Title of Invention

A DETERGENT COMPOSITION AND METHOD OF PREPARING THE SAME

Abstract

The invention relates to a detergent composition comprising of crushed refined soda fines, the crushed refined soda fines obtained from washing of crude trona soda. The amount of crushed refined soda fines is between 20 to 40% by weight and preferably the amount of crushed refined soda fines is substantially 30%. The invention also relates to a detergent composition comprising an enzyme and at least one source of bicarbonate. The invention further relates to a method of preparing a detergent composition.

Full Text

FORM 2 THE PATENTS ACT, 3970 (39 of 1970) & THE PATENTS RULES, 2003 COMPLETE SPECIFIC A TION (See section 10, rule 13) /. Title of the invention A DETERGENT COMPOSITION 2. Applicants) Name Nationality Address TATA CHEMICALS LTD. INDIA BOMBAY HOUSE, 24 HOM] MODI STREET, MUMBAi-400001 3. Preamble to the description COMPLETE SPECIFICA TION The following specification particularly describes the invention and the manner in which it is to be performed. The invention relates to a detergent composition. DESCRIPTION OF RELATED ART Conventional dry mix detergent product formulations are based on synthetic soda ash which is very pure in quality and free from organic matter, clay insolubles and fluorides. Dry detergent compositions are formed by mixing soda ash with one or more surfactants. In addition to soda ash and surfactants, other additives such as builders, brighteners, soil release agents, perfumes etc are also added to detergents. Normally, detergent product is free flow, good bright blue color and exhibits good performance in cleaning and detergency. In detergents soda ash acts as a builder to emulsify oil stains, to reduce the deposit of dirt during washing and rinsing, to deliver a smoother surface in the formulation, to provide alkalinity for cleaning, and to soften laundry water. In powdered laundry detergent, soda ash conditions the water and enhances the processing and performance of formulated cleaning products. Two grades of soda ash i.e., light soda ash and dense soda ash are used for the production of detergents. However, since soda ash has to be manufactured, the cost of manufacturing soda ash adds to the cost of the detergent. In view of this there is a need to develop a detergent composition that is based on a cheaper and naturally available raw material in place of soda ash. Moreover, the detergent composition should be free flowing. SUMMARY The invention relates to a detergent composition comprising of crushed refined soda fines, the crushed refined soda fines obtained from washing of crude trona soda. The amount of crushed refined soda fines is between 20 to 40% by weight and preferably the amount of crushed refined soda fines is substantially 30%. The invention also relates to a detergent composition comprising an enzyme and at least one source of bicarbonate. The invention relates to a method of preparing a detergent comprising mixing crushed refined soda fines with a salt, the crushed refined soda fines obtained from washing of crude trona soda, adding a first surfactant to the mixture while continuing the mixing, adding preferably by spraying an optical brightener to the mixture, adding a second surfactant to the mixture, and adding a flow aid to the mixture to obtain a free flow detergent. BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS The accompanying drawings illustrate the preferred embodiments of the invention and together with the following detailed description serve to explain the principles of the invention. Figure 1 tabulates the results of tests carried out on samples of detergent formulations in accordance with an embodiment. Figure 2 tabulates the result of tests carried out on samples of detergent formulations with enzymes in accordance with an embodiment. Figure 3 shows the graphical presentation of pH vs detergency data on blood stained cloth for effectiveness of enzymes. DETAILED DESCRIPTION To promote an understanding of the principles of the invention, reference will be made to the embodiment and specific language will be used to describe the same. It will nevertheless be understood that no limitation of scope of the invention is thereby intended, such alterations and further modifications in the described composition and such further applications of the principles of the inventions as disclosed therein being contemplated as would normally occur to one skilled in art to which the invention relates. A detergent composition is described. The detergent composition comprises of crushed refined soda fines, the crushed refined soda fines is typically obtained by washing of trona soda. Crushed refined soda fines typically is a waste that is generated from a soda ash plants that use trona soda for the production of soda ash. In the production of soda ash, trona soda is washed to remove insoluble impurities. The effluent that comes out from the overflow of washery of a soda ash plant is known as crushed refined soda fines slurry. The liquid is drained out to leave crushed refined soda fines that are dried in sunlight. In accordance with an aspect the crushed refined soda fines is treated and purified before it is used in a detergent formulation. In accordance with an aspect, the crushed refined soda fines is treated by sieving the raw crushed refined soda fines to obtain crushed refined soda fines with a particle size preferably smaller than or equal to 3mm, drying the crushed refined soda fines to reduce the moisture content, and reducing the particle size of the crushed refined soda fines to below 500 microns. In accordance with an aspect the crushed refined soda fines must be dried in a manner that does not substantially deplete the sodium bicarbonate content. The crushed refined soda fines may be added in any quantity to the detergent composition. The crushed refined soda fines may be added as a part or complete substitute for the soda ash. In accordance with an embodiment crushed refined soda fines is added as a complete substitute for soda ash. In accordance with an aspect the detergent composition contains 25 to 40 % of crushed refined soda fines and preferably the detergent composition contains approximately 30% of crushed refined soda fines. In accordance with an aspect the detergent composition contains surfactants. Any anionic, cationic or neutral surfactant may be added to the detergent composition including but not limited to alkyl aryl sulphonic acids, alkyl sulphonic acids, alkyl sulfuric acids, fatty acids and polyethylelene oxide ether sulphuric acid and their water soluble salts. The surfactants may be used alone or in combination with one another. In accordance with an aspect, the detergent composition contains 10 to 35% of surfactant. In accordance with an aspect, the detergent composition^comprises of two surfactants. In accordance with an aspect, sulphonic acid is added in the detergent composition as the primary surfactant. The sulphonic acid that may be added in the detergent includes but is not limited to linear alkyl benzene sulphonic acid, alphaolefin sulphonic acid, internal sulphonic acid, fatty acid sulphonic acid or a combination thereof. The surfactant may be added to the detergent composition in the range of 10 to 20% and preferably the surfactant may be added to the detergent in the range of 10 to .15%. In accordance with an aspect a secondary surfactant is added to the detergent composition. The secondary surfactant that may be added to the detergent composition includes but is not limited to sodium lauryl sulphate or alpha olefin sulphonate. In accordance with an aspect the detergent composition contains 0.5% to 2% of the secondary surfactant and preferably the detergent composition contains 1% of the secondary surfactant. In accordance with an aspect the detergent composition contains salt. In accordance with an aspect the detergent composition contains 30% to 45% of the salt and preferably the detergent composition contains 35 % to 40% by weight of salt. Any suitable soluble salt may be added to the detergent composition. In accordance with an aspect the detergent composition contains sodium chloride as salt. Sodium chloride is a cheap water salt. Sodium chloride also helps in removing bloodstains in the garment and helps to retain color. In accordance with an aspect, a "layering agent" or "flow aid" may be added to the detergent formulation. The layering agent or flow aid is added to improve the granularity of the product, for example by preventing aggregation and/or caking of the granules. Any suitable layering agent including but not limited to crystalline or amorphous alkali metal silicates, aluminosilicates including zeolites, citrates, dicamol, calcite, diatomaceous earths, dolomite, talc, silica, for example precipitated silica, chlorides such as sodium chloride, sulphate such as magnesium sulphate, carbonates such as calcium carbonate and phosphates such as sodium tripolyphosphate may be use separately or in combination with one another. In accordance with an aspect the detergent composition contains 5% to 25% of a flow aid. In accordance with an aspect, optical brighteners may be added to the detergent composition. Optical brighteners that may be added to the detergent include but are not limited to naphthotriazolylstilbenes, benzoxazolyl, benzimidazoyl, naphthylimide, or diaminostilbene disulfonates. In accordance with an embodiment, the optical brightener is tetrabenzo - tetra azaporphine derivative. In accordance with an aspect, the detergent composition contains 0.05% to 0.25% of optical brightener and preferably the detergent composition contains 0.1 to 0.2% of optical brightener. In accordance with an aspect, an antiredeposition agent may be added to the detergent composition. In accordance with an aspect carboxy methyl cellulose is added as an antiredeposition agent. In accordance with an aspect, the antiredeposition agent may be added to the detergent composition in the range of 1% to 5% by weight and preferably the 2% of antiredepositon is added to the detergent composition. In accordance with an aspect, the detergent formulation contains sodium silicate. The sodium silicate in the detergent composition reacts with sodium fluoride content of crushed refined soda fines thereby removing the fluoride as an insoluble fiuoro-silicate compound. In accordance with an aspect the detergent composition contains 1 % to 5% of sodium silicate by wt and preferably the detergent composition contains 3% by weight of sodium silicate. Sodium silicate is preferably added for detergent formulation suitable for soft water. In accordance with an aspect, the detergent composition contains phosphate builders. The phosphate containing detergent builders include, but are not limited to, the alkali metal, ammonium and alkanolammonium salts of polyphosphates for example tripolyphosphates, pyrophosphates, and glassy polymeric meta-phosphates and/or phosphonates. Various alkali metal phosphates such as sodium and/or potassium tripolyphosphates, pyrophosphates and/or orthophosphates may be used. Phosphonate builders such as ethane-1-hydroxy-1,1-diphosphonate and other known phosphonates may also be used. These builders may be used alone or in combination. In accordance with a preferred embodiment sodium tripolyphosphatesis used as a phosphate builder. In accordance with an aspect, detergent composition may contain 1% to 7% by weight of phosphate builder and preferably the detergent composition contains 5% by weight of phosphate builder. In accordance with an aspect, the detergent composition may contain enzymes. Enzymes in the detergent help to breakdown stains to make them easier to remove. In accordance with an aspect the enzyme used should be effective at a pH higher than 10 and preferably the enzyme should be effective in the pH range of 10 to 11. In accordance with an aspect, the detergent composition contains at least one enzyme. The detergent composition also includes at least one source of bicarbonate to enable effectiveness of enzyme at higher pH values. The effectiveness of enzymes in detergent formulation is affected by the hydroxyl ions. The bicarbonate present in the detergent formulation provides a buffering effect. The bicarbonate ions react with hydroxyl ion to form carbonate ion and water. This allows the enzymes in the detergent composition to be effective even at higher pH levels. In accordance with an aspect, the bicarbonate ions may be any of soda ash, sodium bicarbonate or crushed refined soda fines. In accordance with an embodiment, the source of bicarbonate is crushed refined soda fines. By way of a specific example to establish the effectiveness of enzyme at higher pH ranges, specific formulations are designed to give pH in the range from 9.0 to 11.0 in a 1% solution. Fresh cotton cloth after reflectance measurement was stained with chicken blood. Chicken blood was dispersed in water and cloth was completely dipped in the blood - water and soaked for 10 minutes. Cloth was then dried in the sun and cut into pieces of 5cm by 5cm. Reflectance was measured. Blood stained pieces of cloths were washed in the Launder -o- meter with 2% solution of a sample of the formulations for 10 minutes at ambient temperature of 30 deg C. After washing, washed pieces of cloths were dried in sun and reflectance is measured. Figure 2 tabulates the result. It is observed that all three experiments 1,2 and 4 at pH ranges 9.25, 10.48 and 10.95 has shown better detergency at 76.4%, 79.34% and 82.16% respectively as against control experiment 3 without enzymes at pH 10.75 with detergency at 69.79%. Figure 3 shows the graphical presentation of pH vs detergency data on blood stained cloth for effectiveness of enzymes. In accordance with an aspect, the enzyme used in the detergent composition may include but is not limited to protease, amylase, lipase or cellulase. In accordance with a preferred embodiment, the enzyme used in the detergent composition is protease. In accordance with an aspect, the detergent composition contains 0.1% to 0.6% enzyme and preferably the detergent composition contains 0.4% enzyme. In accordance with an aspect, color or dye may also be optionally added to the detergent composition. In accordance with in aspect, the detergent composition contains 0.03% to 0.05% by weight and preferably the detergent composition contains 0.04% by weight of color. Any suitable dye or color may be used. In accordance with a preferred embodiment phthalocyanine blue is used as a color in the detergent composition. In accordance with an aspect, the detergent composition may contain other additives such as perfumes and colored speckles. In accordance with an aspect, the detergent composition contains 0.075% to 0.05% of perfume. In accordance with an aspect, the detergent composition contains 5% to 0.2% of speckles. In accordance with an aspect, the detergent composition may contain titanium dioxide to improve the color of the detergent composition. In accordance with an aspect, the amount of titanium dioxide may be 0.25% to 0.75% and preferably the amount of titanium dioxide is 0.5%. By way of illustration, the following formulations have displayed the required detergency ability. Formulation A By way of a specific example the detergent composition comprises of between 25 to 35% of crushed refined soda fines, 30 to 40% salt, 0.30 to 0.05% of color, 8 to 15% sulphonic acid, 0.05 to 0.25% optical brightener, 0.5% to 1.5% sodium lauryl sulphate, 7% to 20% micronized dolomite, 0.5 to 5% precipitated silica, 0.2 to 0.5% enzyme, and 1% to 3% speckle. This formulation is particularly suited for hard water. Formulation B By way of a specific example the detergent composition comprises of between 25 to 35% of crushed refined soda fines, 30 to 40% salt, 8 to 15% sulphonic acid, 7 % to 20 % micronized dolomite (flow agent), 0.5 to 5% precipitated silica, 1 to 5% sodium silicate, 0.2 to 0.5% enzyme, 0.05 to 0.25% optical brightener, 0.30 to 0.05% of color and 1 to 3% speckle. This formulation is particularly suited for soft water. Formulation C By way of a specific example the detergent composition comprises of between 25 to. 35% of crushed refined soda fines, 30 to 40% salt, 0.5 to 2% Alpha Olefin sulphonate, 0.05 to 0.25% optical brightener, 0.30 to 0.05% of color, 7 % to 20 % micronjzed dolomite (flow agent), 8 to 15% sulphonic acid,0.0250.1% perfume,0.5 to 5% precipitated silica, I Co 7% sodium tripolyphosphate, and 0.25 to 0.75% titanium dioxide. This formulation is particularly suited for hard water. Formulation D By way of a specific example the detergent composition comprises of between 25 to 35% of crushed refined soda fines, 30 to 40% salt, 0.5 to 2% sodium lauryl sulphate, 0.05 to 0.25% optical brightener, 0.30 to 0.05% of color, 7 % to 20 % micrqnized dolomite (flow agent), 8% to 15% sulphonic acid, 0.025% to 0.1% perfume, 0.5% to 5% precipitated silica, 1% to 5% carboxy methyl cellulose, 1% to 5% Sodium silicate, 1% to 3% speck^ and Q.2% to 0.5% enzyme. This formulation is particularly suited for soft water. When used in a detergent formulation suited for harq water, crushed refined soda fines reduces the hardness of water. The fluoride content in the crushed refined soda fines reacts with the calcium that is present in hard water, to form insoluble Calcium Fluoride by the following formula: 2NaF + CaCl2 = 2NaCl + CaF2 This removes the calcium that is present in hard water. Thus no loss of active detergent takes place and no or very small quantity of sequestering agent is required in the formulation. By way of a specific example, 2.25gms of a sample of product A and B; and S (soda ash containing detergent as control) were dissolved separately in 250 gm of hard water (containing 200ppm of Ca) and soft water (containing 25ppm of Ca) by agitation for 15 minutes. Fluoride was analyzed in the soluble and insoluble part of the solution. Results of analysis indicate that entire quantity of fluoride is precipitated as calcium fluoride. Loss of active detergent is less in formulation A and B as compared to the control S as indicated in Figure 1. By way of a specific example, 2.25gm of a sample of crushed refined soda fines was dissolved in hard water containing 250 gm of hard water containing 20.0 ppm of Ca by agitation for 15 minutes. Solution was analyzed for fluorine. As indicated by figure 1 more than 95% of fluorine present in the beneficiated crushed refined soda fines reacts with calcium ions present in hard water and reduces hardness by more than 50%. By way of a specific example a detergent composition is formed by the process comprising of mixing together crushed refined soda fines, salt and color in a mixer. On the mixture so obtained sulphonic acid is first sprayed on with the mixing on, followed by spraying the optical brightener. To this mixture a second surfactant along with the sodium silicate and antiredeposition agent is then added and mixed. To this mixture flow agents like micronized dolomite and precipitated silica are then added to make the detergent completely free flowing. To this mixture other ingredients such as titanium oxide, speckles, perfume and enzymes are added to form a detergent composition. In accordance with an embodiment each step is carried out for a predetermined period of time. The detergent composition described uses a waste product; crushed refined soda fines that is produced during soda ash manufacture. Moreover, the detergents composition as described is suitable for use in both soft and hard water. The invention will be illustrated by the following examples which are not to be construed as limiting the invention in any way. EXAMPLE 1: In a ribbon mixer of 300kg scale, beneficiated crushed refined soda fines 90kg, Salt 118.5 kg, Color Phthalocyanine Blue 114gms are mixed together for 3 minutes to develop blue color. Sulphonic acid 37.5 kg is sprayed over the mass in the mixer in 15 seconds with the mixing on, optical brightener tetrabenzo - tetraazaporphine derivative 0.60kg slurried in 900ml water is sprayed over the mass and Sodium salt of Alpha Olefin Sulphonate 3kg is dosed. Mixing time at this stage is 1 minute. Sodium Tripolyphosphate 15kg, dolomite 27kg and precipitated silica 6 kg dosed in 30 seconds time to make the detergent product completely free flow. Titanium dioxide 1.5 kg is charged in the mixing mass to improve the color. Perfume is injected in the mass while mixing on. After lapse of 30 seconds mixing detergent product is discharged to hopper. Total mixing time is 4.5 minutes to 5.5minutes. Through hopper, product is milled in cage mill feeding with the help of screw feeder. From cage mill product is discharged to another hopper for packing. EXAMPLE 2 In a ribbon mixer of 300kg scale, beneficiated crushed refined soda fines 90kg, Salt 100.5 kg, Color Phthalocyanine Blue 120gms are mixed together for 3 minutes to develop blue color . Sulphonic acid 36 kg is sprayed over the mass in the mixer in 15 seconds with the mixing on, optical brightener tetrabenzo - tetra azaporphine derivative 0.3 0kg slurried in sulphonic acid is sprayed over the mass along with sulphonic acid while mixing is on. Sodium Silicate 9kg, Sodium salt of Carboxy Methyl Cellulose 6kg and Sodium salt of Lauryl Sulphate 3kg is dosed. Mixing time at this stage is 1 minute. Dolomite 45kg and precipitated silica 3 kg dosed in 30 seconds time to make the detergent product completely free flow. Speckles 6kg of 2kg each of yellow, orange and red is charged. Perfume is injected in the mass while mixing on. After lapse of 30 seconds mixing detergent product is discharged to hopper. Total mixing time is 4.5 minutes to 5.5 minutes. Through hopper, product is milled in cage mill feeding with the help of screw feeder. From cage mill product is discharged to a ribbon blender for mixing with enzymes 1.2kg. After blending with enzymes, product is discharged to another hopper for packing. We claim: 1. A detergent composition comprising of crushed refined soda fines, the crushed refined soda fines obtained from washing of crude trona soda. 2. A detergent composition as claimed in claim 1 wherein the amount of crushed refined soda fines is between 20 to 40% by weight and preferably the amount of crushed refined soda fines is substantially 30%. 3. A detergent composition as claimed in claim 1 comprising of at least one surfactant, the surfactant being any one of cationic, anionic or neutral surfactant. 4. A detergent composition as claimed in claim 1 comprising of a salt. 5. A detergent composition as claimed in claim 1 comprising of a flow aid 6. A detergent composition as claimed in claim 1 comprising of an optical brightener. 7. A detergent composition as claimed in claim 1 comprising of color. 8. A detergent composition as claimed in claim 1 comprising of an antiredeposition agent. 9. A detergent composition as claimed in claim 1 comprising of phosphate builders. 10. A detergent composition as claimed in claim 1 comprising of perfume. 11. A detergent composition as claimed in claim 1 comprising of speckles. 12. A detergent composition comprising an enzyme and at least one source of bicarbonate. 13. A detergent composition as claimed in claim 12 wherein the source of bicarbonate is any one of soda ash, sodium bicarbonate or crushed refined soda fines. 14. A detergent composition as claimed in claim 12 wherein the enzyme is any one of protease, lipase, amylase or cellulase. 15. A detergent composition comprising 25 to 35% of crushed refined soda fines, 30 to 40% salt, 8 to 15% sulphonic acid, 7 % to 20 % micronized dolomite, and 0.5 to 5% precipitated silica. 16. A detergent composition as claimed in claim 15 comprising of 0.2 to 0.5% enzyme. 17. A detergent composition as claimed in claim 15 comprising of 1 to 7% sodium tripolyphosphate. 18. A detergent composition as claimed in claim 15 comprising of 0.25 to 0.75% titanium dioxide. 19. A detergent composition comprising 25 to 35% of crushed refined soda fines, 30 to 40% salt, 8 to 15% sulphonic acid, 1 to 5% sodium silicate, 7 % to 20 % micronized dolomite, 0.5 to 5% precipitated silica, and 0.2 to 0.5% enzyme. 20. A detergent composition as claimed in claim 19 comprising of 1 to 5% carboxy methyl cellulose. 21. A detergent composition as claimed in claims 15 or 19 comprising of 0.5% to 1.5% sodium lauryl sulphate or alpha olefin sulphonate. 22. A detergent composition as claimed in claims 15 or 19 comprising of 0.30 to 0.05% of color. 23. A detergent composition as claimed in claims 15 or 19 comprising of 0.05 to 0.25% optical brightener. 24. A detergent composition as claimed in claims 15 or 19 comprising of 1 to 3% speckle. 25. A detergent composition as claimed in claim 15 or 19 comprising of 0.025 to 0.1% perfume. 26. A method of preparing a detergent comprising - mixing crushed refined soda fines with a salt, the crushed refined soda fines obtained from washing of crude trona soda; adding a first surfactant to the mixture while continuing the mixing; adding preferably by spraying an optical brightener to the mixture; adding a second surfactant to the mixture; and adding a flow aid to the mixture to obtain a free flow detergent. 27. A method as claimed in claim 26 wherein the cotorphthaiocyanine blue is mixed with the crushed refined soda fines. 28. A method as claimed in claim 26 wherein the first surfactant is sulphonic acid. 29. A method as claimed in claim 26 wherein the secondary surfactant is alpha olefin sulphonate or sodium lauryl sulphate. 30. A method as claimed in claim 26 wherein the sodium salt of carboxy methyl cellulose is added along with the secondary surfactant. 31. A method as claimed in claim 26 wherein the sodium silicate is added along with the secondary surfactant. 32. A detergent composition substantially as herein described with reference to and as illustrated with the accompanying figures. 33. A method for forming a detergent composition substantially as herein described with reference to and as illustrated with the accompanying figures. Dated this 14th day of October 2008 Essenese Obhan Of Obhan & Associates Agent for the Applicant

Documents:

2209-mum-2008-abstract.doc

2209-mum-2008-abstract.pdf

2209-MUM-2008-CLAIMS(AMENDED)-(20-7-2012).pdf

2209-MUM-2008-CLAIMS(MARKED COPY)-(20-7-2012).pdf

2209-mum-2008-claims.doc

2209-mum-2008-claims.pdf

2209-MUM-2008-CORRESPONDENCE(14-11-2008).pdf

2209-MUM-2008-CORRESPONDENCE(15-10-2008).pdf

2209-MUM-2008-CORRESPONDENCE(19-11-2013).pdf

2209-MUM-2008-CORRESPONDENCE(21-1-2013).pdf

2209-MUM-2008-CORRESPONDENCE(21-2-2014).pdf

2209-MUM-2008-CORRESPONDENCE(28-5-2010).pdf

2209-MUM-2008-CORRESPONDENCE(28-5-2013).pdf

2209-MUM-2008-CORRESPONDENCE(30-12-2013).pdf

2209-mum-2008-correspondence.pdf

2209-mum-2008-description(complete).doc

2209-mum-2008-description(complete).pdf

2209-MUM-2008-DRAWING(20-7-2012).pdf

2209-mum-2008-drawing.pdf

2209-MUM-2008-FORM 1(14-11-2008).pdf

2209-mum-2008-form 1.pdf

2209-MUM-2008-FORM 18(28-5-2010).pdf

2209-mum-2008-form 2(title page).pdf

2209-mum-2008-form 2.doc

2209-mum-2008-form 2.pdf

2209-MUM-2008-FORM 3(20-7-2012).pdf

2209-mum-2008-form 3.pdf

2209-MUM-2008-POWER OF AUTHORITY(14-11-2008).pdf

2209-MUM-2008-REPLY TO EXAMINATION REPORT(20-7-2012).pdf

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