One of the aliphatic substituents contains at least 8 carbon atoms, typically from about 8 to about 18 carbon atoms, and at least one contains an anionic water-solubilizing group, e.g., carboxy, sulfonate, sulfate; See U.S. Patent No. 3,929,678 to Laughlin et al., issued Dec. 30, 1975, column 19, lines 18-35 (incorporated herein by reference) for examples of ampholytic surfactants.

When included therein, the laundry detergent compositions typically comprise from 0 to about 15%, preferably from about 1 to about 10%, by weight of such ampholytic surfactants.

Zwitterionic surfactants are also suitable for use in laundry detergent compositions. These surfactants can be broadly described as derivatives of secondary and tertiary amines, derivatives of heterocyclic secondary and tertiary amines, or derivatives of quaternary ammonium, quaternary phosphonium, or tertiary sulfonium compounds; see U.S. Patent No. 3,929,678 to Laughlin et al., issued Dec. 30, 1975, Columns 19, line 38, to column 22, line 48 (incorporated herein by reference) for examples of zwitterionic surfactants.

When included therein, the laundry detergent compositions typically comprise from 0 to about 15%, preferably from about 1 to about 10%, by weight of such zwitterionic surfactants.

Semi-polar nonionic surfactants are a special category of nonionic surfactants that include water-soluble amine oxides containing an alkyl moiety having from about 10 to about 18 carbon atoms and 2 moieties selected from the group consisting of alkyl groups and hydroxyalkyl groups having from about 1 to about 3 carbon atoms; water-soluble phosphine oxides containing an alkyl moiety having from about 10 to about 18 carbon atoms and 2 moieties selected from the group consisting of alkyl groups and hydroxyalkyl groups having from about 1 to about 3 carbon atoms.

Semipolar nonionic detergent surfactants include the amine oxide surfactants of the formula:

a.

Builders

The laundry detergent compositions and automatic dishwashing detergent compositions herein contain a builder, preferably non-phosphate detergent builders, although phosphate-containing species are not excluded. These may include, but are not limited to, alkali metal carbonates, bicarbonates, silicates, aluminosilicates, carboxylates, and mixtures of any of the foregoing. The builder system is present in an amount of from 1 to 80% by weight of the composition, usually preferably from 20 to 60% by weight in granular laundry detergent compositions herein, and from 1 to 30% in liquid laundry detergent compositions herein.

Suitable silicates are those with a SiO₂:Na₂O ratio in the range of 1.6 to 3.4, with the so-called amorphous silicates with SiO₂:Na₂O ratios of 2.0 to 2.8 being preferred.

Within the silicate class, highly preferred materials are the crystalline sodium layered silicates of the general formula

NaMSixO2x + 1yH₂O

wherein M is sodium or hydrogen, x is a number from 1.9 to 4 and y is a number from 0 to 20. Crystalline layered sodium silicates of this type are described in EP-A-0 164 514 and processes for their preparation are described in DE-A-34 17 649 and DE-A-37 42 043. For the purposes of the present examples, x in the above general formula has a value of 2, 3 or 4 and is preferably 2. More preferably M is sodium and y is 0 and a preferred example of this formula comprises the form Na₂Si₂O₅. These materials are available from Hoechst AG FRG as NaSKS-5, NaSKS-7, NaSKS-11 and NaSKS-6 respectively. The most preferred material is -Na₂Si₂O₅, NaSKS-6. Crystalline layered silicates are available either as dry ne mixed solids or as solid components of agglomerates with other components enclosed therein.

While a range of aluminosilicate ion exchange materials can be used, preferred sodium aluminosilicate zeolites have the unit cell formula

Naz[(AlO2 )z(SiO2 )y]xH2 O

wherein z and y are at least about 6, the molar ratio of z to y is about 1.0 to about 0.4, and z is about 10 to about 264. Amorphous hydrated aluminosilicate materials useful herein have the empirical formula

Mz(zAlO₂ySiO₂)

wherein M is sodium, potassium, ammonium or substituted ammonium, z is about 0.5 to about 2 and y is 1, the material having a magnesium ion exchange capacity of at least about 50 mg equivalents of CaCO3 hardness per gram of anhydrous aluminosilicate. Hydrated sodium zeolite A having a particle size of about 0.01 to 10 microns is preferred.

The aluminosilicate ion exchange builder materials herein are in hydrated form and contain from about 10 to about 28 weight percent water when crystalline and possibly even higher amounts of water when amorphous. Highly preferred crystalline aluminosilicate ion exchange materials contain from about 18% to about 22% water in their crystal matrix. The crystalline aluminosilicate ion exchange materials are further characterized by a particle size diameter of from about 0.1 µm to about 10 µm. Amorphous materials are often smaller, e.g., down to less than about 0.01 µm. Preferred ion exchange materials have a particle size diameter of from about 0.2 µm to about 4 µm. The term "particle size diameter" herein means the average particle size diameter on a weight basis of a particular ion exchange material as determined by conventional analytical techniques such as microscopic determination using a scanning electron microscope.

Aluminosilicate ion exchange materials useful in the practice of the invention are commercially available. The aluminosilicates useful in the present invention may have a crystalline or amorphous structure and may be naturally occurring aluminosilicates or synthetically derived. A process for preparing aluminosilicate ion exchange materials is set forth in U.S. Patent No. 3,985,669, Krummel et al., issued Oct. 12, 1976. Preferred synthetic crystalline aluminosilicate ion exchange materials useful herein are available under the designations zeolite A, zeolite X, P, and MAP, the latter species being described in EP-A-384,070. In a particularly preferred embodiment, the crystalline aluminosilicate ion exchange material is a zeolite A of the formula:

Na 12 [(AlO 2 ) 12 (SiO 2 ) 12 ]xH 2 O

wherein x is from about 20 to about 30, especially about 27, and has a particle size of generally less than about 5 µm.

Suitable carboxylate builders containing one carboxy group include lactic acid, glycolic acid and ether derivatives thereof as described in Belgian Patent Nos. 831,368, 821,369 and 821,370. Polycarboxylates containing two carboxy groups include the water-soluble salts of succinic acid, malonic (ethylenedioxy)diacetic acid, maleic acid, diglycolic acid, tartaric acid, tartronic acid and fumaric acid, as well as the ether carboxylates described in German Offenlegungsschrift 2,446,686 and 2,446,687 and U.S. Patent No. 3,935,257 and the sulfinyl carboxylates described in Belgian Patent No. 840,623. Polycarboxylates containing three carboxy groups include in particular water-soluble citrates, aconitrates and citraconates, as well as succinate derivatives such as the carboxymethyloxysuccinates described in British Patent No. 1,379,241, lactoxysuccinates described in Dutch Application 7205873 and the oxypolycarboxylate materials such as 2-oxa-1,1,3-propanetricarboxylates described in British Patent No. 1,387,447.

Polycarboxylates containing four carboxy groups include oxydisuccinates described in British Patent No. 1,261,829.1 and the 1,2,2-ethanetetracarboxylates, 1,1,3,3-propanetetracarboxylates and 1,1,2,3-propanetetracarboxylates. Polycarboxylates containing sulfo substituents include the sulfosuccinate derivatives described in British Patent Nos. 1,398,421 and 1,398,422 and in U.S. Patent No. 3,936,448 and the sulfonated pyrolyzed citrates described in British Patent No. 1,082,179, while polycarboxylates containing phosphonic substituents are described in British Patent No. 1,439,000.

Alicyclic and heterocyclic polycarboxylates include cyclopentane cis,cis,cis-tetracarboxylates, cyclopentadienide pentacarboxylates, 2,3,4,5-tetrahydrofuran cis,cis,cis-tetracarboxylates, 2,5-tetrahydrofuran cis-dicarboxylates, 2,2,5,5-tetrahydrofuran tetracarboxylates, 1,2,3,4,5,6-hexane hexacarboxylates and carboxymethyl derivatives of polyhydric alcohols such as sorbitol, mannitol and xylitol. Aromatic polycarboxylates include mellitic acid, pyromellitic acid and the phthalic acid derivatives described in British Patent No. 1,425,343.

Chelating agents

The detergent compositions herein may also optionally contain one or more iron and/or manganese chelating agents. Such chelating agents may be selected from the group consisting of aminocarboxylates, aminophosphonates, polyfunctionally substituted aromatic chelating agents, and mixtures thereof, all as defined below. Without wishing to be bound by theory, it is believed that the benefit of these materials is due in part to their exceptional ability to remove iron and manganese ions from washing solutions by forming soluble chelates.

Aminocarboxylates useful as optional chelating agents include ethylenediaminetetraacetates, N-hydroxyethylethylenediaminetriacetates, nitrilotriacetates, ethylenediaminetetrapropionates, triethylenetetraaminehexacetates, diethylenetriaminepentaacetates and ethanoldiglycines, alkali metal, ammonium and substituted ammonium salts therein and mixtures therein.

Aminophosphonates are also suitable for use as chelating agents in the compositions of the invention when at least low levels of total phosphorus are permitted in detergent compositions and include ethylenediaminetetrakis (methylenephosphonates) as DEQUEST. Preferably, these aminophosphonates do not contain alkyl or alkenyl groups having more than about 6 carbon atoms.

Polyfunctionally substituted aromatic chelating agents are also useful in the compositions herein; see U.S. Patent 3,812,044, issued May 21, 1974 to Connor et al. Preferred compounds of this type in acid form are dihydroxydisulfobenzenes such as 1,2-dihydroxy-3,5-disulfobenzene.

A preferred biodegradable chelating agent for use herein is ethylenediamine disuccinate ("EDDS"), particularly the [S,S] isomer as described in U.S. Patent 4,704,233, Nov. 3, 1987, to Hartman and Perkins.

If used, these chelating agents generally comprise from about 0.1 to about 10% by weight of the detergent compositions herein. More preferably, the chelating agents, if used, comprise from about 0.1 to about 3.0% by weight of such compositions.

Of the above, the preferred polycarboxylates are hydroxycarboxylates containing up to three carboxy groups per molecule, particularly citrates.

The granular detergent compositions and machine dishwashing detergent compositions herein have a pH above 8.5, preferably in the range of 9 to 11.

The present granular laundry detergent compositions are preferably in a compact form, having a bulk density of at least 650 g/l, preferably at least 750 g/l, but may also be in a conventional form with densities in the range of 200 g/l to 700 g/l.

In another embodiment, dishwashing detergent compositions for machine dishwashing are provided:

Dishwashing detergent compositions for automatic dishwashing typically contain, in addition to percarbonate, a builder as described above, a source of alkalinity such as silicate or carbonate, these ingredients constituting up to 70% of the formulation. Optional ingredients include polymers and enzymes.

In yet another embodiment, additive laundry detergent compositions are provided: these compositions typically contain the bleach in amounts of 15 to 80% by weight.

Optional components

Other ingredients known for use in detergent compositions may also be used as optional ingredients in the various embodiments of the present invention, such as bleach activators, bleach catalysts, other bleaching agents, polymers, enzymes, foam suppressors, fabric softening agents, in particular textile softening clay, as well as dyes, fillers, optical brighteners, pH adjusters, non-builder alkalinity sources, enzyme stabilizing agents, hydrotropes, solvents, perfumes.

The percarbonate particles

The compositions described herein contain from 1 to 40% by weight, preferably from 3 to 30% by weight, most preferably from 5 to 25% by weight of an alkali metal percarbonate bleach, in the form of particles having an average particle size of from 250 to 900 micrometers, preferably from 500 to 700 micrometers.

When the compositions herein are laundry additives, the proportion of percarbonate is 20 to 80% by weight.

The alkali metal bleach is usually in the form of the sodium salt. Sodium percarbonate is an addition compound of the formula corresponding to 2Na₂CO₃ · 3H₂O₂. To improve storage stability, the percarbonate bleach may be coated with another mixed salt of an alkali metal sulfate and carbonate. Such coatings together with coating processes have already been described in GB-1 466 799, issued to Interox on 9 March 1977. The weight ratio of the mixed salt coating material to percarbonate is in the range of 1:2000 to 1:4, more preferably 1:99 to 1:9, and most preferably 1:49 to 1:19. Preferably, the mixed salt consists of sodium sulfate and sodium carbonate, having the general formula 2Na₂SO₄.n.Na₂CO₃, where n is 0.1 to 3, preferably 0.3 to 1.0, and most preferably 0.2 to 0.5.

Other suitable coating materials are sodium silicate, with a SiO2:Na2O ratio of 1.6:1 to 2.8:1, and magnesium silicate.

Commercially available carbonate/sulfate coated percarbonate bleach may include a low level of heavy metal sequestrant such as EDTA, 1-hydroxyethylidene, 1,1- diphosphonic acid (HEDP) or an aminophosphonate which is incorporated during the manufacturing process.

Bleach activators

The present compositions, particularly the granular laundry detergent compositions and laundry additives described above, preferably contain from 1 to 20% by weight of the composition, preferably from 2 to 15%, most preferably from 3 to 10% by weight of a peroxyacid bleach activator, in addition to the percarbonate bleach described above.

Peroxyacid bleach activators (bleach precursors) as additional bleaching components can be selected from a wide range class and are preferably those containing one or more N- or O-acyl groups.

Suitable classes include anhydrides, esters, amides and acylated derivatives of imidazoles and oximes and examples of useful materials within these classes are described in GB-A-1586789. The most preferred classes are esters as described in GB-A-836 988, 864 798, 1 147 871 and 2 143 231 and amides as described in GB-A-855 735 and 1 246 338.

Particularly preferred bleach activator compounds as additional bleach components are the N,N,N'N'-tetra-acetylated compounds of the formula

where x can be 0 or an integer between 1 and 6.

Examples include tetraacetylmethylenediamine (TAMD) in which x = 1, tetraacetylethylenediamine (TAED) in which x = 2, and tetraacetylhexylenediamine (TAHD) in which x = 6. These and analogous compounds are described in GB-A-907 356. The most preferred peroxyacid bleach activator as an additional bleach component is TAED.

Another preferred class of peroxyacid bleaching compounds are the amide substituted compounds of the following general formulas:

or

wherein R¹ is an aryl or alkaryl group having from about 1 to about 14 carbon atoms, R² is an alkylene, arylene and alkarylene group having from about 1 to about 14 carbon atoms, and R⁵ is H or an alkyl, aryl or alkaryl group having from 1 to 10 carbon atoms and L is essentially any leaving group. R¹ preferably contains from about 6 to 12 carbon atoms. R² preferably contains from about 4 to 8 carbon atoms. R¹ can be a straight chain or branched chain alkyl, substituted aryl or alkylaryl having branching, substitution or both and can be derived from either synthetic sources or natural sources including, for example, tallow fat. Analogous structural variations are permissible for R². The substitution may include alkyl, aryl, halogen, nitrogen, sulfur and other typical substituent groups or organic compounds. R⁵ is preferably H or methyl. R¹ and R⁵ should not contain more than 18 carbon atoms in total. Amide-substituted bleach activator compounds of this type are described in EP-A-0 170 386.

Another class of bleach activators used in combination with percarbonate includes C8, C9 and/or C10 (6-octanamidocaproyl)oxybenzenesulfonate, 2-phenyl-(4H)3,1-benzoxazin-4-one, benzoyllactam, preferably benzoylcaprolactam and nonanoyllactam, preferably nonanoylcaprolactam.

Bleach

The granular laundry detergent, automatic dishwashing detergent compositions or laundry additives herein may contain an additional bleaching agent, in addition to the percarbonate.

The additional bleaching agent, if used, is either an inorganic persalt, such as perborate, persulfate, or a preformed organic peracid or perimidic acid, such as N,N-phthaloylaminoperoxycaproic acid, 2-carboxyphthaloylaminoperoxycaproic acid, N,N- phthaloylaminoperoxyvaleric acid, nonylamide of peroxyadipic acid, 1,12-diperoxydodecano- (doic) acid, peroxybenzoic acid and ring-substituted peroxybenzoic acid, monoperoxyphthalic acid (magnesium salt, hexhydrate), diperoxybrassylic acid.

Polymers

Also useful are various organic polymers, some of which can act as builders to improve detergency. Such polymers may include sodium carboxy-lower alkyl celluloses, sodium lower alkyl celluloses and sodium hydroxy-lower alkyl celluloses such as sodium carboxymethyl cellulose, sodium methyl cellulose and sodium hydroxypropyl cellulose, polyvinyl alcohols (often also including some polyvinyl acetate), polyacrylamides, polyacrylates and various copolymers such as those of maleic and acrylic acids. Molecular weights for such polymers vary over a wide range but are usually within the range of 2,000 to 100,000. Also useful are terpolymers of maleic/acrylic acid and vinyl alcohol having a molecular weight in the range of 3,000 to 70,000.

Polymeric polycarboxylate builders are set forth in U.S. Patent 3,308,067, Diehl, issued March 7, 1967. Such materials include the water-soluble salts of homo- and copolymers of aliphatic carboxylic acids such as maleic acid, itaconic acid, mesaconic acid, fumaric acid, aconitic acid, citraconic acid, and methylenemalonic acid.

Polyaspartate and polyglutamate dispersants may be used, especially with zeolite builders. Dispersants such as polyaspartate preferably have a molecular weight of about 10,000.

Other useful polymers include species known as soil release polymers as described in EP-A-185 427 and EP-A-311 342.

Still other polymers suitable for use herein include dye transfer inhibiting polymers such as polyvinylpyrrolidone, polyvinylpyrridine, N-oxide-N-vinylpyrrolidone, N-imidazole-polyvinyloxozolidone, or polyvinylimidazole.

Enzymes

Enzymatic materials may be included in the detergent compositions herein. Suitable are proteases, lipases, cellulases, peroxidases, amylases and mixtures thereof.

A suitable lipase enzyme is manufactured and sold by Novo Industries A/S (Denmark) under the trade name Lipolase and is mentioned together with other suitable lipases in EP-A-0258068 (Novo Nordisk).

Suitable cellulases are described, for example, in WO-91/17243 and WO-91/17244 (Nordisk).

Preferred commercially available protease enzymes include those sold under the trade names Alcalase and Savinase by Novo Industries A/S (Denmark) and Maxatase by International Bio-Synthetics, Inc. (Netherlands).

Other proteases include protease A (see European patent application 130 756, published Jan 9, 1985) and protease B (see European patent application serial no. 87303761.8, granted April 28, 1987, and European patent application 130 756, Bolt et al., published Jan 9, 1985).

Peroxidase enzymes are used in combination with oxygen sources, e.g. percarbonate, perborate, persulfate, hydrogen peroxide, etc. They are used for "solution bleaching", i.e. to prevent the transfer of dyes or pigments removed during washing operations to other substrates in the wash solution. Peroxidase enzymes are known in the art and include, for example, horseradish peroxidase, ligninase and haloperoxidase, such as chloro- and bromoperoxidase. Peroxidase-containing detergent compositions are described, for example, in International PCT Application WO-89/099813 and in WO-91/05839.

Amylases include, for example, bacterial amylases obtained from a special strain of B. licheniforms, described in more detail in GB-1 296 839 (Novo). Preferred commercially available amylases include, for example, Rapidase, sold by International Bio-Synthetics Inc., and Termamyl, sold by Novo Nordisk A/S.

Fungal amylases, such as Fungamyl® amylase, marketed by Novo Nordisk, can also be used.

Preferred method for preparing the laundry detergent composition herein

In a preferred method of preparing the laundry detergent compositions, particularly when a high bulk density is desired, part or all of the surfactant contained in the final composition is introduced in the form of discrete particles; the particles may take the form of flakes, prilled granules, "marumes", noodles, ribbons, but are preferably in the form of granules. The most preferred way of processing the particles is by agglomerating powders (such as aluminosilicate, carbonate) with highly active surfactant pastes and controlling the particle size of the resulting agglomerates within certain limits. Such a process involves mixing an effective amount of powder with a highly active surfactant paste in one or more agglomerators, such as a pan agglomerator, a Z-blade mixer, or more preferably an in-line mixer such as those available from Schugi (Holland) BV, 29 Chroomstraat 8211, AS, Lelystad, the Netherlands, and Gebrüder Lodige Maschinenbau GmbH, D-4790 Paderborn 1, Elsenerstrasse 7-9, Postfach 2050, Germany. The most preferred mixer is a high shear mixer, such as a Lodige CB (trade name).

A high activity surfactant paste comprising 50 to 95%, preferably 70 to 85% by weight surfactant is used. The surfactant system may comprise any of the groups of anionic, nonionic, cationic, amphoteric and zwitterionic surfactants or mixtures thereof. The paste may be pumped into the agglomerator at a temperature high enough to maintain a pumpable viscosity but low enough to prevent decomposition of the anionic surfactants used. An operating temperature of the paste of 50°C to 80°C is typical.

A particularly suitable process for the preparation of surfactant particles from highly active surfactant pastes is described in more detail in EP-510 746, published on 28 October 1992.

The free-flowing surfactant particles produced by the process described above are then mixed with other detergent components, such as the alkali metal percarbonate-containing particles, to produce a finished detergent composition.

This mixing can be done in any suitable equipment. Liquid detergents, such as non-ionic surfactant and perfume, can be sprayed onto the surface of one or more of the granule components or onto the finished composition.

Secondary packaging

According to the present invention, more than one filled primary package is combined in a secondary package. A secondary package containing a group of filled primary packages is hereinafter referred to as a shipping unit. Preferably, the shipping unit has a rectangular shape. In this way, the shipping unit is suitable for being stacked with other similar shipping units for storage and transport. A complete assembly or pallet stack is obtained by stacking several of these shipping units. The secondary package may preferably consist of a wrapped film. Preferably, the wrapped film may consist of polyethylene or paper-based films. A paper-based film is preferably a film consisting of a layer of plastic film laminated to a paper layer. More preferably, the polyethylene films have a thickness in the range of about 20 µm to 200 µm, more preferably in the range of about 50 µm to 100 µm. The paper-based films preferably have a weight in the range of about 50 g/m² to 200 g/m². For example, a paper-based film consists of a layer of polyethylene with a thickness of 50 µm and a paper layer with a weight of 80 g/m².

The packaging method for filled primary packages (15) into the secondary package according to the present invention is realized with a conventional vertical packaging machine, the so-called vertical form-fill-seal (= VFFS). A partial perspective view of such a packaging machine is shown in Fig. 1. These vertical packaging machines include, among other things, at least one forming projection or shoulder (10) The process for producing the secondary packaging with the VFFS is a continuous batch process. The film (1) is fed into the VFFS machine in a flat configuration. This film is fed to the forming projection (10), which is also the filling head (11). The film is pulled around the forming projection (10), which extends in a vertical tube.

By pulling the plastic film around the forming projection, the plastic film is formed into a tubular configuration with overlapping vertical edges (2). "Vertical" in the sense that these edges are parallel to the filling direction of the VFFS machine. In order to maintain the tubular configuration of the plastic film, the overlapping vertical edges (2) of the film are partially sealed together with the longitudinal seal (12). According to the invention, the vertical edges are only partially sealed together, i.e. the seal is interrupted at least in one area along the vertical edges (2). The interruption of the seal allows free access to the interior of the secondary package. The dimension of this interrupted seal is such that a user can insert at least one finger into the interrupted area, but not large enough to allow the exit of filled primary packages. Preferably, the interrupted area is sized to allow the insertion of a hand. Allowing the user to insert at least one finger or hand into the interrupted area facilitates opening of the secondary packaging by pulling the partial seal along the vertical edges (2). Preferably, more than one interrupted area is obtained with the partial seal along the vertical edges (2). For example, if the vertical edge (2) is 80 cm long, a 2 cm long seal is interrupted at 11 cm before the next 2 cm seal. This is repeated along the vertical edge up to 80 cm. The same can be done with a vertical edge (2) that is 50 cm long.

The film in tube form is further sealed on the opposite end of the filling head to form a bottom seal (3) with the cross seal inside the external clamps (14). The bag thus formed is a secondary package (20) according to the present invention with an open end towards the filling head of the forming projection. This secondary package can now be filled with several filled primary packages through the filling head and the open end.

The filled primary packages (15) are dropped by the filling head (11) into the secondary package (20) through the open end of the secondary package. The filled primary packages pile up from the bottom seal (3) of the secondary package. Preferably, the filled primary packages are dropped into the secondary package in such a way that the filled primary packages do not rotate in the secondary package during the fall within this secondary bag. This is particularly important when the shape of the filled packages allows a minimum package gap in a particular direction and not in another direction which might force the secondary package to have an increased packaging capacity. ing space. Indeed, for example, for rectangular filled primary packages, the length of the secondary package can be reduced by lining the filled primary packages along the width rather than the length or height of the primary packages. This is preferably achieved by tailoring the dimension of the secondary package to the dimensions of the filled primary packages. As an example, the secondary package has a rectangular shape and the following dimensions: length about 38 cm, width about 14.5 cm, and height about 14.5 cm. Accordingly, four flexible pouches with dimensions of about 9.2 cm long, 14.5 cm wide, and 14.0 cm high can be packed into this secondary package as described above.

Preferably, the filled primary packages that should go into a secondary package are assembled first. The assembly of the filled primary packages is also accomplished without the use of a securing device, such as wrapping with a tape, for example. Therefore, the assembled, filled primary packages are dropped into the secondary package as a whole assembled bundle. It has been found that this assembly of the filled primary packages further ensures that the filled bags do not rotate 180 degrees or in any other direction during the drop into the secondary package.

Preferably, the external clamps (14) of the VFFS hold the secondary package around the bottom seal during filling of the secondary package. The external clamps are typically used to clamp the film while sealing and/or cutting the film. Indeed, the film is typically secured between the two halves of the external clamps prior to sealing and/or cutting. In this case, the film around the bottom seal is initially secured between the two halves of the external clamp during filling with the filled primary packages to support the placement of the filled primary packages in the secondary package. This avoids the film of the secondary package being stretched to the point of tearing during placement and stacking of the filled primary packages. It has been found that the total weight that can be dropped in this way through the filling head into the secondary packaging without any risk to the external clamps can be up to 25 kg. However, the VFFS can be equipped with an additional support device to support the placement of the filled primary packaging, which can bear a higher load.

After the secondary packaging is filled with several filled primary packages and the bottom seal (3) has been sufficiently cooled, the outer clamps (14) are opened and the secondary packaging with the filled primary packages is advanced to a holding device (16). The holding device holds the secondary packaging, which is filled with the primary packages during the advancement of the secondary packaging, until all filled primary packages contained in the secondary packaging are located under the transverse seal. This holding system is located below the outer clamps (14) and the secondary packaging with the filled primary packages is advanced to a holding device (16). external clamps (14). Preferably, the holding means consists of a plane which is movable in a direction parallel to the filling of the secondary package with the primary packages. The filled secondary package held by the holding means reduces the tension on the film of the secondary package, which reduces the possibility of tearing of this film. The holding means further assist in adjusting the height of the top seal on the secondary package with respect to the height of the filled primary packages within the secondary package. Consequently, the holding means ensures that the top seal tightly closes the top of the secondary package around the filled bags. Preferably, the holding system is further capable of lifting the secondary package filled with the primary packages towards the transverse seal to correct the position of the top seal on the secondary package.

Consequently, the filled primary packages are wrapped in a substantially tight manner within the secondary package, so that the primary packages have less space to turn around or rotate 180 degrees within the secondary package. This means that the secondary package filled with the filled primary packages forms a compact bundle. Nevertheless, the secondary package itself does not exert any tensioning force on the filled packages contained therein. Therefore, the secondary package prevents the filled primary packages, especially if they are filled flexible bags, from being deformed by the secondary package. In fact, rectangular flexible filled bags can be deformed into a round shape when the filled bags are bundled together in a stretch film wrap, for example. The round shape of the filled flexible bags is a disadvantage when stacking bundles of filled flexible bags on top of each other, as the stability of the stack is lower compared to stacked rectangular bags.

As a further preferred option, before sealing the top end opposite to the bottom seal of the secondary package, the outer clamps are preferably practically closed again and the film conveying system of the film in the VFFS is turned over. In this way, the secondary package is pulled up again until the filled primary packages are at least partially pressed against the outer clamps. In fact, the outer clamps are practically closed so that the filled primary packages cannot pass through the outer clamps. Preferably, the outer clamps are closed more than 50%, more preferably about 80%. This reduces the length of the film used for a secondary package. Consequently, the filled primary packages are wrapped within the secondary package in a substantially tight manner so that the primary packages have less space to turn around or rotate 180 degrees within the secondary package. This means that the secondary package filled with the filled primary packages forms a compact bundle. It was found that wrapping the filled primary packaging with the secondary packaging is further improved when this reversal of the film conveying system in the VFFS is combined with the holding system as described above. In addition, the filled secondary packaging held by the holding device reduces the tension on the film of the secondary packaging, which reduces the possibility of tearing the film.

In order to form a top seal (4) opposite to the bottom seal (3), the outer clamps are fully closed. After the clamps are fully closed, a top seal opposite to the bottom seal is formed, which completely seals the secondary package with the filled primary packages. In addition, this sealed secondary package is cut above the top seal. After the top seal has cooled, the sealed and finished secondary package is released from the outer clamps. This packaging system described above uses a sufficiently tight film wrap to form a bundle of primary packages without deforming the primary packages. In fact, the filled primary packages are not under a significant tension within the secondary package according to the present invention compared to a stretch film, for example. Nevertheless, the primary packages are bundled sufficiently tightly so that the primary packages are prevented from moving substantially within the secondary package.

Preferably, the bottom seal (3) and/or the top seal (4) are interrupted seals and not continuous seals. Typically, the overlapping vertical edges (2) along the bottom seal and the top seal are completely sealed to the bottom and top seal. However, this does not allow the exit of a filled primary package located at an extreme end of the secondary package near the bottom or top seal. In fact, only around the middle of the secondary package is the opening of the overlapping vertical edges wide enough to allow the exit of the filled primary packages from the secondary package. A filled primary package located at an extreme end can only leave the secondary package if the filled primary packages located in the middle area of the secondary package are first taken out from the interior of the secondary package. Consequently, these filled primary packagings can only be removed from the secondary packaging if the filled primary packagings located at one extreme end are brought approximately to the middle part of the secondary packaging.

In contrast, it was found that if the overlapping vertical edges (2) are not sealed at all or are only partially sealed with the bottom and/or the top seal of the secondary packaging at least in the area (2a) of overlap of the vertical edges along the bottom and/or the top seal, all filled primary packages can be removed from the secondary packaging more easily. and often without the whole procedure described above. In fact, the unsealed or partially sealed part of the overlapping vertical edges allows a sufficient widening of the opening between the vertical edges even near the bottom and/or the top seal. Consequently, a filled primary package at the extreme end of a secondary package can be more easily removed directly from the secondary package, and often without first emptying the secondary package.

In order to achieve that the overlapping vertical edges (2) are not sealed or are only partially sealed with the bottom (3) and/or the top seal (4), the transverse seal comprises an interruption of the sealing area corresponding to the whole or part of the overlapping vertical edges. This interruption in the sealing area prevents the overlapping vertical edges from being completely sealed together with the bottom and/or the top seal of the secondary packaging. The partial sealing of the overlapping vertical edges with the bottom and/or the top seal further prevents the overlapping vertical edges from being loose and flapping around. In fact, loose or flapping overlapping vertical edges can hinder the handling of the secondary packaging.

Packaging the primary packages according to the present invention as previously described further enables the reduction of the packaging costs required for handling, storing and transporting the filled primary packages. In addition, packaging the primary packages into the secondary packages according to the present invention is relatively simple, which also reduces the manufacturing costs.

Preferably, the sealed and finished secondary package falls onto a feed section which brings the sealed secondary package containing the filled bags to a location where the secondary packages can be stacked one on top of the other to form a pallet. It has been found that the granular or powder detergent according to the present invention contained in the bags and stacked one on top of the other within the secondary package as described above is practically non-caking, so that the detergent does not stick or clump together to form an insoluble block. Preferably, tie films are placed between the stacked shipping units. The tie films increase the friction between the stacked shipping units. Consequently, the tie films significantly prevent the shipping units from sliding when they are stacked one on top of the other, thereby increasing the stability of the pallet.

Another possibility to significantly prevent the shipping units from sliding when they are stacked on top of each other is to apply an adhesive or glue to a portion of the outermost surface of the secondary packaging or to make the secondary packaging from an embossed film. The adhesive or glue can be sprayed onto at least a portion of the outermost surface of the secondary packaging. The embossed film preferably consists of anti-skid dimples which are embossed onto at least certain areas of the secondary packaging film before the film is folded to the forming projection. the VFFS machine. To further improve the stability of the pallet, the embossed film can be combined with the previously described connecting films. Furthermore, the entire pallet can be further stabilized, especially for transport, for example with a stretch film that is wrapped around the pallet.

The pallet manufactured as described above allows the elimination of any external casings that support the load or weight of the stacking assembly. This results in a significant cost saving in the total amount of packaging material used to manufacture pallets suitable for storage and transport. Furthermore, waste is also significantly reduced. In fact, the outer casings are usually not reused but simply disposed of. It has been found that the pallet according to the present invention can reduce waste by at least 50%, preferably at least 80%, compared to pallets that use corrugated cardboard as outer casings.

Example The following granular laundry detergent composition was prepared:

% by weight

Anionic surfactant agglomerate* 30

Compacted layered silicate granules (available from Hoechst under the trade name SKS-6) 18

Percarbonate** 25

TAED agglomerate 9

Foam suppressor agglomerate 2

Encapsulated perfume 0.2

Granular compact soda ash 8.4

Granular acrylic/maleic acid copolymer 3.2

Enzymes 3,6

Granular soil release polymer 0.6

100

*Anionic surfactant agglomerates were prepared from 78% active surfactant paste comprising C45AS/C35AE3S (alkyl sulfate/alkyl ethoxy sulfate) in the ratio 80:20. The paste consisted of agglomerates with a powder mixture according to the process described in EP-A-510 746. The obtained anionic surfactant granules had a composition of 30% C45AS, 7.5% C35AE3S, 24% zeolite, 20% carbonate, 2.5% CMC, 12% acrylic/maleic acid copolymer, and a balance of moisture.

**Percarbonate coated with 2.5% carbonate/sulfate with a mean particle size of 500 µm.

The mixture containing the granular components listed above was placed in a 140-litre rotary drum running at 25 rpm. During the operation of the drum, a mixture of non-ionic surfactant (C25E3) and a 20% aqueous solution of an optical brightener in a ratio of 14:1 was sprayed onto the granular mixture in a proportion of 7% by weight of the granular components. The spraying time was about 1-2 minutes. Immediately thereafter, perfume was sprayed in a proportion of 0.5% by weight of the granular components while simultaneously rotating the drum. Thereafter, without stopping the drum rotation, a flow aid was slowly added to the mixer, which took about 30 seconds. The type of flow aid used in the example was partially hydrated zeolite A (6% moisture) and the amount of additive was 8%. After the flow aid addition was completed, the mixer was allowed to rotate for about 1 minute and then stopped. The final product was then removed from the rotating drum. The final product had a powder cake strength of 50 g/cm², at about 20 g/cm².

The final product was filled into a flexible bag and the flexible bags were assembled into a shipping unit within a secondary package according to the present invention. These shipping units were then stacked in an arrangement forming a pallet. The pallet was found to be sufficiently stable during storage and transportation. In addition, it was found that the detergent composition did not cake significantly within the flexible bags. This was always the case where the detergent composition was in a stacked arrangement. It was found that even the detergent composition located at the lowest position of the stacked arrangement, where the entire weight of the rest of the pallet is supported, did not cake significantly.

Claims (7)

1. A method for placing filled packages in a secondary packaging, the method comprising the following steps: (1) feeding a film (1) into a vertical form-fill-seal (= VFFS) machine in flat configuration; (2) conveying the film to the forming projection or shoulder (10), wherein the forming projection comprises a filling head (11) and extends in a vertical tube; (3) pulling the film around the forming projection (10) to form a tubular configuration of the film; (4) the complete or partial sealing of the vertical edges (2) of the film; (5) sealing the tubular formed film at the opposite end to the filling head (11) to form a bottom seal (3) with an open bag forming a secondary package; (6) filling the secondary package with more than one filled primary package (15) by dropping the primary packages through the filling head (11) of the forming projection (10) and through the open end of the secondary package; (7) substantially firmly sealing the open end of the secondary package around the filled primary packages contained in the secondary package to form a top seal (4) and closing the secondary package around the filled primary packages; (8) cutting the closed secondary packaging above the top seal (4); the method being characterized in that the seal is interrupted along the vertical edges (2) in at least one region, said region being dimensioned such that a user can insert at least one finger into the interrupted region, but not large enough to allow filled primary packages to pass through. 2. Method according to claim 1, characterized in that the external clamps (14) of the VFFS hold the secondary packaging around the bottom seal (3) during filling of the secondary packaging with the filled primary packaging (15). 3. Method according to at least one of the preceding claims, characterized in that the filled primary packages (15) are first bundled together before they are dropped into the secondary package. 4. Method according to at least one of the preceding claims, characterized in that the VFFS machine further comprises a holding system (16) for holding and preferably lifting the secondary packaging filled with the primary packaging (15). 5. Method according to at least one of claims 2 to 4, characterized in that before sealing the open end opposite the bottom seal (3) of the secondary packaging, the external clamps (14) are practically closed and the film feed system of the film in the VFFS is reversed. 6. Method according to at least one of the preceding claims, characterized in that the closed secondary packaging falls onto a feed section which conveys the closed secondary packaging (15) containing the filled primary packaging (15) to a location where the secondary packaging can be stacked on top of one another to form a pallet. 7. Method according to at least one of the preceding claims, characterized in that the bottom seal (3) and/or the upper seal (4) are interrupted seals.