Note: Descriptions are shown in the official language in which they were submitted.
CA 02592729 2007-06-21
DETERGENT POUCH COMPRISING SUPERPOSED
OR SUPERPOSABLE COMPARTMENTS
Technical field
The present invention is in the field of dishwashing, in particular it relates
to a water
soluble multi-compartment pouch adapted to fit the dishwasher dispenser and to
deliver
product into the pre-wash, main wash and/or post-rinse cycles of the
dishwashing
machine. The pouch contains a cleaning composition for release on dissolution
of the
pouch. The invention also relates to a process for the manufacture of the
pouches and to a
pack for the storage, distribution and display of the pouches.
Back ound of the invention
Unitised doses of dishwashing detergents are found to be more attractive and
convenient
to some consumers because they avoid the need of the consumer to measure the
product
thercby giving rise to a more precise dosing and avoiding wasteful overdosing
or
underdosing. For this reason automatic dishwashing detergent products in
tablet form
have become very popular. Detergent products in pouch form are also known in
the art,
they have the advantage over tablets of avoiding the contact of the consumer
fingers with
the dishwashing compositiori which may contain bleach and/or other irritant
substances.
The automatic dishwashing process usually involves a initial pre-wasb cycle,
main-wash
cycle and several hot rinse cycles. Better performance is obtained when the
detergent is
delivered at the beginning of the main-wash cycle than when the detergent is
delivered in
the pre-wash cycle since it can be lost with the initial water. In laundry
washing
machines the detergent can be placed in the drum or in the dispenser, however,
in
dishwashers the detergent is generally delivered into the main wash via the
dispenser to
avoid premature dissolution in the pze-wash. The amount of detergent is
therefore limited
3o by the volume of the dispenser. Dispensers vary in volume and shape from
manufacturer
to manufacturer. In the case of detergent in loose form (i.e., powders, paste
and liquids),
CA 02592729 2007-06-21
2
the volume of the dispenser is a decisive factor. In the case of unit dose
forms, such as
tablet, the geometry and shape of the dispenser plays also a very important
role.
Tablets can be designed to have a size and shape which fit all machines. One
of the
drawbacks of detergent tablets is the fact that their manufacturing process
requires the
additional step of powder compaction. This decreases enzyme activity and slows
down
the dissolution rate of the ingredients formin.g the tablet, or requires the
use of complex
and expensive disintegrant systems, or makes it difficult to achieve
differential
dissolution of the detergent active ingredients.
Some detergent ingredients used in dishwashing detergent compositions are
liquids.
These liquid ingredients can be difficult or costly to include in a solid
detergent
composition. Also, certain ingredients are preferably transported and supplied
to
detergent manufacturers in a liquid form and require additional, and sometimes
costly,
.15 process steps to enable them to be included in a solid detergent
composition. An example
of these detergent ingredients is surfactant, especially nonionic surfactant
which are
typically liquid at room temperature or are typically transported and supplied
to detergent
manufacturers in liquid form. Another example is organic solvents.
Current methods of incorporating liquid ingredients into solid detergent.
compositions
include absorbing the liquid ingredient onto a solid carrier, for example by
mixing,
agglomeration or spray-on techniques. Typically, solid detergent compositions
comprise
only low amounts of these liquid detergent ingredients due to the difficulty
and expense
of incorporating these liquid ingredients into a solid detergent. Furthermore,
the
incorporation of liquid ingredients into solid detergent compositions can
impact on the
dissolution characteristics of the composition (for example as the result of
fornling
surfactant gel phases), can increase the moisture pick-up by water sensitive
ingredients
and can also lead to problems of flowability. It would be advantageous to have
a
detergent composition which allows the different ingredients to be in their
natural state
i.e., liquid or solid. This would facilitate the manufacturing process,
increase the
component stability and furthermore allow the delivery of liquid ingredients
prior or post
to the delivery of solid ingredients. For example differential dissolution of
active
CA 02592729 2007-06-21
3
ingredients would be beneficial in the case of enzyme/bleach compositions to
avoid
oxidation of enzymes by the bleach in the dishwashing liquor. It would also be
advantageous to separate bleach from perfume.
Another factor that can contribute to the inefficient delivery of actives to
the wash, in the
case of tablets, is the need for adding carrier materials, as for example
porous materials
able to bind active liquid materials, binders and disintegrants. In
particular, the
incorporation of liquid surfactants to powder form detergent compositions can
raise
considerable processing difficulties and also the problem of poor dissolution
through the
formation of surfactant gel phases.
There is still the need for a multi-compartment unitised dose form capable of
fitting the
dispensers of different dishwashing machine types and which allows for the
simultaneous
delivery of incompatible ingredients and ingredients in different physical
fomis. There is
also need for a simplified manufacturing process for multi-compartment pouch
production and for multi-compartment pouches with improved strength, handling
and
dissolution characteristics as well as excellent aesthetics.
The most common process for making water-soluble pouches with products such as
cleaning products is the so-called vertical form-fill-sealing process. Hereby,
a vertical
tube is formed by folding a film. The bottom end of the tube is sealed to give
rise to an
open pouch. This pouch is partially filled allowing a head space whereby the
top part of
the open pouch is then subsequently sealed together to close the pouch, and to
give rise to
the next open pouch. The first pouch is subsequently cut and the process is
repeated. The
pouches formed in such a way usually have pillow shape.
A second known process for making pouches is by use of a die having a series
of moulds
and forming from a film, open pouches in these moulds, which can then be
filled and
sealed. This method uses the pouch film material more efficiently and the
process has
more flexibility in terms of pouch shapes and ingredients used. However, the
process has
limited suitability for industrial application, because it cannot produce
large quantities of
pouches (per time unit), in an easy and efficient manner.
CA 02592729 2007-06-21
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A third process proposed is the formation of pouches in moulds present on the
surface of
a circular drum. Hereby, a film is circulated over the drum and pockets are
formed, which
pass under a filling machine to fill the open pockets. The filling and sealing
needs to take
place at the highest point (top) of the circle described by the drum, e.g.
typically, filling is
done just before the rotating drum starts the downwards circular motion, and
sealing just
after the drum starts its downwards motion.
One problem associated with the vertical filling machine is that the process
is not very
efficient: the process is intermittent and very slow, for example due to
process speed
changes from one step to the next step, and each pouch formation step result
typically
only in one string of pouches in one dimension; thus, only a limited amount of
pouches
per minute can be formed. Moreover, large quantities of film are used per
product dose,
because the method does not allow complete filling of the pouches, there is a
substantial
seal along the vertical dimension of each pouch, and the method does not allow
stretching
of the film. Also, there is not much flexibility in shapes of pouches formed.
Problems associated with the second process using a die with moulds include
also the fact
that the process is intermittent (or an indexing process), and that the
process is slow and
involves acceleration and deceleration, which reduces the overall speed and
moreover,
causes product spillage out of the open pouches. Also, the output of this
process is not
very high (per time. unit).
The circular drum process overcomes some of the disadvantages of these
processes
because it does not entail speed changes (no acceleration/ deceleration), it
can readily
provide pouches arranged in two dimensions and the shape of the pouches can be
varied
to some extent. However, spillage from the pouches can be quite substantial,
due to the
circular movement, which causes product to spill onto the sealing area, and
this can cause
problems with sealing (leaking seals). Also, the process does not allow the
pouches to be
filled completely, because the spillage is then even more of a problem. Also,
this process
has even more significant problems when used for liquid products, which are
more likely
to cause large spillage, due to the circular motion. Moreover, the filling and
sealing has to
CA 02592729 2007-06-21
be done around the highest point of the circular path of the drum, thereby
hugely reducing
the overall speed and the output of the pouch formation process.
All the known processes, moreover are designed primarily for making single
5 compartment pouches. There is still need for a process to make multi-
compartment
water-soluble pouches which overcome the above issues, namely a continuous
process,
with a fast production rate and which minimize the amount of film:used for
each pouch.
There is also a need for a process of making multi-compartment water-soluble
pouches
having improved strength and adapted for use in machine dishwashing.
Summar~of the invention
According to a first aspect of the present invention, there is provided a
machine
dishwashing product in the form of water-soluble pouch. The pouch comprises a
plurality
of compartments in generally superposed or superposable relationship, for
example, the
plurality of compartments can be symmetrically arranged one above another,
side by side
(such that they can be folded into a superposed relationship) or any other
convenient
disposition provided that the compartments are superposable in use. Each
compartment
contains one or more detergent active components or detergent auxiliaries.
Water-soluble
pouches comprising a plurality of compartments are herein referred to as multi-
compartment pouches. Multi-compartment pouches in which the compartments are
in a
superposed relationship are especially advantageous when one or more of the
comparlments comprise a moisture sensitive ingredient, because the compartment
comprising a moisture sensitive ingredient can be placed in intermediate or
bottom layers
and thus they have less surface area exposed to the surrounding environment,
therefore
reducing the possibility of picldng up moisture from the surroundings.
The pouch preferably has a volume of from about 5 to about 70 ml, preferably
from about
15 to about 60 ml, more preferably from about 18 to 57 ml, and a
longitudinal/transverse
aspect ratio in the range from about 2:1 to about 1:8, preferably from about
1:1 to about
1:4. The longitudinal dimension is defined as the maximum height of the pouch
when the
CA 02592729 2007-06-21
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pouch is lying on one of the bases. which has the maximum footprint with the
pouch
compartments superposed in a longitudinal direction, i.e. one. over another,
and under a
static load of about 2 Kg. The transverse dimension is defined as the maximum
width of
the pouch in a plane perpendicular to the longitudinal direction under the
same
conditions. These dimensions are adequate to fit the dispensers of the
majority of
dishwashers. Although the shape of the pouch can vary widely, in order to
maximise the
available volume, preferred pouches have a base as similar as possible to the
footprint of
the majority of the dispensers, that is generally rectangular.
In one embodiment the plurality of compartments of the water-soluble pouch are
in
generally superposed relationship and the pouch comprises upper and lower
generally
opposing outer walls, a skirt-like side walls, forming the sides of the pouch,
and one or
more internal partitioning walls, separating different compartments from one
another, and
wherein each of said upper and lower outer walls and slcut-like side wall are
formed by
thermoforming, vacuum forming or a combination thereof.
Thus, according to another aspect of the invention there is provided a machine
dishwashing product in the form of a water-soluble pouch comprising a
plurality of
compartments in generally superposed relationship, each compartment containing
one
more detergent active or auxiliary components, wherein the pouch comprises
upper and
lower generally opposing outer walls, a skirt-like side watl and one or more
intemal
partitioning walls, and wherein each of said upper and lower outer waIls
artd'said skirt-
like side wall are formed by thermoforming, vacuum forming or a combination
thereof.
In a preferred embodiment each internal partitioning wall of the water-soluble
multi-
compartment pouch is secured to an outer or side wall of the pouch along a
single seal
line or to both an outer and a side wall of the pouch along a plurality of
seal'lines that are
at least partially non-overlapping. Preferably each partitioning wall is
secured to one or
more outer or sides wall by heat or solvent sealing.
In especially preferred embodiments at least one internal partitioning wall of
the multi-
compartment pouch is secured to an upper or lower outer wall along a first
continuos seal
CA 02592729 2007-06-21
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line and one or both of said outer wall and said partitioning wall are secured
to the skirt-
like side wall along a second continuous seal line and wherein the seal lines
in the case of
heat seals are essentially non-overlapping and in the case of solvent seals
are at least
partially non-overlapping.
Non-overlapping seal lines are particularly advantageous in the case of multi-
compartment pouches made by a process involving several non-simultaneous heat
sealing
steps. Without wishing to be bound by theory, it is believed that the heat
seal mechanism
involves the step of water evaporation from the film, therefore it is very
difficult to
achieve a good overlapping seal unless the two seals are formed
simultaneously. Heat
sealing is preferred in cases in which the pouches are filled with water
sensitive
components. Solvent sealing can reduce processing cost,. can produce stronger
seals and
can make the process faster. Partially non-overlapping seals allow for the
superposition
of a plurality of compartments of different sizes.
Preferably, at least one internal partitioning wall of the multi-compariment
pouch is
secured to the upper outer wall along a first seal line defining the waist
line of the sldrt-
like wall and wherein the second non-overlapping or at least partially non-
overlapping
seal is preferably off-set below the waist line-defining seal line in the
direction of the
lower outer wall. The skirt-like side wall is also preferably slightly
gathered or puckered
in the final pouch to provide a mattress-like appearance.
Thus, according to another aspect of the invention, there is provided a
machine
dishwashing product in the form of a water-soluble pouch comprising a
plurality of
compartments in generally superposed relationship, each compartment containing
one
more detergent active components, wherein the pouch comprises upper and lower
generally opposing outer walls, a skirt-like side wall and one or more
internal partitioning
walls wherein at least one internal partitioning wall is secured to an upper
or lower outer
wall along a first seal line and one or both of said outer wall and said
partitioning wall are
secured to the skirt-like side wall along a second seal line and wherein the
seal lines are at
least partially non-overlapping.
CA 02592729 2007-06-21
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In another embodiment the water-soluble pouch comprises a plurality of
compartments in
side-by-side but generally superposable relationship (for example, the
compartments can
be folded over each other). The pouch comprises upper and lower generally
opposing
outer walls, one or more skirt-like side walls and one or more external
partitioning walls,
.5 and wherein each of said upper and lower outer walls and skirt-like side
walls are formed
by thermoforming, vacuum forming or a combination thereof.
In one embodiment at 'least one of the plurality of compartments of the water-
soluble
pouch comprises a powder or densified powder composition. The powder
composition
usually comprises traditional solid materials used in dishwashing. detergent,
such as
builders, alkalinity sources, enzymes, bleaches, etc. The powder composition
can be in
the form of dry powder, hydrated powder, agglomerates, encapsulated materials,
extrudates, tablets or mixtures thereof. It is also useful to have water-
soluble pouches
with several compartments comprising different powder compositions, usually
compositions in different compartments comprise incompatible actives or
actives which
need to be delivered at different times of the dishwashing process. It is
advantageous to
have bleach and enzymes in different compartments.
In a preferred embodiment at least one of the powder compartments.comprises
particulate
2o bleach. The bleach is preferably selected from inorganic peroxides
inclusive of
perborates and percarbonates, organic peracids inclusive of preformed
monoperoxy
carboxylic acids, such as phthaloyl amido peroxy hexanoic acid and di-acyl
peroxides.
In the case of powder compositions differential dissolution can be obtained,
for example,
by varying the degree of powder compression and/or particle size of 'the
powder
compositions in the same or different compartments. Another way to obtain
differential
dissolution is to use water-soluble films of different thickness or different
degree or rate
of solubility under in-use conditions. Film solubility can be controlled by
for example
pH, temperature, ionic strength or any other means. For purposes of achieving
phased or
sequential delivery of detergent actives, it is preferred that each of the
compartments of
the pouch have a different disintegration rate or dissolution profile under in-
use
conditions.
CA 02592729 2007-06-21
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In another embodiment at least one of the plurality of compartments of the
water-soluble
pouch comprises a liquid composition. The liquid compositions comprise
traditional
liquid materials used in dishwashing detergents, such as non-ionic surfactants
or the
organic solvents described hereinbelow. In preferred embodiments the liquid
composition comprises detergency enzyme. Especially useful are water-soluble
pouches
having one compartment comprising a liquid composition and another compartment
comprising a solid composition. In the case of liquid compositions, especially
liquid
compositions enclosed within a secondary pack, it is desirable to have a water
content in
the composition similar to the water content in the fihn in order to avoid
transfer of water.
from one to another. In cases in which the content of water is lower in the
composition
than in the film, water can migrate from the film to the composition maldng
the water-
soluble pouch brittle. For similar reasons, it is also desirable to have a
similar amount of
plasticiser in the composition and in the film.
In another embodiment at least one of the plurality of compartments of the
water-soluble
pouch comprises a composition in the form of a paste. The multi-compartment
pouches
can also include compositions in the form of a gel or a wax.
In preferred embodiments at least one of the plurality of compositions of the
water-
soluble pouch comprises an organic solvent system compatible with the water-
soluble
pouch. The organic solvent system can simply act as a liquid carrier, but in
preferred
compositions, the solvent can aid removal, of cooked-, baked- or burnt-on soil
and thus
has detergent functionality in its own right. The organic solvent system
(comprising a
single solvent compound or a mixture of solvent compounds) preferably has a
volatile
organic content above 1 mm Hg and more preferably above 0.1 mm Hg of less than
about
50%, preferably less than about 20% and more preferably less than about 10 /a
by weight
of the solvent system. Herein volatile organic content of the solvent system
is defined as
the content of organic components in the solvent system having a vapor
pressure higher
than the prescn'bed limit at 25 C and atmospheric pressure.
CA 02592729 2007-06-21
The organic solvent system for use herein is preferably selected from
organoarnine
solvents, inclusive of alkanolamines, alkylamines, alkyleneamines and mixtures
thereof;
alcoholic solvents inclusive of aromatic, aliphatic (preferably Ca-Cao) and
cycloaliphatic
alcohols and mixtures thereof; glycols and glycol derivatives inclusive of C2-
C3
5 (poly)alkylene glycols, glycol ethers, glycol esters and mixtures thereoF
and mixtures
selected from organoamine solvents, alcoholic solvents, glycols and glycol
derivatives. In
one preferred embodiment the organic solvent comprises organoamine (especially
:..
alkanolamine) solvent and glycol ether solvent, preferably in a weight ratio
of from about
3:1 to about 1:3, and wherein the glycol ether solvent is selected from
ethylene glycol
10 monobutyl ether, diethylene glycol monobutyl ether, ethylene glycol
monomethyl ether,
ethylene glycol monoethyl ether, diethylene glycol monomethyl ether,
diethylene glycol
monoethyl ether, propylene glycol monobutyl ether, and mixtares thereof.
Preferably,
the glycol ether is a mixture of diethylene glycol monobutyl ether and
propylene glycol
butyl ether, especially in a weight ratio of from about 1:2 to about 2:1.
There is also provided a method of washing dishware/tableware in an automatic
dishwashing machine using the machine dishwashing product described herein.
The
method is suitable for simultaneous or sequential delivery of detergent
actives into one or
more of the pre-wash, main-wash or rinse cycles of the washing machine but is
especially
suitable for delivery in the main-wash or rinse cycles.
According to another aspect of the present invention, there is provided a
process for
making a water-soluble pouch. The pouch is suitable for use in machine
washing,
including laundry and dishwashing, and comprises a plurality of compartments
in
generally superposed or superposable relationship, each comprising a detergent
active
component. The process comprising the steps of: i) forming a first moving web
of filled
and optionally sealed pouches releasably mounted on a first moving (preferably
rotating)
endless surface; ii) forming a second moving web of filled and sealed pouches
releasably
mounted on a second moving (preferably rotating) endless surface; iii)
superposing and
sealing or securing said first and second moving webs to form a superposed and
sealed
web; and iv) separating said superposed and sealed web into a plurality of
water-soluble
multi-compartment pouches. In a preferred embodiment, the second moving
endless
CA 02592729 2007-06-21
il
surface moves in synchronism with said first moving endless surface. This
facilitates to
carry out the process in a continuous manner.
The first web of filled open pouches can be closed with any web closure means,
such as
for example a film of pouch forming material but in a preferred embodiment is
preferably
closed with the second web of pouches, this avoids the use of an extra layer
of film. The
web closure means preferably moves in synchronism with the fiist endless
surface and the
first web of open pouches mounted thereon. In preferred embodiments the second
web of
pouches is inverted prior to the closure of the first web of open pouches,
this being
preferred from the view point of facilitating the superposition on web-sealing
process.
The first moving web of open pouches can be formed, for example, by feeding a
water-
soluble film to a die having a series of moulds. The moulds can be of any
convenient size
and shape, preferred for use herein being wtangular moulds having a footprint
adequate
to fit the majority of dishwasher dispensers. Apart from being advantageous
for dispenser
fit, rectangular pouches inherently have regions of different film thickness
on the fhn and
this can contribute to improve the dissolution profile of the pouch.
The open.pouches can be formed using thermoforniing, for example by heating
the
moulds or by applying heat in any other known way such as blowing hot air or
using
heating lamps. If desired, vacuum assistance can be employed to help drive the
film into
the mould. Open pouches can alternatively be formed by vacuum-forming, in
which case
heat assistance can be provided to facilitate the process. In general
thermoforming is
primarily a plastic deformation process while vacuum-forming is primarily an
elastic
' deformation process. The two techniques can be combined to produce pouches
with any
desired degree of elasticity/plasticity.
The first web of open pouches is preferably formed on a fnst rotating endless
surface, this
surface being preferably horizontal or substantially horizontal during the
filling of the
pouches.
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12
Thus, according to another aspect of the present invention there is provided a
process for
making a water-soluble pouch and which comprises a plurality of compartments
in
generally superposed relationship, each comprising a detergent active or
auxiliary
component, the process comprising the steps of forming and filling a moving
horizontal
or substantially horizontal web of open pouches releasably mounted on a first
moving
endless surface and closing the web of open pouches with a superposed moving
web of
pre-forrned, filled and sealed pouches moving in synchronism therewith. The
first
endless surface is preferably moving in continuous horizontal or substantially
horizontal
motion and preferably in continuous horizontal rectilinear motion during the
step of
filling the first moving web of open pouches.
In preferred embodiments, the first open web of open pouches is filled by
means of a
product filling station comprising means for filling quantities of one or more
product feed
streams into each of the open pouches. Preferably this filling station is
arranged to move
in synchronism with the first web of open pouches during fxlling step, thereby
avoiding
any acceleration/deceleration of the open pouches during filling and
consequent spillage
of detergent and contamination of the sealing area. The horizontal rectilinear
movement
of the first web of open pouches allows full or more complete filling of the
open pouches
giving rise to a better utilisation of the film, Alteznatively, the filling
station can be
stationary.
The detergent product can be delivered into each of the open pouches through
individual
dosing or dispensing devices having a single feeder or means for supplying a
single
product feed stream, this being preferred in cases where a single premixed
composition is
to be delivered into the pouch. In the case of multi component liquid
compositions, each
pouch can be filled by means of multiple feedeis or means for supplying a
plurality of
product feed streams, each feeder delivering a different liquid composition
(or component
thereof), so as to avoid the need for a premixing step. In the case of multi
component
powder compositions, again each pouch can be filled by means of multiple
feeders, each
one delivering a powder composition (or component thereof) so as to form
distinct layers
of product. In the case of powder compositions it is advantageous to have a
masking belt
CA 02592729 2007-06-21
13
having an orifice of the same size or slightly smaller than the aperture of
the open pouch,
in order to avoid seal contamination.
The first web of open pouches can be optionally closed and sealed with film
after filling
and prior to superposing and sealing the second moving web of pouches. The
second web
of pouches can be made separately but in preferred embodiments the second web
of
pouches is horizontal or substantially horizontal during the filling of the
pouches. In a
preferred embodiment the step of filling the second moving horizontal web of
open
pouches is accomplished using a second product filling station moving in
synchronism
with the second endless surface. In one embodiment, the filling station
comprises means
for delivering a plurality of product feed streams, as in the case of the
filling station for
the first web of open pouches described hereinabove. Where the first web is
itself sealed
with film prior to superposing the two webs, the two webs may if required be
secured to
one another along a discontinuous seal line.
Although each of the first and second endless surfaces and the corresponding
web of
pouches can be adapted for movement in either a horizontal rectilinear or
curvilinear
manner during filling of the pouches, preferred herein is a-process wherein
the first
endless surface is moving in horizontal rectilinear motion during the step of
filling the
first moving web of open pouches and wherein the second endless surface is
moving in
substantially horizontal rectilinear or curvilinear motion during the step of
filling the
second moving web of open pouches.
Preferably the second endless surface rotates in a direction counter to the
fnst endless
surface.
The pouches of the second web are also preferably covered, closed and sealed
with film
closure means after filling and prior to superposing on the first web of
pouches and
sealing of the two webs. Preferred for use herein is heat sealing, that can be
done by any
known medium, for example direct application, infra-red, ultrasonic, ra.dio
frequency,
laser. Solvent sealing can alternatively be used herein.
CA 02592729 2007-06-21
14
The web of two compartment pouches formed in this way is thereafter divided
into
individual pouches, for example by cutting means known per se. Preferably, the
pouches
are produced with a constant pitch at, a constant speed, this can facilitate
the automation
of the packaging process. Although the process described herein above is
directed to the
manufacture of dual-compartment pouches, multi-compartment pouches with more
than
two comparlments can be manufactured in a similar manner, for example by
superposing
and sealing three or more web of pouches. Also very useful for use herein
being multi-
compartment pouches in which at least one of the conzpartments is horizontally
divided
into a plurality of compartments.
According to another process aspect, there is provided a process for making a
water-
soluble pouch suitable for use in machirie washing, including laundry and
dishwashing
and which comprises a plurality of compartments in generally superposed or
superposable
relationship, each compartment comprises a detergent active or auxiliary
component, the
process comprising the steps, of:
a) forming and partially filling a moving web of open pouches releasably
mounted on
a moving endless surface, the partial filling being such as to leave
sufficient space
for the formation of a second compartment in the same mould;
b) closing and sealing said moving web with web closure means moving in
synchronism therewith whereby the web closure means is introduced into the
partially filled pouches so as to form a plurality of closed and superposed
open
compartments;
c) filling, closing and sealing the superposed open compartments by means of a
second web closure means moving in synchronism with said moving web; and
d) separating said web into a plurality of water-soluble multi-compartment
pouches.
In the above process the formation of multi-compartment pouches requires only
one
moving endless surface, which can be beneficial from the capital cost point of
view.
Each pouch is formed in a single mould. After the web of open pouches is
formed, each
open pouch is partially filled, closed and sealed to give rise to a second
open
comparhnent, which is itself then filled, closed and sealed. In a preferred
embodiment
the sealing steps are undertaken by means of solvent sealing.
CA 02592729 2007-06-21
The term "filling" as used herein includes both 'partial" and " complete"
filling of a pouch
or compartarent thereof. An open pouch or compartment is considered to be
completely
filled, when the product fills at least about 90% of the volume of the open
pouch or
5 compartment. "Partial" filling is construed accordingly.
In a slightly modified version of this process, the sealing step is undertaken
at a later
stage of the process. Thus, according to this aspect, there is provided a
process for
making a water-soluble pouch suitable for use in machine washing, including
laundry and
10 dishwashing and which comprises a plurality of compartments in generally
superposed or
superposable relationship, each comprising a detergent active or auxiliary
component, the
process comprising the steps of:
a) forming and partially filling a moving web of open ponches releasably
mounted on
a moving endless surface;
15 b) closing said moving web with web closure means moving in synchroiiism
therewith
whereby the web closure means is introduced into the partially filled pouches
so as
to form a plurality of closed and superposed open compartments;
c) filling and closing the superposed open compartments by means of a second
web
closure means moving in synchronism with said moving web;
d) sealing said web and said first and second web closure means; and
e) separating said web into a plurality of water-soluble multi-compartment
pouches.
In a preferred execution of this process, the sealing step is undertaken by
means of
ultrasonic sealing.
In another variation on this approach, the web of open pouches in step (a) is
filled, either
partially or completely, with a first composition comprising a detergent
active or auxiliary
and thereafter either the composition is densified or the pouch enlarged to
provide
sufficient space for the formation of the second comparkment. In the case of a
powder
composition, densification can be achieved by compaction, tapping, stamping,
vibrating,
etc, densification being preferably such as to provide a bulk density increase
of at least
about 5%, preferably at least about 10%, and especially at least about 20%,
more
CA 02592729 2007-06-21
16
preferably at least about 30%. The final bulk density is preferably at least
about 0.6 g/cc,
more preferably at least about 0.8 g/cc, more especially at least about I
g/cc. Means for
enlargement of the pouch includes means for altering the size or volume of the
mould, for
example, a moveable floor section, an insert of variable size or volume, etc.
In alternative executions, the superposed open compattments can also be formed
after the
step of closing and sealing the moving web of open pouches. Thus, according to
a further
process aspect, there is provided a process for maldng a water-soluble pouch
which
comprises a plurality of compartments in generally superposed or superposable
relationship, each comprising a detergent active or auxiliary component, the
process
comprising the steps of=
a) forming and filling a moving web of open pouches releasably mounted on a
moving endless surface;
b) closing and sealing said moving web with web closure means moving in
synchronism therewith so as to form a plurality of closed compartments;
c) forming a recess within some or all of the closed compartments formed in
step (b)
so as to generate a plurality of open compartments superposed above the closed
compartments;
d) filling, closing and sealing the superposed open compartments by means of a
second web closure means moviag in synchronism with said moving web; and
e) separating said web into a plurality of water-soluble multi-compartment
pouches.
Again in a slightly modified version of this process, the sealing step is
undertaken at a
later stage of the process. Thus, according to yet another process aspect,
there is provided
a process for making a water-soluble pouch and which comprises a plurality of
compartments in generally superposed or superposable relationship, each
comprising a
detergent active or auxiliary component, the process comprising the steps of:
a) forming and filling a moving web of open pouches releasably mounted on a
moving
endless surface;
b) closing said moving web with web closure means moving in synchronism
therewith
so as to form a plurality of closed compartments;
CA 02592729 2007-06-21
17
c) forming a recess within some or all of the closed compartments formed in
step (b)
so as to generate a plurality of open compartments superposed above the closed
compartments;
d) filling and closing the superposed open compartments by means of a second
web
closUre means moving in synchronism with said moving web;
e) sealing said web and said first and second web closure means; and
f) separating said web into a plurality of water-soluble multi-comparhnent
pouches.
For purposes of forming the recesses, the closed compartments can be subjected
to a
powder compression or compaction stage as described above with, if necessary,
means
such as vent holes being provided in the web to enable venting of air from the
compressed
compartments.
In aIi these process aspects, the endless surface is preferably moving in
continuous
horizontal or substantially horizontal, preferably rectilinear, motion during
the steps of
filling the open pouches and superposed open compartments of the moving web.
Alternatively, the motion can be intermittent, although is less preferred. It
is also
preferred that the steps of filling are accomplished using product filling
station moving in
synchronism with the endless surface. Suitably, the product filling station
can comprise
means for filling quantities of a plurality of product feed streams into each
of said
compartments.
Preferably, the multi-compartment pouches formed according. to any of the
processes
described herein comprise a plurality of compartments containing a powder
composition
and a plurality of compartments containing a liquid, gel or paste composition.
It will be
understood moreover that by the use of appropriate feed stations, it is
possible to
manufacture multi-compartment pouches incorporating a number of different or
distinctive powder compositions and/or different or distinctive liquid, gel or
paste
compositions. This can be expecially valuable for manufacturing unit dose
forms
displaying novel visual and/or other sensorial effects.
CA 02592729 2007-06-21
18
Thus, in another process aspect, there is provided a process for forming a
plurality of
multi-compartment pouches in a multiplicity of sensorially distinctive groups,
the process
comprising filling each of a multiplicity of compartmental groups with a
corresponding
sensoriaUy distinctive composition, whereby the resulting groups are
distinctive in terms
of colour, shape, size, pattern or ornament, or wherein the groups are
distinctive in terms
of providing a unique sensorial signal such as smell, sound, feel, etc.
The present invention also provides a display pack comprising an outer package
such as a
see-through container, for example a transparent or translucent carton or
bottle which
contains a plurality of water-soluble pouches or other unit doses of detergent
product in a
multiplicity of visually or otherwise sensorially distinctive groups. By
visually distinctive
herein is meant that the groups can be distinguished in terms of shape,
colour, size,
pattern, ornament, etc. Otherwise the groups are distinctive in terms of
providing a
unique sensorial signal such as smell, sound, feel, etc.
In a preferred embodiment there is provided a see-through, preferably
transparent,
dishwashing detergent pack wherein the number of distinctive groups of pouches
or other
unit doses is at least 2, preferably at least 3, more preferably at least 4,
and especially at
least 6 and wherein the number of unit doses per pack is at least about 10,
preferably at
least about 16 an more preferably at least about 20. Preferably the unit doses
are multi-
compartment pouches, each compartment itself possibly being visually or
otherwise
distinctive from the remainder of the compartments in an individual pouch. In
a preferred
embodiment, groups of pouches are distinctive in temis of colour. In the case
of multi-
compartment pouches at least one group of pouches has one compartment which is
visually distinctive, for example in terms of colour, from the corresponding
compartment
in one or more other groups of pouches. Preferably in such embodiments, all
pouch
groups have at least one 'common' compartment, i.e. the appearance of which is
the same
from group to group. Preferably the visually distinctive compartment contains
a liquid,
gel or paste; the common compartment contains a powder or tablet. The pouches
can be
arranged in any form in the pack, either randomly or following an order, for
example
suitable arrangements including layers wherein each pouch comprises at least
one
compartment of a different colour to any of the compartments of the remainder
of the
CA 02592729 2007-06-21
19
pouches on the same layer. The pack can be made of plastic or any other
suitable
material, provided the material is strong enough to protect the pouches during
transport.
This kind of pack is also very useful because the user does not need to open
the pack to
see how, many pouches there are left, the different colour pouches are very
easy to
identify from the exterior. Altematively, the pack can have non-see-tluough
outer
packaging, perhaps with indicia or artwork representing the visually-
distinctive contents
of the pack. -
In another embodiment distinctive groups of pouches contain different
perfumes. The
perfumes can be colour associated perfumes, for example, yellow with lemon
smell, pink
with strawberry smell, blue with sea smell, etc.
The processes described herein for making multi-cdmpartment pouches can be
adapted to
form a plurality of pouches in a multiplicity of sensorially distinctive
groups as described
above, whereby each of a multiplicity of compartmental groups is 'filled with
a
corresponding sensorially-distinctive composition. This simplifies the
manufacture of the
display pack of the invention.
Detailed description of the invention
The present invention envisages multi-compartment water-soluble pouches of
optimum
shape and dimensions to be placed in the majority of dishwasher dispensers.
The pouches
of the invention allow optimal use of the dishwashing machine dispenser, as
well as
optimal delivery . and storage of dishwashing compositions, without loosing
the
convenience of unit dose form. The multi-compartment unit dose executions
include unit
dose forms comprising in separated compartments either powder, liquid or
paste.
Especially useful compositions are those containing an organic solvent capable
of remove
baked-, cook- or burnt-on soils. The invention also envisages multi-
compartment
executions which allow differential delivery of compositions contained in
different
compartments.
CA 02592729 2007-06-21
The invention also envisages a process for the manufacture of multi-
compartment water-
soluble pouches. The process is fast and very versatile, furthermore, it
allows for an
efficient use of the water-soluble film.
5 Finally, the invention, envisages a detergent pack having improved display
attributes and
which makes it very easy for the consumer to evaluate the amount of pouches in
the pack.
The dishwashing composition, or components for use herein, are contained in
the internal
volume space of the pouch, and are typically separated from the outside
environment by a
10 barrier of water-soluble material. Typically, different components of the
composition
contained in different compartments of the pouch are separated from one
another by a
barrier of water-soluble material.
The compartments of the water-soluble pouch may be of a different colour from
each
15 other, for example a fnst compartment may be green or blue, and a second
compartment
may be white or yellow. One compartment of the pouch may be opaque or semi-
opaque,
and a second compartment of the pouch may be translucent, transparent, or semi-
transparent- The comparhnents of the pouch may be the same size, having the
same
internal volume, or may be different sizes having different intemal volumes.
Suitable water-soluble pouches include for example dual-compartment pouches
comprising loose powder, densified powder or a tablet in a first compartment
and a liquid,
paste, or waxy or translucent gel detergent in a second compartment. The
second liquid,
paste or gel compartment could also contain a separate packed powder, for
example in the
form of micro-beads, noodles or one or more pearlized balls allowing a delayed
or
sequential release effects. If the first compartment comprises a tablet, this
tablet can have
a recess of a size and geometrical shape, (e.g. square, round or oval) so as
to partially or
totally house the second compartment. In pouches comprising powder in the
first
compartment, the powder can be arranged in layers tb.at can be of different
colours.
Alternatively, dual compartment pouches can comprise powder of the same or
different
colours in the two compartments, the powder comprising flecks of one or more
colours or
CA 02592729 2007-06-21
21
having a uniform colour. One of the two compartments could also comprise a
separate
densified powder phase (allowing delayed or controlled release), for example
in the form
of micro.-beads, noodles or one or more pearlized balls. Other dual
compartment pouches
comprise a single or multi-phase liquid, paste or waxy or translucent gel
detergent in the
two compartments, each compartment either comprising multi-phase liquid or
gels being
of the same or different colour and/or density. Either or both of these
compartments can
also comprise a separate densified powder phase (allowing delayed or
controlled release), ,_.=
for example in the form of micro-beads, noodles or one or more pearlized
balls. The
compartments of all the above described dual compartment pouches can be
superposed or
be in superposable (e.g. side by side) relationship.
Multi-compartment pouches, having three compartments, can have superposed
compartments of any geometrical shape in a sandwich like disposition, for -
example
having either loose or compacted powder in the two outer compartments and
having a
liquid, paste or waxy or translucent gel in the middle compartment. Contrary,
the liquid,
paste or waxy or translucent gel can be in the two outer compartments, perhaps
containing suspended solids and speckles, and the powder can be in the middle
compariment. A multi-compartment pouch can also have a tablet with more than
one
recess in the first compartment and with multiple other compartments totally
or partially
housed in the recesses of the tablet.
The pouches can be packed in a string, each pouch being individualiy separable
by a
perforation line. . Therefore, each pouch can be individually torn-off from
the remainder
of the string by the end-user.
Especially suitable for use herein are multi-compartment pouches having a
first
comparkment comprising a liquid composition and a second compartment
comprising a
powder composition wherein the weight ratio of the liquid to the solid
composition is
from about 1:30, to about 30:1, preferably form about 1:1 to about 1:25 and
more
preferably from about 1:15 to about 1:20.
CA 02592729 2007-06-21
22
For reasons of deformability and dispenser fit under compression forces,
pouches or
pouch compartments containing a component which is liquid will usually contain
an air
bubble having a volume of up to about 50%, preferably up to about 40%, more
preferably
up to about 30%, more preferably up to about 20%, more preferably up to about
10% of
the volume space of said compartment.
The pouch is preferably made of a pouch material which is soluble or
dispersible in water,
and has a water-solubility of at least 50%, preferably at least 75% or even at
least 95%, as
measured by the method set out here after using a glass-filter with a maximum
pore size
of 20 microns.
50 grams 0.1 gram of pouch material is added in a pre-weighed 400 ml beaker
and
245m1 iml of distilled water is added. This is stirred vigorously on a
magnetic stirrer
set at 600 rpm, for 30 minutes. Then, the mixture is filtered through a folded
qualitative
sintered-glass filter with a pore size as defined above (max. 20 micron). The
water is
dried off from the collected filtrate by any conventional method, and the
weight of the
remaining material is determined (which is the dissolved or dispersed
fraotion). Then, the
% solubility or dispersability can be calculated.
Preferred pouch materials are polymeric materials, preferably polymers which
are formed
into a film or sheet. The pouch material can, for example, be obtained by
casting, blow-
moulding, extrusion or blown extrusion of the polymeric material, as known in
the art.
Preferred polymers, copolymers or derivatives thereof suitable for use as
pouch material
are selected from polyvinyl alcohols, polyvinyl pyrrolidone, polyalkylene
oxides,
acrylamide, acrylic acid, cellulose, cellulose ethers, cellulose esters,
cellulose amides,
polyvinyl acetates, polycarboxylic acids and salts, polyaminoacids or
peptides,
polyamides, polyacrylamide, copolymers of maleic/acrylic acids,
polysaccharides
including starch and gelatine, natural gums such as xanthum and carragum. More
preferred polymers are selected from polyacrylates and water-soluble acrylate
copolymers, methylcellulose, carboxymethylcellulose sodium, dextrin,
ethylcellulose,
hydroxyethyl cellulose, hydroxypropyl methylcellulose, maltodextrin,
polymethacrylates,
CA 02592729 2007-06-21
23
and most preferably selected from polyvinyl alcohols, polyvinyl alcohol
copolymers and
hydroxypropyl methyl cellulose (HPMC), and combinations thereof. Preferably,
the level
of polymer in the pouch material, for example a PVA polymer, is at least 60%.
The polymer can have any weight average molecular weight, prefera.bly from
about 1000
to 1,000,000, more preferably from about 10,000 to 300,000 yet more preferably
from
about 20,000 to 150,000.
Mixtures of polymers can also be used as the pouch material. This can be
beneficial to
control the mechanical and/or dissolution properties of the compartments or
pouch,
depending on the application thereof and the required needs. Suitable mixtnres
include
for example mixtures wherein one polymer has a higher water-solubility than
another
polymer, and/or one polymer has a higher mechanical strength than another,
polymer.
Also suitable are mixtures of polymers having different weight average
molecular
weights, for example a mixture of PVA or a copolymer thereof of a weight
average
molecular weight of about 10,000- 40,000, preferably around 20,000, and of PVA
or
copolyiner thereof, with a weight average molecular weight of about 100,000 to
300,000,
preferably around 150,000.
Also suitable herein are polymer blend compositions, for example comprising
hydrolytically degradable and water-soluble polymer blends such as polylactide
and
polyvinyl alcohol, obtained by mixing polylactide and polyvinyl alcohol,
typically
comprising about 1-35% by weight polylactide and about 65% to 99% by weight
polyvinyl alcohol.
Preferred for use herein are polymers which are from about 60% to about 98%
hydrolysed, preferably about 80% to about 90% hydrolysed, to improve the
dissolution
characteristics of the material.
Most preferred pouch materials are PVA films known under the trade reference
Monosol
M8630, as sold by Chris-Craft Industrial Products of Gary, Indiana, US, and
PVA films
of corresponding solubility and deformability characteristics. Other films
suitable for use
CA 02592729 2007-06-21
24
herein include films known under the trade reference PT film or the K-series
of films
supplied by Aicello, or VF-HP film supplied by Kuraray.
The pouch material herein can also comprise one or more additive ingredients.
For
example, it can be beneficial to add plasticisers, for example glycerol,
ethylene glycol,
diethyleneglycol, propylene glycol, sorbitol and mixtures thereof. Other
additives include
functional detergent additives to be delivered to the wash water, for example
organic
polymeric dispersants, etc.
The detergent and cleaning compositions herein can comprise traditional
detergency
components and can also comprise organic solvents having a cleaning function
and
organic solvents having a carrier or diluent function or some other
specialised function.
The compositions will =generally be built and comprise one or more detergent
active
,
components which may be selected from bleaching agents, surfactants,
alkalinity sources,
enzymes, thickeners (in the case of liquid, paste, cream or gel compositions),
anti-
corrosion agents (e.g. sodium silicate) and disrupting- and binding agents (in
the case of
powder, granules or tablets). Highly preferred detergent components include a
builder
compound, an alkalinity source, a surfactant, an enzyme and a bleaching agent.
Unless otherwise specified, the components descnbed hereinbelow can be
incorporated
either in the organic solvent compositions and/or the detergent or cleaning
compositions.
The organic solvents should be selected so as to be compatible with the
tableware/cookware as well as with the different parts of an automatic
dishwashing
machine. Furthermore, the solvent system should be effective and safe to use
having a
volatile organic content above 1 mm Hg (and preferably above 0.1 mm Hg) of
less than
about 50%, preferably less than about 30%, more preferably less than about 10%
by
weight of the solvent system. Also they should have very mild pleasant odours.
The
individual organic solvents used herein generaliy have a boiling point above
about 150 C,
flash point above about 100 C and vapor pressure below about 1 mm Hg,
preferably
below 0.1 mm Hg at 25 C and atmospheric pressure.
CA 02592729 2007-06-21
Solvents that can be used herein include: i) alcohols, such as benzyl alcohol,
1,4-
cyclohexanedimethanol, 2-ethyl-l-hexanol, furfuryl alcohol, 1,2-hexanediol and
other
similar materials; ii) amines, such as alkanolamines (e.g. primary
alkanolamines:
monoethanolamine, monoisopropanolamine, diethylethanolamine, ethyl
diethanolamine;
5 secondary alkanolammes: diethanolamine, diisopropanolamine, 2-
(methylamino)ethanol;
ternary alkanolamines: triethanolamine, triisopropanolamine); alkylamines
(e.g. primary
alkylamines: monomethylamine, monoethylamine, monopropylamine, monobutylamine,
monopentylasnine, cyclohexylamine), secondary allcylamines: (dimethylamine),
alkylene
amines (primary alkylene amines: ethylenediamine, propylenediamine) and other
similar
10 materials; iii) esters, such as ethyl lactate, methyl ester, ethyl
acetoacetate, ethylene glycol
monobutyl ether acetate, diethylene glycol monoethyl ether acetate, diethylene
glycol
monobutyl ether acetate and other similar materials;' iv) glycol ethers, such
as ethylene
glycol monobutyl ether, diethylene glycol monobutyl ether, ethylene glycol
monomethyl
ether, ethylene glycol monoethyl ether, diethylene glycol monomethyl ether,
diethylene
15 glycol monoethyl ether, propylene glycol butyl ether and other similar
materials; v)
glycols, such as propylene glycol, diethylene glycol, hexylene glycol (2-
methyl-2, 4
pentanediol), triethylene glycol, composition and dipropylene glycol and other
similar
materials; and mixtures thereof.
Surfactant
In the methods of the present invention for use in automatic dishwashing the
detergent
surfactant is preferably low foaming by itself or in combination with other
components
(i.e. suds suppressers). Surfactants suitable herein include anionic
surfactants such as
alkyl sulfates, alkyl ether sulfates, alkyl benzene sulfonates, alkyl glyceryl
sulfonates,
alkyl and alkenyl sulphonates, alkyl ethoxy carboxylates, N-acyl sarcosinates,
N-acyl
taurates and alkyl succinates and sulfosuccinates, wherein the alkyl, alkenyl
or acyl
moiety is C5-C20, preferably C I O-Cl g linear or branched; cationic
surfactants such as
chlorine esters (US-A-4228042, US-A-4239660 and US-A-4260529) and mono C6-C16
, N-alkyl or alkenyl ammonium surfactants wherein the remaining N positions
are
substituted by methyl, hydroxyethyl or hydroxypropyl groups; low and high
cloud point
nonionic surfactants and mixtures thereof including nonionic alkoxylated
surfactants
CA 02592729 2007-06-21
26
(especially ethoxylates derived from C6-Cl g primary alcohols), ethoxylated-
propoxylated alcohols (e.g., BASF Poly-Tergent SLF18), epoxy-capped
poly(oxyalkylated) alcohols (e.g., BASF Poly-Tergent SLF18B - see WO-A-
94/22800),
ether-capped poly(oxyalkylated) alcohol surfactants, and block polyoxyethylene-
polyoxypropylene polymeric compounds such as PLURONICO, REVERSED
PLURONIC , and TETRONIC by the BASF-Wyandotte Corp., Wyandotte, Michigan;
arnphoteric surfactants such as the C12-C20 alkyl amine oxides (preferred
amine oxides for
use herein include CIZ lauryldimethyl amine oxide, C14 and Ct6 hexadecyl
dimethyl amine
oxide), and alkyl amphocarboxylic surfactants such as MiranolTM C2M; and
zwitterionic
surfactants such as the betaines and sultaines; and mixtnres thereof.
Surfactants suitable
herein are disclosed, for example, in US-A-3,929,678 , US-A- 4,259,217, EP-A-
0414
549, WO-A-93/08876 and WO-A-93/08874. Surfactants are typically present at a
level
of from about 0.2% to about 30% by weight, more preferably from about 0.5% to
about
10% by weight, most preferably from about 1% to about 5% by weight of
composition.
Preferred surfactant for use.herein are low foaming and include low cloud
point nonionic
surfactants and mixtures of higher foaming surfactants with low cloud point
nonionic
surfactants which act as suds suppresser therefor.
Builder
Builders suitable for use in detergent and cleaning compositions herein
include water-
soluble builders such as citrates, carbonates and polyphosphates e.g. sodium
tripolyphosphate and sodium tripolyphosphate hexahydrate, potassium
tripolyphosphate
and mixed sodium and potassium tripolyphosphate salts; and partially water-
soluble or
insoluble builders such as crystalline layered silicates (EP-A-0164514 and EP-
A-
0293640) and aluminosilicates inclusive of Zeolites A, B, P, X, HS and MAP.
The
builder is typically present at a level of from about 1% to about 80% by
weight,
preferably from about 10% to about 70% by weight, most preferably from about
20% to
about 60% by weight of composition.
Amorphous sodium silicates having an Si02:Na20 ratio of from 1.8 to 3.0,
preferably
from 1.8 to 2.4, most preferably 2.0 can also be used herein although highly
preferred
CA 02592729 2007-06-21
27
from the viewpoint of long term storage stability are compositions containing
less than
about 22%, preferably less than about 15% total (amorphous and crystalline)
silicate.
Enzyme
Enzymes suitable herein include bacterial and fungal cellulases such as
Carezyme and
Celluzyme (Novo Nordisk A/S); peroxidases; lipases such as Amano-P (Amano =
Pharmaceutical Co.), Ml LipaseR and LipomaxR (Gist-Brocades) and LipolaseR and
Lipolase iJltraR ~Novo); cutinases; proteases such as EsperaseR, AlcalaseR,
DurazymR and
SavinaseR (Novo) and MaxataseR, MaxacalR, ProperaseR and MaxapemR (Gist-
Brocades);
a and R amylases such as Purafect Ox AmR (Genencor) and TermamylR, BanR,
FungamylR, DuramylR, and NatalaseR (Novo); pectinases; and mixtures thereof.
Enzymes
are preferably added herein as prills, granulates, or cogranulates at lev.els
typically in the
range from about 0.0001% to about 2% pure enzyme by weight of composition.
Bleaching agent
Bleaching agents suitable herein, include chlorine and oxygen bleaches,
especially
inorganic perhydrate salts such as sodium perborate mono-and tetrahydrates and
sodium
percarbonate optionally coated to provide controlled rate of release (see, for
example,
GB-A-1466799 on sulfate/carbonate coatings), preformed organic peroxyacids and
mixtures thereof with organic peroxyacid bleach precursors and/or transiti on
metai-
containing bleach catalysts (especially manganese or cobalt). Inorganic
perhydrate salts
are typically incorporated at levels in the range from about 1% to about 40%
by weight,
preferably from about 2% to about 30% by weight and more preferably from abut
5% to
about 25% by weight of composition. Peroxyacid bleach precursors preferred for
use
herein include precursors of perbenzoic acid and substituted perbenzoic acid;
cationic
peroxyacid precursors; peracetic acid precursors such as TAED, sodium
acetoxybenzene
sulfonate and pentaacetylglucose; pernonanoic acid precursors such as sodium
3,5,5-
trimethylhexanoyloxybenzene sulfonate (iso-NOBS) and sodium nonanoyloxybenzene
sulfonate (NOBS); amide substituted alkyl peroxyacid precursors (EP-A-
0170386); and
benzoxazin peroxyacid precursors (EP-A-0332294 and EP-A-0482807). Bleach
CA 02592729 2007-06-21
28
precursors are typically incorporated at levels in the range from about 0.5%
to about 25%,
preferably from about 1% to about 10% by weight of composition while the
preformed
organic peroxyacids themselves are typically incorporated at levels in the
range from
0.5% to 25% by weight, more preferably from 1% to 10% by weight of
composition:
Bleach catalysts preferred for use herein include the manganese
triazacyclononane and
related complexes (US-A-4246612, US-A-5227084); Co, Cu, Mn and Fe
bispyridylamine
and related complexes (US-A-5114611); and pentamine acetate cobalt(III) and
related
complexes(US-A-4810410).
Low cloud point non-ionic surfactants and suds suppressers
The suds suppressers suitable for use herein include nonionic surfactants
having a low
cloud point. "Cloud point", as used herein, is a well known property of
nonionic
surfactants which is the result of the surfactant becoming less soluble with
increasing
temperature, the temperature at which the appearance of a second phase is
observable is
referred to as the "cloud point" (See Kirk Othmer, pp. 360-362). As used
herein, a "low
cloud point" nonionic surfactant is defined as a nonionic surfactant system
ingredient
having a cloud point of less than 30 _ C., preferably less than about 20 C.,
and even more
preferably less than about 10 C., and most preferably less than about 7:5 C.
Typical
low cloud point nonionic sarfactants include nonionic. alkoxylated
surfactants, especially
ethoxylates derived from primary alcohol, and
polyoxypropylene/polyoxyethylene/polyoxypropylene (PO/EO/PO) reverse block
polymers. Also, such low cloud point= nonionic surfactants include, for
example,
ethoxylated-propoxylated alcohol (e.g., BASF Poly-Tergent SLF18) and epoxy-
capped
poly(oxyallrylated) alcohols (e.g., BASF Poly-Tergent SLF 18B series of
nonionics, as
descn'bed, for example, in US-A-5,576,281).
Preferred low cloud point surfactants are the ether-capped poly(oxyalkylated)
suds
suppresser having the formula:
CA 02592729 2007-06-21
29
RI O-( CH2 - CH -O)X - (CH2 -CH2 -0)y - (CH2 .-CH-O)z-H
R2 R3
wherein R' is a linear, alkyl hydrocarbon having an average of from about 7 to
about 12
carbon atoms, RZ is a linear, alkyl hydrocarbon of about I to about 4 carbon
atoms, R3 is a
5, linear, alkyl hydrocarbon of about 1 to about 4 carbon atoms, x is an
integer of about 1 to
about 6, y is an integer of about 4 to about 15, and z is an integer of about
4 to about 25.
Other low cloud point nonionic surfactants are the ether-capped
poly(oxyalkylated)
having the formula:
RrO(RaO)nCH(CH3)ORm
wherein, RI is selected from the group consisting of linear or branched,
saturated or
unsaturated, substituted or unsubstitated, aliphatic or aromatic hydrocarbon
radicals
having from about 7 to about 12 carbon atoms; RII may be the same or
different, and is
independently selected from the group consisting of branched or linear C2 to
C7 alkylene
in any given molecule; n is a number from 1 to about 30; and Rm is selected
from the
group consisting of:
(i) a 4 to 8 membered substituted, or unsubstituted heterocyclic ring
containing
from 1 to 3 hetero atoms; and
(ii) linear or branched, saturated or unsaturated, substituted or
unsubstituted,
cyclic or acyclic, aliphatic or aromatic hydrocarbon radicals having from
about 1 to about 30 carbon atoms;
(b) provided that when RZ is (ii) then either: (A) at least one of R' is other
than C2
to C3 alkylene; or (B) RZ has from 6 to 30 carbon atoms, and with the further
proviso that when RZ has from 8 to 18 carbon atoms, R is other than Cl to C$
alkyl.
Other suitable components herein include organic polymers having dispersant,
anti-
redeposition, soil release or other detergency properties invention in levels
of from about
0.1% to about 30%, preferably from about 0.5% to about 15%, most preferably
from
CA 02592729 2007-06-21
about 1% to about I0% by weight of composition. Preferred anti-redeposition
polymers
herein include acrylic acid containing polymers such as Soka.lan PA30, PA20,
PA15,
PA10 and Sokalan CP10 (BASF GmbH), Acuso145N, 480N, 460N (Rohm and Haas),
acrylic acid/maleic acid copolymers such as Sokalan CP5 and
acrylic/methacrylic
5 copolymers. Preferred soil release polymers herein include a1kyl and
hydroxyalkyl
celluloses (US-A-4,000,093), polyoxyethylenes, polyoxypropylenes and
copolymers
thereof, and nonionic and anionic polymers based on terephthalate esters of
ethylene
glycol, propylene glycol and mixtures thereof.
10 Heavy metal sequestrants and crystal growth inhibitors are suitable for use
herein in
levels generally from about 0.005% to about 20%, preferably from about 0.1% to
about
10%, more preferably from about 0.25% to about 7.5% and most preferably from
about
0.5% to about 5% by weight of composition, for example diethylenetriamine
penta
(methylene phosphonate), ethylenediamine tetra(methylene phosphonate)
15 hexamethylenediamine tetra(methylene phosphonate), ethylene diphosphonate,
hydroxy-
ethylene-l,1-diphosphonate, nitrilotriacetate, ethylenediaminotetracetate,
ethylenediamine-N,N'-disuccinate in their salt and free acid forms.
The compositions herein can contain a corrosion inhibitor such as organic
silver coating
20 agents in levels of from about 0.05% to about 10%, preferably from about
0.1% to about
5% by weight of composition (especially paraffins such as Winog 70 sold by
Wintershall,
Salzbergen, Germany), nitrogen-containing corrosion inhibitor compounds (for
example
benzotriazole and benzimadazole - see GB-A-1137741) and Mn(II) compounds,
particularly Mn(II) salts of organic ligands in levels of from about 0.005% to
about 5%,
25 preferably from about 0.01% to about 1%, more preferably from about 0.02%
to about
0.4% by weight of the composition.
Other suitable components herein include colorants, water-soluble bismuth
compounds
such as bismuth acetate and bismuth citrate at levels of from about 0.01% to
about 5%,
30 enzyme stabilizers such as calcium ion, boric acid, propylene glycol and
chlorine bleach
scavengers at levels of from about 0.01% to about 6%, lime soap dispersants
(see WO-A-
CA 02592729 2007-06-21
31
93/08877), suds suppressors (see W0-93/08876 and EP-A-0705324), polymeric dye
transfer inhibiting agents, optical brighteners, perfumes, fillers and clay.
Liquid detergent compositions can contain low quantities of low molecular
weight
primary or secondary alcohols such as methanol, ethanol, propanol and
isopropanol can
be used in the liquid detergent of the present invention. Other suitable
carrier solvents
used in low quantities includes glycerol, propylene glycol, ethylene glycol,
1,2-
propanediol, sorbitol and mixtures thereof.
The process used herein for forming the first and/or second moving webs
involves
continuously feeding a water-soluble $lm onto an endless surface, preferably
onto a
horizontal or substantially horizontal portion of an endless surface, or
otherwise, onto a
non-horizontal portion of this surface, such that it moves continuously
towards and
eventually onto the horizontal or substantially horizontal portion of the
surface.
Naturally, different film material and/or fihns of different thickness may be
employed in
making the first and second moving webs, where for instance compartments
having
different solubility or release characteristics are required.
In a preferred embodiment for making both the first and second moving webs a
portion of
.20 the endless surface will move continuously in horizontal rectilinear
motion, until it rotates
around an axis perpendicular to the direction of motion, typically about 180
degrees, and
then move in the opposite direction, usually again in horizontal rectilineat
motion.
Eventually, the surface will rotate again to reach its initial position. In
other
embodiments, the surface moves in curvilinear, for example circular motion,
whereby at
least a portion of the surface is substantially horizontal for a simple but
finite period of
time. Where employed, such embodiments are mainly valuable for making the
second
moving web.
The term 'endless surface' as used herein, means that the surface is endless
in one
dimension at least, preferably only in one dimension. For example, the surface
is
preferably part of a rotating platen conveyer belt comprising moulds, as
described below
in more detail.
CA 02592729 2007-06-21
32
The horizontal or substantially horizontal portion of the surface can have any
width,
typically depending on the number of rows of moulds across the width, the size
of the
moulds and the size of the spacing between moulds. Where designed to operate
in
horizontal rectilinear =manner the horizontal portion of the endless surface
can have any
length, typically depending on the number of process steps required to take
place on this
portion of the surface (during the continuous horizontal motion of the
surface), on the
time required per step and on the optimum speed of the surface needed for
these steps. Of
course, by using a lower or higher continuous speed throughout the process,
the length of
the surface may need to be shorter or longer. For example, if several steps
are perfoinied
on the horizontal portion, the portion needs to be longer or the speed slower
than if for
example only two steps are done on the horizontal portion.
Preferred may be that the width of the surface is up to 1.5 meters, or even up
to 1.0 meters
or preferably between 30 and 60 cm: Preferred may be that the horizontal
portion of the
endless surface is from 2 to 20 meters , or even 4 to 12 meters or even from 6
to 10 or
even 9 meters.
The surface is typically moved with a constant speed throughout the process,
which can
be any constant speed. Preferred may be speeds of between 1 and 80 m/min, or
even 10
to 60m/min or even from 2- to 50 m/min or even 30 to 40 m/min.
The process is preferably done on an endless surface which has a horizontal
motion for
such a time to allow formation of the web of pouches, filling of the pouches,
superposition of the second moving web of pouches, sealing of the two moving
webs and
cutting to separate the superposed webs into a plurality of multi-
compartmental pouches.
Then, pouches are removed from the surface and the surface will rotate around
an axis
perpendicular to the direction of motion, typically about 180 degrees, to then
move in
opposite direction, typically also horizontally, to then rotate again, where
after step a)
starts again.
CA 02592729 2007-06-21
33
Preferably, the surface is part of and/ or preferably removably connected to a
moving,
rotating belt, for example a conveyer belt or platen conveyer belt. Then
preferably, the
surface can be removed and replaced with another surface having other
dimensions or
comprising moulds of a different shape or dimension. This allows the equipment
to be
cleaned easily and moreover to be used for the production of different types
of pouches.
This may for example be a belt having a series of platens, whereof the number
and size
will depend on the length of the horizontal portion and diameter of turning
cycles of the
surface, for example having 50 to 150 or even 60 to 120 or even 70 to 100
platens, for
example each having a length (direction of motion of platen and surface) of 5
to 150 cm,
preferably 10 to 100 cm or even 20 to 45cm.
The platens then form together the endless surface or part thereof and
typically the
moulds are comprised on the surface of the platens, for example each platen
may have a
number of moulds, for example up to 20 moulds in the direction of the width,
or even
from 2 to 10 or even 3 to 8, and for example up to 15 or even 1 to 10 or 'even
2 to 6 or
even 2 to 5 moulds lengthwise, i.e. in the direction of motion of the patens.
The surface, or typically the belt connected to the surface, can be
continuously moved by
use of any known method. Preferred is the use of a zero-elongation chain
system, which
drives the surface or the belt connected to the surface.
If a platen conveyer belt is used, this preferably contains a) a main belt
(preferably of
steel) and b) series of platens, which comprise 1) a surface with moulds, such
that the
platens form the endless surface with moulds described above, and 2) a vacuum
chute
connection and 3) preferably a base plate between the platens and the vacuum
chute
connection. Then, the platens are preferably mounted onto the main belt such
that there is
no air leakage from junctions between platens. The platen conveyer belt as a
whole
moves then preferably along (over; under) a static vacuum system (vacuum
chamber).
Preferred may be that the surface is connected to 2 or more different vacuum
systems,
which each provide a different under pressure and/ or provide such an under
pressure in
shorter or longer tame-span or for a shorter or longer duration. For example,
it may be
CA 02592729 2007-06-21
34
preferred that a first vacuum system provides a under-pressure continuously on
the area
between or along the moulds/ edges and another system only provides a vacuum
for a
certain amount of time, to draw the film into the moulds. For example, the
vacuum
drawing the film into the mould can be applied only for 0.2 to 5 seconds, or
even 0.3 to 3
or even 2 seconds, or even 0.5 to 1.5 seconds, once the film is on the
horizontal portion of
the surface. This vacuum may preferably be such that it provides an under-
pressure of
between -100mbar to -1000mbar, or even from -200mbar to -600mbar.
Preferred may be for example that the two or more vacuum systems, or
preferably pumps
are connected to the chutes described above, such that each vacuum system is
connected
to each chute, preferably such that the systems are not interconnected with in
the chute, to
thus completely separate the vacuums from one another and to guarantee
controlled
delivery of vacuum to the moulds/ surface between / along mould/ edges.
It should be understood that thus all platens and the main belt move
continuously,
typically with the same constant speed.
The surface, or platens described above, are preferably made from corrosion
resistant
material, which is durable and easy to clean. Preferred may be that the
surface or platens,
including the mould areas are made of aluminium, preferably mixed with nickel,
or
optionally only the outside layers comprising nickel and/ or nickel aluminium
mixtures.
Preferably, at least the top layer between and/ or in the moulds of the
surface is of
deformable resilient material, preferably at least the top layer between the
moulds. The
material is typically such that it has a friction coefficient of 0.1 or more,
preferably 0.3 or
more. For example, the top layer between the moulds, but even in the moulds,
can be of
rubber, silicon material or cork, preferably rubber or silicon rubber.
Preferred is also that
the material is not too hard, for example similar to silicon rubber having a
shore value of
10 to 90.
The moulds can have any shape, length, width and depth, depending on the
required
dimensions of the pouches. Per surface, the moulds can also vary of size and
shape from
CA 02592729 2007-06-21
one to another, if desirable. For example, it may be preferred that the volume
of the final
pouches is between 5 and 300m1, or even 10 and 150m1 or even 20 and 100mI or
even up
to 80rnl and that the mould sizes are adjusted accordingly.
5 The feeding of the film to, and typically onto or on top of the surface and
preferably onto
the horizontal portion thereof, is done continuously, and thus typically with
a constant '
speed throughout the process. This can be done by any known method, preferably
by use
of rollers from which the film unwinds. The film can be transported from the
rollers to
the surface by any means, for example guided by a belt, preferably a
deformable resilient
10 belt, for example a belt of rubber or silicone material, including silicone
rubber. The
material is typically such that it has a friction coefficient of 0.1 or more,
preferably 0.3 or
more.
Preferred may be that the rollers rewind the fihn with a speed of at least
l00m/min, or
15 even 120 to 700m/min, or even 150 to 500rn/min, or even 250 to 400m/min.
Once on the surface, the film can be held in position, e.g. fixed or fixated
on the surface,
by any means. For example, the film can be held with grips or clips on the
edges of the
surface, where there are no moulds, or pressed down with rollers on the edges
of the
20 surface, where there are no moulds, or held down by a belt on the edges of
the surface,
where there are no moulds.
For ease of operating and film positioning, for improved accuracy and better
alignment
reliability, and as to not loose too much of the film surface (i.e. positioned
in or under the
25 grips, clips rollers or belt), and moreover as to reduce the tension on the
f lm or ensure
more homogeneous tension on the film, it is preferred that the film is held in
position by
application of vacuum on the film, thus drawing or pulling the filmin fixed
position on
the surface. Typically this is done by applying a vacuum (or under-pressure)
through the
surface which is to hold the film, e.g under the film. Also, this method is
suitable even if
30 the film width is larger than the surface, so this system is more flexible
than the use of
grips of clips.
CA 02592729 2007-06-21
36
Preferably, the vacuum is applied along the edges of the film and thus
typically the edges
of the surface, and/ or on the surface area between or around the moulds,
typically along
the edges of the moulds. Preferred is that the vacuum is (at least) applied
along the edges
of the surface.
Preferably, said surface thereto comprises holes which are connected to a
device which
can provide a vacuum, as lanown in the art, or so-called vacuum chamber(s).
Thus, the
surface has preferably holes along the edges of the surface and/ or holes
around or
between the moulds.
Preferred is that the holes are small, preferably of a diameter of 0.1mm to 20
mm, or even
0.2 to 10mm or even 0.5 to 7 or even 1 to 5mm.
Preferably, at least some of the holes are close to the mould edges, to reduce
wrinkling in
the area around the mould edges, which in a preferred embodiment herein serves
as
closing or sealing area; preferably the distance between the edge of the mould
and the
edge of the first or closest hole is 0.25 to 20 mm form the edge of the mould,
or even
preferably 0.5 to 5mm or even I to 2mm.
Preferred is that rows of holes are present along the edge of the surface and/
or along the
edges of the moulds; preferred may be that 2 or 3 or more rows of holes are
present.
The use of many small holes in the manner described above ensures more
homogeneous
tension of the film, and it reduces the tension needed to fixate the film, and
it improves
the fixation and it reduces the chance of wrinkling of the film.
The use of a vacuum to fix the film in position is in particular beneficial
when the film is
subsequently drawn into the moulds by application of a vacuum as well, as
described
herein after.
The open pouches can be formed in the moulds by any method, and as described
above,
preferred methods include the use of (at least) a vacuum or under-pressure to
draw the
CA 02592729 2007-06-21
37
film into the moulds. Preferred methods (also) include heating and/ or wetting
the film
and thereby making the film more flexible or even stretched, so that it adopts
the shape of
the mould; preferably, combined with applying a vacuum onto the fihn, which
pulls the
film into the moulds, or combinations of all these methods.
Preferred is that at least vacuum is used herein. In the case of pouches
comprising
powders it is advantageous to pin prick the film for a number of reasons:
firstly, to reduce =
the possibility of film defects during the pouch formation, for example film
defects giving
rise to rupture of the film can be generated if the stretching of the film is
too fast,
secondly to pemiit the release of any gases derived from the product enclosed
in the
pouch, as for example oxygen formation in the case of powders containing
bleach, and
thirdly, to allow the continuous release of perfume. When also heat and/ or
wetting is
used, this can be used before, during or after the use of the vacuum,
preferably. during or
before application of the vacuum.
Preferred is thus that each mould comprises one or more holes which are
connected to a
system which can provide a vacuum through these holes, onto the film above the
holes, as
described herein in more detail. Preferred is that the vacuum system is a
vacuum
chamber comprises at least two different units, each separated in different
compartments,
as described herein.
Heat can be applied by any means, for example directly, by passing the film
under a
heating element or through hot air, prior to feeding it onto the surface or
once on the
surface, or indirectly, for example by heating the surface or applying a hot
item onto the
film, for exmnple to temperatures of 50 to 120 C, or even 60 to 90 C,
preferably for
example with infira red light.
The film can be wetted by any mean, for example directly by spraying a wetting
agent
(including water, solutions of the film material or plasticisers for the film
material) onto
the film, prior to feeding it onto the surface or once on the surface, or
indirectly by
wetting the surface or by applying a wet item onto the film.
CA 02592729 2007-06-21
38
The filling of the first and second webs of open pouches can be done by any
known
method for filling (moving) items. The exact most preferred method depends on
the
product form and speed of filling required.
One method is for example flood dosing, whereby the web of open pouches passes
with
continuous horizontal or substantially horizontal motion under a dosing unit
which is
static and which has a device to accurately dose a set amount or volume of
product per
time unit. The problem or disadvantage of this method may be that product will
be
dispensed on the areas between the open pouches, which typically serves as
sealing area;
this not only may be a waste of product, but also makes sealing more
difficult. This
problem is particulate acute in the case of products in the form of mobile
liquids. Paste or
gel-form products are more amenable to this kind of.filling process.
Generally, preferred methods include continuous motion in line filling, which
uses a
dispensing unit positioned above the open pouches which has a endless,
rotating surface
with nozzles, which typically moves rotatably with continuous motion, whereby
the
nozzles move with the same speed as the pouches and in the same direction,
such that
each open pouch is under the same nozzle or nozzles for the duration of the
dispensing
step. After the filling step, the nozzles rotate and return to the original
position, to start
another dispensing/ filling step. Every nozzle or a number of nozzles
together, is
preferably connected to a device which can accurately coiitrol that only a set
amount or
volume of product is dispensed during one rotation per nozzle, e.g. thus in
one pouch.
Preferred may be that the filling/ dispensing system is such that from 10 to
100 cycles
(filling steps) can be done per minute, or even 30 to 80 or even 40 to 70 per
minute. This
will of course be adjusted depending o the size of the open pouches, speed of
the surface
etc.
A highly preferred method for filling the open pouches suitable for surface
moving in
horizontal rectilinear motion is a reciprocating-motion-filling method. This
process
preferably uses a moving filling station which is returnable (changes
direction of motion)
and variable in speed. The filling station has typically a series of nozzles
which each
CA 02592729 2007-06-21
39
move with the same speed as the open pouches (to be filled) and in the same
direction for
the period that product needs to dispensed into the open pouches. Then,
typically when a
pouch is full, the nozzle or nozzles which filled the pouch stop their
movement along with
the pouch and return in opposite direction, to then stop again, such that it
is positioned
above another open pouch(es) which is (are) still to be filled, and to then
start moving
again in opposite direction, with the same speed and direction as the open
pouches, until
it reaches the speed of the pouches, to then continue with this speed and
start dispensing =
and filling of the pouch(es), as in the previous filling cycle. The speed of
the returning
movement may be higher than the speed of the movement during filling.
Every nozzle or a number of nozzles together is preferably connected to a
device which
can accurately control that only a set amount or volume of product is
dispensed during
one rotation per nozzle, e.g. thus in one pouch.
The filling unit or station used in the process of the invention preferably
uses a flow meter
and/ or positive displacement pump to dose the correct amounts or volumes of
product
per, open pouch, in particular a positive displacement pump has been found to
very
accurate. Hereby, the required amount or volume of product is introduced in
the pump
and this is then fed to. the nozzles. For example, if the system is such that
60 pouches are
to be filled per filling cycle, typically 60 nozzles are provided, connected
to 60 positive
displacement pumps (one pump per nozzle, per pouch), which are all connected
to a
general tank with product.
The pumps can be adjusted depending on the product to be dispensed. For
example, if the
product is a viscous liquid, the pumps need to be stronger, if a fast filling,
and thus
movement of the surface is required.
Other methods which can be used include flow measurement, by use of a magnetic
flow
meter or mass flow meter, and pressure flow filling/measurement (which keeps
the
pressure constant and controlling filling time and thereby volume).
CA 02592729 2007-06-21
It can also be preferred to use a filling system whereby, prior to filling, a
second surface
with openings, which each has a surface area equal or less than the surface
area of an
open pouch, is placed above the continuously moving web of open pouches and is
moved
continuously in the direction of the web of pouches and with the speed of the
web of open
5 pouches, such that each opening remains positioned above one open pouch
during the
filling step and that the space between at least part of the moulds is covered
by said
surface, preferably said second surface being an endless, rotatably moving
belt.
The Slling will then take place through the openings on this surface or belt,
such that the
10 product can only enter in the open pouches and not on the area between the
pouches,
which is covered. This is advantageous because the area between the open
pouches
(between the moulds), which typically serves as sealing area when closing the
pouches,
remains free of product, which ensures a better or easier seal.
15 The filled, open pouches are then closed, which can be done by any method.
Preferably,
this is also done while in horizontai position and in continuous, constant
motion, and
preferably on the horizontal portion of the endless surface described above.
Preferred in the case of the second moving web is that the closing is done by
continuously
20 feeding a second material or film, preferably water-soluble film, over and
onto the web of
open pouches and then preferably sealing the first film and second film
together, typically
in the area between the moulds and thus between the pouches. Preferred is that
the
closing material is fed onto the open pouches with the same speed and moving
in the
same direction as the open pouches
Preferred in the case of the fist moving web is that the closing material is
the second web
of closed, filled pouches, closing being accomplished as described above, i.e.
by placing
the web of closed filled pouches on the open pouches in a continuous manner,
preferably
with constant speed and moving in the same direction of the open pouches, and
which is
subsequently sealed to the first film. Alternatively, the first moving web can
also be
closed using a film of material as described above for the second web prior to
superposing and sealing the first and second moving webs of pouches. Such
CA 02592729 2007-06-21
41
embodiments may be preferred in the case of . multi-liquid composition
containing
products or where it is required to manufacture pouches in side-by-side but
superposable
relationship.
The sealing can be done by any method. The sealing may be done in a dis-
continuous
manner, for example by transporting the web of pouches to another sealing area
and
sealing equipment. However, the sealing is preferably done continuously and
preferably :..
with constant speed whilst the closed web of pouches moves continuously and
with
constant speed, and it may also preferably done in horizontal position,
preferably also on
said horizontal portion of the surface.
Preferred methods include heat sealing, solvent welding, and solvent or wet
sealing.
Hereby it may be preferred that only the area which is to form the seal, is
treated with
heat or solvent. The heat or solvent can be applied by any method, preferably
on the
closing material, preferably only on the areas which are to form the seal.
Preferred may be that when heat sealing is used, a roller with cavities of the
size of the
part of the pouch, which is not enclosed by the mould, and having a pattern of
the
pouches, is (continuously) rolled over the web pouches, passing under the
roller. Hereby,
the heated roller contact only the area which is to be the sealing areas,
namely between
the pouches, around the edges of the moulds. Typically sealing temperatures
are from 50
to 300 C, or even from 80 to up to 200 C, depending on the film material of
course. Also
useful is a movable, returnable sealing device, operating as the returnable,
movable
filling/ dosing device above, which contacts the area between the moulds,
around the
edges, for a certain time, to form the seal, and then moves away from the
sealing area, to
return backwards, to start another sealing cycle. In the case of heat sealing,
it is important
that the sealing area of the second web to the first web does not overlap the
sealing area
of the individual first and/or second webs of pouches.
If solvent or wet sealing or welding is used, it may be preferred that also
heat is applied.
Preferred wet or solvent sealing/ welding methods include applying selectively
solvent
onto the area between the moulds, or on the closing material, by for example,
spraying or
CA 02592729 2007-06-21
42
printing this onto these areas, and then applying pressure onto these areas,
to form the
seal. Sealing rolls and belts as described above (optionally also providing
heat) can be
used, for example.
The superposed and sealed webs of pouches can then be cut by a cutting device,
which
cuts the pouches from one another, in separate superposed multi-compartment
pouches
which partially cuts the web so as to form multi-compartment pouches via side-
by-side
but superposable arrangement.
The cutting can be done by any known mthod It may be prefen-ed that the
ciutting is also
done in continuous manner, and preferably with constant speed and preferably
while in
horizontal position. However, the cutting step -does not need to be done in
horizontal
position, nor continuously. For example the web of closed (sealed) pouches can
be
transported to the cutting device, e.g. to another surface, where the cutting
device
operates. Although, for ease of processing it may be preferred to perform the
cutting step
on the same surface as the previous steps.
The cutting device can for example be a sharp item or a hot item, whereby in
the 'latter
case, the that 'burns' through the filmJ sealing area. Preferred may be a
roller with sharp
tools, such as a knife, with cavities of the size and pattern of the pouches,
which rolls over
the pouches such that the sharp tools only touch the area to be cut. Preferred
may also be
when the web of pouches is moving in one direction (e.g. continuously and/ or
horizontally, for example still on the endless surface herein) a static device
contacting the
area between the pouches along the direction of movement can be used, to cut
the
pouches in the direction of movement in a continuous manner. Then, the cutting
between
the pouches along the direction of the width of the web of pouches can be done
by an
intermittent cutting step, for example by applying a cutting device for a
brief period onto.
the area, removing the cutting device and repeating this action with the next
set of
pouches.
The pouch, when used herein can be of any form, shape and material which is
suitable to
hold the product prior to use, e.g. without allowing the release of the
compositions from
CA 02592729 2007-06-21
43
the pouch prior to contact of the pouched composition to water. The exact
execution will
depend on for example the type and amount of the compositions in the poiich,
the
characteristics required from the pouch to hold, protect and deliver or
release the
compositions, the number of compartments in the pouch.
Preferred herein are water-soluble pouches having one compartment comprising a
liquid
composition and another compartment comprising a powder or densified powder
:.,
composition. During the manufacture of the liquid compartment an air bubble is
typically formed. This air bubble can reduce the compressibility of the pouch
and
therefore the ease of closing the dispenser after placing the pouch therein.
It has been
found that ease of closing is increased when the ratio of the air bubble
diameter to the
maximum lateral dimension of the pouch footprint is from about 1:5 to about
1:2.
Preferably, the bubble has a diameter from about 9 to about 16 mm. The bubble
dimension can be controlled by process parameters.
In use, the water-soluble pouch is usually placed within the washing machine
dispenser
and released during the main cycle of the dishwashing process. However, the
dispensers
of some dishwashing. machines are not completely water tight, mainly for two
reasons,
either the dispenser has some apertures allowing water ingiess or the
dispenser is sealed
with a rubber band that can deform with time due to the . high temperature of
the
dishwashing process. Water ingress into the dispenser can cause premature
leaking of
some of the pouch content which is thus lost at the end of the pre-wash. This
problem is
especially acute in the case of pouches comprising liquid compositions having
a low
viscosity wherein a considerable amount of the product can be lost before the
main-wash
cycle. The problem can be overcome by making the pouch or at least the liquid
compartment thereof out of a film material which is designated to survive the
pre-wash
and to release the pouch contents at or after the start of the main-wash
cycle. Tn European
machines, the pre-wash is usually a cold water cycle (about 20 C or less)
without
detergent and lasting for about 10 to 15 min.
Preferably the film material has a water solubility according to the
hereinbelow defined
test of less than about 50%, more preferably less than about 20% and
especially less than
CA 02592729 2007-06-21
44
about 5% under cold water conditions (20 C or below) when exposed to the water
for at
least 10 minutes, preferably at least 15 minutes; and a water solubility of at
least about
50%, more preferably at least about 75% and especially at least about 95%
under warm
water conditions (30 C or above, preferably 40 C or above) when exposed to the
water
for about 5 minutes and preferably when exposed to the water for about 3
minutes. Such
film materials are herein refen-ed to as being substantially insoluble in cold
water but
soluble in warm water. Sometimes this is abbreviated simply to "warm water
soluble".
50 grams 0.1 gram of pouch material is added in a pre-weighed 400 ml beaker
and
245m1 Iml of distilled water is added. This is kept at the desired
temperature, by using
a water bath, and stirred vigorously on a magnetic stirrer set at 600 rpm, for
the desired
time. Then, the mixture is filtered through a folded qualitative sintered-
glass filter with a
maximum pore size of 20 m. The water is dried off from the collected filtrate
by any
conventional method, and the weight of the remaining material is determined
(which is
the dissolved or dispersed fraction). Then, the % solubility or dispersability
can be
calculated.
Commercially available fihns insoluble in cold water and soluble in hot water
include
BP26 available from Aicello, L10 and L15 available from Aquafilm, VF-M and VM-
S
available from Kuraray and E-2060 available from Monosol.
In a preferred embodiment a multi-compartment pouch comprises a first
compartment
comprising a liquid composition and a second compartment comprising a powder
or
densified powder composition. Preferably, the liquid compartment is made of a
warm
water-soluble material as described hereinabove and the powder or densified
powder
compartment is made of cold water-soluble material, i.e., a material which is
soluble to an
extent of at least 50%, preferably at least 75%, more preferably at least 95%
by weight
under cold water conditions (20 C or below) when exposed to the water for
about 5
minutes and preferably when exposed to the water for about 3 minutes. Due to
the way in
which European dishwashing machines operate (they are filled with cold water
and the
cold water is heated by means of a heater), the comparhnent made of warm water-
soluble
material takes longer to dissolve than the compartment made of cold water-
soluble
CA 02592729 2007-06-21
material. This kind of pouch allows for a delayed release of the liquid
composition
providing optimised use of the detergent coznposition. Preferably, the liquid
composition
comprises detergency enzyme, this being advantageous from the enzyme storage
stability
viewpoint, the enzyme being separated from the bleach and from highly alkaline
5 materials contained in the powder or densified powder composition.
Furthermore, the
liquid containing compartment (substantially cold water-insoluble and warm
water-
soluble) will take longer to dissolve or disintegrate than the solid
containing compartment (cold water-soluble), minimizing the negative
interaction in the wash liquor between
bleach and enzymes and between surfactant and enzymes and providing improved
protein
10 soil removal and spotting benefits in the later stages of the dishwashing
process.
Pouch compartrnents containing solid compositions, in particular oxygen bleach
comprising compositions, are usually pin-pricked in order to allow the leakage
of any
formed oxygen. The holes formed by pin pricking also allow the leakage of
perfumes or
15 malodors, however. For example, surfactants often have an unpleasant smell
associated
with them and when such pouches are packed within a secondary package, the
unpleasant
surfactant smell can be concentrated into the package head space and released
each time
that the user open the package. This problem can be avoided by including the
surfactant
in the liquid composition, since liquid containing compartments must be made
free of pin
20 holes. Thus, according to another embodiment, the liquid composition
comprises a
surfactant. Another advantage of having the surfactant in the liquid phase is
to avoid
problems of loading the surfactant onto the solid material. A further
advantage is that the
surfactant is released with a certain delay with respect to the solid
composition, this
allows better performance of the bleach and enzymes which can be adversely
affected by
25 interaction between the surfactant and the table/dishware surfaces.
Preferably perfume is introduced in the solid composition, pin prickling
allowing for slow
release of the perfume before the product is used in the dishwasher.
30 Films substantially insoluble in cold water and soluble in warm water have
relatively low
moisture and plasticiser content, therefore the film would require a
significant time and
temperature in order to seal by means of heat sealing. These requirements can
lead to
CA 02592729 2007-06-21
46
damage of the film such as for example pin-holes at the point where the film
is stretched
into the mould, causing leakage, especially problematic in the case of pouches
containing
liquid. Therefore, it is preferred that compartments made of films
substantially insoluble
in cold water and soluble in warm water and which house liquids are sealed
using solvent
which partially hydrates the film prior to sealing, lowering. the time and
temperature
required for sealing, generating strong seals and avoiding pin-hole formation.
In the
preferred embodiment of differential solubility pouches having one compartment
comprising a liquid composition and another compartment comprising a powder
composition wherein the liquid compartment is made of material substantially
insoluble
in cold water and soluble in warm water and the powder compartment is made of
material
which is soluble in cold water, it is preferred that the liquid compartment be
sealed by
solvent sealing while the liquid compartment is sealed to the powder
comparhnent by
heat sealing.
The pouch can also be placed outside the dispenser, for example in the cutlery
basket, in a
net or on the door of the dishwasher. In this case, it is preferred to make
the entire pouch
of a film material, as for example the one described herein above, which
protects the
pouch content until at least the start of the nzain-wash cycle.
Although the nature of the pouched products is such that it.readily dissolves
or disperses
into the water, it may be preferred that disintegrating agents such as
effervescence
sources, water-swellable polymers or clays are present in the pouch itself,
and/ or in the
product therein, in particular effervescence sources based on an acid and a
carbonate
source. Suitable acids include theorganic carboxylic acids such as fumaric
acid, maleic
acid, malic acid, citric acid; suitable carbonate sources include sodium salts
of carbonate,
bicarbonate, peroarbonate. Preferred levels for the disintegrating aids or
effervescence
sources or both are from 0.05% to 15% or even from 0.2% to 10% or even form
0.3 to 5%
by weight of total pouched composition.
ElMles: ,
Abbreviations used in Examples
In the examples, the abbreviated component identifications have the following
meanings:
CA 02592729 2007-06-21
47
Carbonate : Anhydrous sodium carbonate
STPP : Sodium tripolyphosphate
Silicate : Amorphous Sodium Silicate (SiO2;Na2O = from 2:1 to
4:1)
HEDP : Ethane 1-hydroxy-l,l-diphosphonic acid
Perborate : Sodium perborate monohydrate - '_r, I
Percarbonate : Sodium percarbonate of the nominal formula
2Na2CO3.3H202
Carbonate : Anhydrous sodium carbonate
Termamyl : a-amylase available from Novo Nordisk A/S
Savinase protease available from Novo Nordisk A/S
FN3 : protease available from Genencor
SLF18 . Poly-Tergent available from BASF
ACNi : allcyl capped non-ionic surfactant of formula Cy/il Hj9a3
EOg-cyclohexyl acetal
C14A0 : tetradecyl diruethyl amine oxide
C16AO : hexadecyl dimethyl amine oxide
Duramyl : a-amylase available from Novo Nordisk A/S
DPM : dipropylene glycol methyl ether
DPG : dipropylene glycol
Methocel : cellulosic thickener available from Dow Chemical
In the following examples a111evels are quoted as per cent (%) by weight.
Examples 1 to 8
The compositions of examples 1 to 4 are introduced in a two compartment
layered PVA
rectangular base pouch. The dual compartment pouch is made from a Monosol
M8630
film as supplied by Chris-Craft Industrial Products. 17.2 g of the particulate
composition
and 4 g of the liquid composition are placed in the two different compartments
of the
pouch. The pouch dimensions under 2 Kg load are: length 3.7 cm, width 3.4 cm
and
CA 02592729 2007-06-21
48
height 1.5 cm. The longitudinal/transverse aspect ratio is thus 1.5:3.2 or
1:2.47. The
pouch is manufactured using a two-endless surface process, both surfaces
moving in
continuous horizontal rectilinear motion as herein described. According to
this process a
first web of pouches is prepared by forming and filling a first moving web of
open
pouches mounted on the fnt endless surface and closing the first web of open
pouches
with the second web of filled and sealed pouches moving in synchronism
therewith.
The pouch is introduced in the 25 ml dispenser compartment of a Bosch Siemens
6032
dishwashing machine, the dispenser is closed and the washing machine operated
in its
normal 55 C program.
Example 1 2 3 4
Particulate corn sition
C14A0 5 5
C16AO .5 5
ACNI 5 5
SLFi8 5 5
STPP 55 55 56 56
HEDP 1 1 1 1
Termamyl 1.5 1.5
FN3 2 2
Percarbonate 15 15 15.5 15.5
Carbonate 9 9 10 10
Silicate 6 6 7 7
Perfume 0.5 0.5 0.5 0.5
Liqnid composition
DPG 99.5 99.5 95 95
FN3 Liquid 2.6 2.4
Duramyl Liquid 2.0 2.4 _T - Dye 0.5 0.5 0.4 0.2
CA 02592729 2007-06-21
49
Example 5 6 7 8
Particulate comMsition
STPP 60 60 61 61
HEDP 1 1 1 1
Termamyl 1.5 1.5
FN3 2 2
Percarbonate 17 17 17.5 17.5
Carbonate 11 11 12 12
Silicate 7 7 8 8
Perfume 0.5 0.5 0.5 0.5
Liq,uid comnosition
DPG 59.5 59.5 55 55
FN3 Liquid 2.6 2.4
Duramyl Liquid 2.0 2.4
C14 AO 20 20
C16 AO 20 20
ACNI 20 20
SLF18 20 20
Dye 0.5 0.5 0.4 0.2
