U.S. patent number 3,832,431 [Application Number 05/229,750] was granted by the patent office on 1974-08-27 for process for making marbleized soap or detergent.
This patent grant is currently assigned to Lever Brothers Company. Invention is credited to Raymond George Matthaei.
United States Patent |
3,832,431 |
Matthaei |
August 27, 1974 |
PROCESS FOR MAKING MARBLEIZED SOAP OR DETERGENT
Abstract
A marbleized mass of soap in the form of a log is produced by
passing soap particles through a modified two-stage plodder and
injecting a soap additive, e.g., a dye, into the compressed soap
mass during extrusion of the soap. The process and apparatus can be
used also to produce marbleized detergent logs.
Inventors: |
Matthaei; Raymond George
(Fairlawn, NJ) |
Assignee: |
Lever Brothers Company (New
York, NY)
|
Family
ID: |
26923576 |
Appl.
No.: |
05/229,750 |
Filed: |
February 28, 1972 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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875091 |
Nov 10, 1969 |
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Current U.S.
Class: |
264/75; 264/102;
264/349; 264/78; 264/211; 510/440; 510/447; 510/451 |
Current CPC
Class: |
C11D
13/08 (20130101); B29C 48/175 (20190201); B29C
48/395 (20190201); C11D 13/18 (20130101); B29C
48/06 (20190201) |
Current International
Class: |
B29C
47/04 (20060101); B29C 47/38 (20060101); C11D
13/00 (20060101); C11D 13/18 (20060101); C11D
13/08 (20060101); B29b 001/04 (); B29f
003/12 () |
Field of
Search: |
;264/75,78,245,37,211,102,349,89 ;252/109,134 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Thurlow; Jeffery R.
Attorney, Agent or Firm: Boustead; John
Parent Case Text
REFERENCE TO OTHER APPLICATION
This application is a continuation-in-part of my co-pending
application, Ser. No. 875,091, filed Nov. 10, 1969, now abandoned.
Claims
I claim:
1. The method of making a marbleized soap or detergent mass which
comprises simultaneously compressing a base soap or detergent while
injecting from 0.04 to 5.01 ml. per pound of said base soap or
detergent of an additive composition comprising a 0.5 to 30% dye
solution into said base soap or detergent in the extrusion means of
a two stage soap plodder at one or more points along the axis of
movement of the soap through a stage spaced 5 to 75% of the length
of said stage from the point of discharge therefrom and extruding
from the soap plodder, at a temperature of about 70.degree.F. to
about 160.degree.F., a marbleized mass of base soap or detergent
containing the additive.
2. The method of claim 1 in which the base is soap, and injection
occurs in the first stage of said plodder, and the first stage
discharges through a relatively open pressure plate.
3. The method of claim 2 in which the point of injection is spaced
from the point of discharge a distance equal to 5 to 45% of the
length of said first stage.
4. The method of claim 3 in which the extrusion temperature is
85.degree.F to 125.degree.F.
5. The method of claim 1 in which injection occurs in the second
stage of said plodder.
6. The method of claim 2 in which said additive injection is
accomplished by a pulsating flow injection, the periods of the
pulse cycle during which additive is added and during which
additive is not added being up to about 8 seconds and 75 seconds
respectively.
7. The method of claim 2 in which the base soap contains 5 - 95%
coco soap, 5 - 95% tallow soap, 0 - 30% free fatty acid, 0 - 26%
water, 0.1 - 5% NaCl.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method and apparatus for the production
of marbleized soap masses including detergent masses.
2. Description of the Prior Art
Marbleized soap masses have been produced, most frequently in the
form of a marbleized soap bar having various colors distributed
apparently at random throughout the soap mass. As presently known,
such soap masses have been produced either by a framing process or
by introduction of a dye into the vacuum chamber between stages of
a two-stage soap plodder. Soap framing -- a batch process -- has
its inherent disadvantages, and the introduction of the dye into
the vacuum chamber is subject to the disadvantages that the ability
to control the appearance of the finished product is relatively
limited in that the dye-addition location is fixed. Soap logs
produced in this fashion frequently suffer from a relatively high
degree of dye-migration to the outer portion of the soap mass and
consequent non-uniform distribution of the dye throughout the soap
mass, lack of adequate contrast, and the lack of relatively
reproducible variations in the finished soap patterns.
SUMMARY OF THE INVENTION
It has now been found that a marbleized soap mass can be produced
by injecting a soap additive composition under pressure into the
compressed soap mass as it passes through one of the stages of a
modified two-stage soap plodder. The additive injection can be
effected through one or more nozzles in either the first or the
second compression stage and the additive can be continuously or
intermittently injected.
In the preferred embodiment of this invention, a marbleized soap is
produced in which the injected additive is a dye and the marbleized
product is an otherwise homogeneous mass having colored streaks
distributed throughout the mass to produce a variegated appearance.
The invention is also useful in producing heterogeneous soap masses
in which the injected additive is a composition such as a
sequestering agent, a deodorant, a perfume or lanolin. The addition
of these later materials by the method of my invention greatly
reduces prior processing problems inherent in the use of such
additives. As used herein, the term "marbleized" soap referes to
all of the described soap masses although for purposes of
simplicity the description of my invention hereafter will be
directed to the production of variegated soap masses by dye
injection.
The process and apparatus of my invention will produce a marbleized
mass having greater or less contrast between differently colored
areas according to the process variables including the soap
formulation, the plasticity of the soap mass, the amount of
additive used, the point of additive injection, the size of
extrusion equipment used and similar variables. Thus, the present
description is directed to applicant's preferred embodiment in
which variations within the mass are in distinct zones distributed
substantially throughout the mass. Many of the process variables
within reasonable limits are non-critical but relate only to degree
of contrast to be obtained between differently colored areas of the
soap mass.
In a typical soap production according to my invention a kettle
soap is mixed with desired addition agents such as perfumes,
fillers, germicides, emollients, water, salt, etc. and milled. The
milled chips are fed to the first stage -- or refiner barrel -- of
a modified two-stage plodder in which the soap chips are compressed
under the action of an extrusion screw at a temperature of
70.degree.F to 160.degree.F preferably 85.degree.F to 125.degree.F.
A dye solution (0.5 to 30 percent solution) is injected into the
compressed soap mass as it passes through the first stage of the
plodder.
The compacted soap is discharged from the first stage of the
plodder through a specially designed end plate. Whereas in the
usual form of a soap plodder the first stage discharge comprises a
combination of a 20 to 40 mesh woven screen and a metal backing
plate having a myriad of small holes (e.g. in a soap plodder with a
10 inch cylinder diameter the backing plate has 3/8 inch diameter
holes) through which extrusion of the soap mass produces numerous
ribbons or filaments of soap; I provide a pressure plate which is
relatively open having large holes or shaped apertures. By way of
comparison, the usual first stage discharge plate and screen has
openings which occupy 27% or less of its face area, i.e., it is
27%, or less, open; the pressure plate used in the method and
apparatus of my invention is at least 35% and preferably at least
50% and up to 85% open.
The soap with entrapped dye solution is extruded through the
relatively large openings of the pressure plate and cut into
pellets as it enters into a vacuum chamber enclosing the discharge
side of the pressure plate.
In the vacuum chamber entrapped air within the soap pellets is
removed. The soap pellets pass through the vacuum chamber and into
the plodder second stage which compresses the soap pellets and
extrudes the soap as a continuous log of marbleized soap.
Thereafter, the marbleized log is cut and stamped into soap bars in
the manner known in the art and waste from the cutting and stamping
is recycled to the first stage feed.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a somewhat schematic cross-sectional view of a modified
two-stage soap plodder and associated apparatus adapted for use
according to the teaching of the present invention.
FIG. 2 is a plan view of a pressure plate used in the apparatus
shown in FIG. 1.
FIG. 3 is a plan view of an alternate pressure plate to that shown
in FIG. 2.
FIG. 4 is a side elevation partly in section of an injection
nozzle.
FIG. 5 is a side elevation of a modified injection nozzle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a two-stage soap plodder 10 is shown
consisting of a water jacketed upper barrel 12 -- sometimes called
the refiner barrel -- a vacuum chamber 14 and a water jacketed
lower barrel 16. Barrels 12 and 16 are cylindrical and contain,
respectively, extrusion screws 20 and 28 each of which is rotatably
driven by conventional means (not shown) the flights of each screw
passing close to the interior wall of each barrel. Particles of
soap -- chips or pellets -- are introduced to one end of the upper
barrel 12 through inlet hopper 18 and are picked up by the feed-end
flights of extrusion screw 20. Rotation of extrusion screw 20 in
barrel 12 compacts the soap particles and urges the compacted soap
along the axis of barrel 12 and through a pressure plate 22. Blade
cutter 24 is provided on the face of pressure plate 22 and operates
to cut the soap extruded through plate 22 into pellets one-half to
4 inches in length.
Having passed through pressure plate 22 and rotary cutter 24, the
soap pellets enter vacuum chamber 14 in which gases entrapped in
the soap are removed by the action of a vacuum on the order of
approximately 25-29 inches of mercury. Chamber 14 is evacuated
through vacuum line 26. The soap pellets discharged fall upon the
feed end flights of a second extrusion screw 28 in lower barrel 16.
Rotation of extrusion screw 28 within barrel 16 compacts the
pellets, urges the compacted soap along the axis of barrel 16, and
extrudes a continuous log 31 of soap through a nose plate 30 having
an exit aperture shaped according to the form of soap log
desired.
In the practice of the present invention, a soap additive is
injected into the compacted soap during its passage through plodder
10. The injection is made by means of one or more of a series of
nozzles 32 - 37 extending through the walls of the plodder barrels
12 and 16; each nozzle is provided with a stream of additive by a
conduit 38 and positive displacement pump 40. As shown in FIG. 1,
these nozzles can be located in either or both of the bottom barrel
and the top barrel and the location of each nozzle can be varied
along the length of the barrel. The dye should be injected into,
and entrapped within the soap while the latter is under the
compressive influence of the extrusion screw. Therefore, the
injection nozzle should not be any closer to the feed end of the
barrel than the point at which the soap in the barrel becomes
compressed nor so close to the discharge end of the barrel that the
dye passes out of the barrel as a separate liquid phase, i.e.,
before it becomes entrapped within the soap. Suitable nozzle
positions are spaced from the discharge end of the barrel a
distance equal to about 5% to about 75% of the barrel length.
While a series of six nozzles are shown in FIG. 1, this is merely
illustrative of different injection sites that can be used. I have
found it preferable when working with a single additive to inject
the additive at only a single point and this preferably in upper
barrel 12 at a point along the axis of barrel 12 at a distance of 5
to 45% of the barrel length from pressure plate 22. However,
simultaneous injection through more than one nozzle can be used,
especially when it is desired to inject more than one soap
additive, e.g., in the injection of different dye streams.
Nozzles 32 - 37 project into the space between barrels 12, 16 and
extrusion screws 20, 28. The latter are provided with a registering
notch 39 for each nozzle. It is possible to avoid the use of
nozzles and accomplish the desired injection through orifices in
the flights or shaft of a hollowed out extrusion screw. However,
the use of nozzles is preferred since they also act as picker pins
to reduce slippage and churning in the plodder barrel and thereby
aid in increasing the rate of soap extrusion.
As stated above, I prefer to inject additive in the upper barrel 12
at a point relatively close to pressure plate 22, i.e., through
nozzle 33 in FIG. 1. FIG. 1 shows the configuration of the
discharge end of upper barrel 12 when the additive injection occurs
within upper barrel 12. In order to avoid excessive mixing of the
soap and additive mass, a relatively open pressure plate is used,
i.e., one that is at least 35% and preferably 50% open. This can be
accomplished by using a plate having a plurality of large holes 42
or shaped apertures distributed across the plate surface each
extending through the plate to permit the passage of soap.
The openings in plate 22 should be as large as possible while
providing for the maintenance of vacuum in chamber 14 and the
development of adequate pressure -- 40 to 350 psig - within barrel
12 to compact the soap chips or pellets fed to hopper 18 into a
continuous mass of soap. For example when using a 10 inch plodder,
i.e., the inside diameter of barrels 12 and 16 is 10 inches, a
suitable pressure plate 22 has holes 42 distributed across its
surface each hole having an inside diameter of 1 to 11/4 inches.
This insures that relatively large soap pellets 63 pass into vacuum
chamber 14. An alternate construction of pressure plate 22 is shown
in FIG. 3. In this instance, a plate 22' is provided having an open
face except for a series of struts 44. This type of pressure plate
is especially useful with smaller diameter extrusion screws e.g., 6
inch.
Screw 20 is provided with the last screw flight terminated a short
distance -- typically 2 inches -- from pressure plate 22. This
permits a heel of soap 62 to form between screw 20 and pressure
plate 22 and aids in the maintenance of vacuum in chamber 14 and
the development of pressure in barrel 12. In FIG. 1, the soap is
shown only at heel 62 and pellets 63. This remainder of the soap
throughout plodder 10 has been omitted to allow for the showing of
details in the drawing.
When additive injection occurs only in the lower barrel 16, the
discharge end of upper barrel 12 can be enclosed by the usual form
of pressure plate which comprises a combination of a 20 to 40 mesh
screen and a metal backing plate having a myriad of small holes
distributed across its surface. As an aid to the distribution of
additive throughout the soap mass when the additive injection
occurs in lower barrel 16, a baffle plate can be provided in nose
plate 30 or between nose plate 30 and barrel 16.
In FIGS. 4 and 5, typical injection nozzles 32 - 37 are shown. In
FIG. 4, the nozzle is provided with an end outlet port 45 whereas
in FIG. 5 a side outlet port 46 is provided for location in the
plodder barrel facing its discharge end.
After log 31 is discharged from nose plate 30 it is treated
according to conventional practice by a cutting and stamping
apparatus 61 from which individual bars 64 of suitable shape are
discharged on conveyor belt 65. Bars 64 having capacity shapes or
landed shapes can be produced. I have found that soap scraps from
the cutting and stamping apparatus 61 can be recycled to inlet
hopper 18, as by conveyor belt 60 and processed through the plodder
10 without destroying the marbleized appearance of the product.
Understandably, the soap produced when scraps are recycled is more
highly colored than when the soap is processed without recycle but
this is often a desirable result. The amount of scrap recycle to
hopper 18 can amount to as much as 30% of the total soap fed to
hopper 18.
The conditions under which marbleized soap is produced in plodder
10 are those normally encountered in soap plodding. In particular,
the soap is processed through plodder 10 at temperatures between
70.degree.F and 160.degree.F and preferably between 85.degree.F and
125.degree.F; these temperatures referring to the temperature of
the soap in the plodder and at the discharge from nose plate 30.
The soap plodder can be operated at normal capacity and throughput
is limited by the allowable temperature rise within the soap mass.
Pressures within barrels 12 and 16 will be 40 - 350 psig.
Illustrative of the production of bars of soap having a marbleized
appearance are the following examples.
Example I
Green Streaks on White
Chips of soap comprising 36.68 percent coconut fatty acid sodium
soap, 44.47 percent tallow acid sodium soap and 6.15 percent
coconut fatty acids, are mixed with germicide, preservative and
perfume in the proportions:
Weight Ingredients Percent ______________________________________
36.68: 44.47 coco: tallow sodium soap chips 81.65 coco fatty acid
6.15 Germicide TBS:TCC 3:1 ratio 2.0 Perfume 1.0 Water 8 NaCl 1.2
______________________________________
The soap chips, germicides, preservative, perfume and water are
mixed and milled. Fifty pounds per minute of milled chips are
charged to the hopper 18 and forced by means of extrusion screw 20
through pressure plate 22 into the vacuum chamber 14. A 10 inch
(barrel diameter) plodder was used, pressure plate 22 having 11/4
inch holes 42.
A 10 percent dye solution containing Monastral Fast Green dye in
aqueous solution was injected through a single nozzle 33 located in
barrel 12 approximately 5 inches from plate 22.
The dye was injected in a pulsating flow cycle whereby 11 ml. were
injected in 3 seconds followed by a 28 second period during which
no dye was injected. A highly desirable marbleized pattern with
sharp contrasting green and white areas extending throughout the
soap mass was produced.
Example II
Green Streaks on White Soap
Milled soap chips having the composition given hereinafter were fed
to the hopper 18 of a double-barrel vacuum plodder.
______________________________________ Ingredients Weight %
______________________________________ 20 coco: 80 tallow sodium
soap 82.8 Preservatives .2 Perfume 1.0 NaCl 0.5 Water 15.5
______________________________________
The above example was processed in the same way as example one,
except that the injection was in the lower barrel 16, i.e., the
position represented by nozzle 37. The rate of addition of the
colorant solution was varied from 1 cc/8.33 lbs. of mixed soap to 1
cc/.256 lbs. of mixed soap. The best rate found during this run was
around 1 cc/1.28 lbs. of mixed soap.
The best results are observed in processing soaps of relatively
high plasticity, as these soaps pass through the plodder without
excessive mixing of the injected dye throughout the soap mass.
Plasticity can be improved by the addition of suitable agents,
e.g., petrolatum, mineral oil, glycerine, or by hardening of
certain ingredients prior to use.
In general, soap formulations within the following ranges may be
used:
Coco soap (i.e. palm, olive, stearic, etc.) -- 5 to 95% preferably
-- 5 to 45% Tallow soap (i.e. choice white grease etc.) -- 5 to 95%
preferably -- 45 to 95% Free fatty acid -- 0 to 30% preferably -- 5
to 10% Water -- 0 to 26% NaCl -- 0.1 to 5%
Other known soap formulations may be used and the soap component
can be replaced by detergent materials such as sodium fatty alcohol
sulfates, alkyloxyhydroxypropane sulfonates, and sodium fatty acyl
taurates. Translucent soaps can also be used and these can contain
nacreous pigments comprising transparent platelets of high
refractive index which produce pearlescent soap bars.
Dye compositions containing water or oil soluble dyes particularly
color-fast compositions can be used. Suitable dyes used include
those sold under the following names:
Monastral Fast Green
Monastral Fast Blue
Heliogen Green
Heliogen Blue
F d & c red No. 4
D & c red No. 19
Dye concentrations between 0.5 and 30% are added either continuouly
or in a pulsating flow of from 0.04 ml. to 5.0 ml. of dye solution
per pound of soap. It has been observed that a pulsating flow of
dye facilitates the use of larger dye quantities without undue
mixing of the dye as the soap passes through the plodder, i.e., the
addition of dye in pulses provides a product in which the contrast
between additive colored zones and base colored zones is greater
than when the dye additive is added at a constant rate. The pulse
cycle may vary up to 8 seconds of additive injection followed by a
75 second period during which no additive is injected.
* * * * *