Process for making a high density detergent composition from starting detergent ingredients

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT The present process is used in the production of low dosage detergent agglomerates directly from starting detergent ingredients rather than conventional "post-tower" detergent granules.
By "post-tower" detergent granules, we mean those detergent granules which have been processed through a conventional spray-drying tower or similar apparatus.
The process of the invention allows for production of low dosage detergents in an environmentally conscious manner in that the use of spray drying techniques and the like which typically emit pollutants though their towers or stacks into the atmosphere is eliminated.
This feature of the process invention is extremely desirable in geographic areas which are especially sensitive to emission of pollutants into the atmosphere.
PROCESS Reference is now made to FIG.
1 which presents a flow chart illustrating the instant process and various embodiments thereof.
In the first step of the process, the invention entails continuously mixing into a high speed mixer/densifier 10 several streams of starting detergent ingredients including a surfactant paste stream 12 and a dry starting detergent material stream 14.
The surfactant paste 12 preferably comprises from about 25% to about 65%, preferably from about 35% to about 55% and, most preferably from about 38% to about 44%, of a detergent surfactant in an aqueous paste form.
Preferably, the dry starting detergent material 14 comprises from about 20% to about 50%, preferably from about 25% to about 45% and, most preferably from about 30% to about 40% of an aluminosilicate or zeolite builder, and from about 10% to about 40%, preferably from about 15% to about 30% and, most preferably from about 15% to about 25% of a sodium carbonate.
It should be understood that additional starting detergent ingredients several of which are described hereinafter may be mixed into high speed mixer/densifier 10 without departing from the scope of the invention.
However, it has surprisingly been found that the surfactant paste 12 and the dry starting detergent material 14 are continuously mixed within the ratio ranges described herein so as to insure production of the desired free flowing, crisp, high density detergent composition