Technical field
[0001] The present invention is in the field of dishwashing, in particular it relates to
a process for the manufacture of water soluble multicompartment pouches.
Background of the invention
[0002] 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
thereby 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 composition which may contain bleach and/or other irritant substances.
[0003] The automatic dishwashing process usually involves a initial pre-wash 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 pre-wash. The amount of detergent is therefore
limited 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), 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.
[0004] 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 forming 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.
[0005] 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,
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.
[0006] 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 forming
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
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.
[0007] 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.
[0008] There is still the need for a multi-compartment unitised close 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 forms.
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.
[0009] 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.
[0010] 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.
[0011] 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.
[0012] 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.
[0013] 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).
[0014] 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 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.
[0015] All the known processes, moreover are designed primarily for making single 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.
[0016] US5224601 describes a process for producing a package which comprises; moulding a first sheet
of water soluble or water dispersible material to form a non-planar sheet comprising
at least one recess adapted to retain a pesticidal composition, the recess being bounded
by a substantially planar flange; placing a second sheet on the flange and across
every recess; placing a third sheet of water soluble or water dispersible material
over said second sheet to enclose therewith at least one further component of said
multi-component composition; and heat sealing the first, second and third sheets along
the flange to form a continuous water soluble or water dispersible heat seal.
Summary of the invention
[0017] According to an 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
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 surface moves in synchronism
with said first moving endless surface. This facilitates to carry out the process
in a continuous manner.
[0018] 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 first 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.
[0019] 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 rectangular 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
film and this can contribute to improve the dissolution profile of the pouch.
[0020] The open pouches can be formed using thermoforming, 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 beat
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.
[0021] The first web of open pouches is preferably formed on a first rotating endless surface,
this surface being preferably horizontal or substantially horizontal during the filling
of the pouches.
[0022] 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 filling 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. Alternatively, the
filling station can be stationary.
[0023] 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 feeders 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 having an orifice of the same size or slightly smaller than
the aperture of the open pouch, in order to avoid seal contamination.
[0024] 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.
[0025] 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.
[0026] Preferably the second endless surface rotates in a direction counter to the first
endless surface.
[0027] 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, radio
frequency, laser. Solvent sealing can alternatively be used herein.
[0028] 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 compartments 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 compartments is horizontally divided into a plurality
of compartments.
[0029] According to another process aspect, there is provided a process for making a water-soluble
pouch suitable for use in machine 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.
[0030] 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 compartment,
which is itself then filled, closed and sealed. In a preferred embodiment the sealing
steps are undertaken by means of solvent sealing.
[0031] The term "filling" as used herein includes both "partial" and "complete" filling
of a pouch or compartment 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 compartment. "Partial" filling is construed accordingly.
[0032] 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 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 pouches releasably mounted,
on a moving endless surface;
- b) closing 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 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.
[0033] In a preferred execution of this process, the sealing step is undertaken by means
of ultrasonic sealing.
[0034] 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 compartment. 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 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 1 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.
[0035] In alternative executions, the superposed open compartments 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 making 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 moving in synchronism with said moving web; and
- e) separating said web into a plurality of water-soluble multi-compartment pouches.
[0036] 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;
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-compartment pouches.
[0037] 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.
[0038] In all 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.
[0039] 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.
[0040] 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 sensorially 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.
Detailed description of the invention
[0041] The invention 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.
[0042] 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 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.
[0043] The compartments of the water-soluble pouch may be of a different colour from each
other, for example a first 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 semitransparent.
The compartments of the pouch may be the same size, having the same internal volume,
or may be different sizes having different internal volumes.
[0044] 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 that can be of different
colours.
[0045] 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 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.
[0046] 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 compartment. 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.
[0047] The pouches can be packed in a string, each pouch being individually separable by
a perforation line. Therefore, each pouch can be individually torn-off from the remainder
of the string by the end-user.
[0048] Especially suitable for use herein are multi-compartment pouches having a first compartment
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.
[0049] 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.
[0050] 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.
[0051] 50 grams ± 0.1 gram of pouch material is added in a pre-weighed 400 ml beaker and
245ml ± 1ml 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
fraction). Then, the % solubility or dispersability can be calculated.
[0052] 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
[0053] 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, 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%.
[0054] The polymer can have any weight average molecular weight, preferably 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.
[0055] 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 mixtures 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 copolymer
thereof, with a weight average molecular weight of about 100,000 to 300,000, preferably
around 150,000.
[0056] 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.
[0057] 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.
[0058] 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 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.
[0059] 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.
[0060] 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), anticorrosion
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.
[0061] Unless otherwise specified, the components described hereinbelow can be incorporated
either in the organic solvent compositions and/or the detergent or cleaning compositions.
[0062] 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 generally 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.
[0063] Solvents that can be used herein include: i) alcohols, such as benzyl alcohol, 1,4-cyclohexanedimethanol,
2-ethyl-1-hexanol, furfuryl alcohol, 1,2-hexanediol and other similar materials; ii)
amines, such as alkanolamines (e.g. primary alkanolamines: monoethanolamine, monoisopropanolamine,
diethylethanolamine, ethyl diethanolamine; secondary alkanolamines: diethanolamine,
diisopropanolamine, 2-(methylamino)ethanol; ternary alkanolamines: triethanolamine,
triisopropanolamine); alkylamines (e.g. primary alkylamines: monomethylamine, monoethylamine,
monopropylamine, monobutylamine, monopentylamine, cyclohexylamine), secondary alkylamines:
(dimethylamine), alkylene amines (primary alkylene amines: ethylenediamine, propylenediamine)
and other similar 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 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
[0064] 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 C
5-C
20, preferably C
10-C
18 linear or branched; cationic surfactants such as chlorine esters (
US-A-4228042,
US-A-4239660 and
US-A-4260529) and mono C
6-C
16 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 (especially
ethoxylates derived from C
6-C
18 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 PLURONIC®, REVERSED PLURONIC®, and TETRONIC® by the BASF-Wyandotte
Corp., Wyandotte, Michigan; amphoteric surfactants such as the C
12-C
20 alkyl amine oxides (preferred amine oxides for use herein include C
12 lauryldimethyl amine oxide, C
14 and C
16 hexadecyl dimethyl amine oxide), and alkyl amphocarboxylic surfactants such as Miranol
™ C2M; and zwitterionic surfactants such as the betaines and sultaines; and mixtures
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
[0065] 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.
[0066] Amorphous sodium silicates having an SiO
2:Na
2O 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 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
[0067] 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.), M1 Lipase
R and Lipomax
R (Gist-Brocades) and Lipolase
R and Lipolase Ultra
R (Novo); cutinases; proteases such as Esperase
R, Alcalase
R, Durazym
R and Savinase
R (Novo) and Maxatase
R, Maxacal
R, Properase
R and Maxapem
R (Gist-Brocades); α and β amylases such as Purafect Ox- Am
R (Genencor) and Termamyl
R, Ban
R, Fungamyl
R, Duramyl
R, and Natalase
R (Novo); pectinases; and mixtures thereof. Enzymes are preferably added herein as
prills, granulates, or cogranulates at levels typically in the range from about 0.0001%
to about 2% pure enzyme by weight of composition.
Bleaching agent
[0068] 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 transition metal-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 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
[0069] 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 surfactants 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(oxyalkylated) alcohols (e.g., BASF Poly-Tergent® SLF18B series
of nonionics, as described, for example, in
US-A-5,576,281).
[0070] Preferred low cloud point surfactants are the ether-capped poly(oxyalkylated) suds
suppresser having the formula:
wherein R
1 is a linear, alkyl hydrocarbon having an average of from about 7 to about 12 carbon
atoms, R
2 is a linear, alkyl hydrocarbon of about 1 to about 4 carbon atoms, R
3 is a 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.
[0071] Other low cloud point nonionic surfactants are the ether-capped poly(oxyalkylated)
having the formula:
R
IO(R
IIO)
n,CH(CH
3)OR
III
wherein, R
I is selected from the group consisting of linear or branched, saturated or unsaturated,
substituted or unsubstituted, aliphatic or aromatic hydrocarbon radicals having from
about 7 to about 12 carbon atoms; R
II may be the same or different, and is independently selected from the group consisting
of branched or linear C
2 to C
7 alkylene in any given molecule; n is a number from 1 to about 30; and R
III 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 R2 is (ii) then either: (A) at least one of R1 is other than C2 to C3 alkylene; or (B) R2 has from 6 to 30 carbon atoms, and with the further proviso that when R2 has from 8 to 18 carbon atoms, R is other than C1 to C5 alkyl.
[0072] 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 about
1% to about 10% by weight of composition. Preferred anti-redeposition polymers herein
include acrylic acid containing polymers such as Sokalan PA30, PA20, PA15, PA10 and
Sokalan CP10 (BASF GmbH), Acusol 45N, 480N, 460N (Rohm and Haas), acrylic acid/maleic
acid copolymers such as Sokalan CP5 and acrylic/methacrylic copolymers. Preferred
soil release polymers herein include alkyl 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.
[0073] 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) hexamethylenediamine
tetra(methylene phosphonate), ethylene diphosphonate, hydroxyethylene-1,1-diphosphonate,
nitrilotriacetate, ethylenediaminotetracetate, ethylenediamine-N,N'-disuccinate in
their salt and free acid forms.
[0074] The compositions herein can contain a corrosion inhibitor such as organic silver
coating 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%, preferably from about 0.01% to about 1%, more preferably
from about 0.02% to about 0.4% by weight of the composition.
[0075] 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%, 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-93/08877), suds suppressors (see
WO-93/08876 and
EP-A-0705324), polymeric dye transfer inhibiting agents, optical brighteners, perfumes, fillers
and clay.
[0076] 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.
[0077] The process used herein for forming the first and/or second moving webs involves
continuously feeding a water-soluble film 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 films 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.
[0078] In a preferred embodiment for making both the first and second moving webs a portion
of 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
rectilinear 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.
[0079] 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.
[0080] 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 performed 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.
[0081] 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.
[0082] 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.
[0083] 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.
[0084] 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.
[0085] 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 I to 10 or even
2 to 6 or even 2 to 5 moulds lengthwise, i.e. in the direction of motion of the patens.
[0086] 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.
[0087] 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).
[0088] 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 time-span or for a shorter or longer duration. For example, it
may be 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.
[0089] 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.
[0090] It should be understood that thus all platens and the main belt move continuously,
typically with the same constant speed.
[0091] 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.
[0092] 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.
[0093] 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 one to another, if desirable. For example, it may be preferred that the volume
of the final pouches is between 5 and 300ml, or even 10 and 150ml or even 20 and 100ml
or even up to 80ml and that the mould sizes are adjusted accordingly.
[0094] 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 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.
[0095] Preferred may be that the rollers rewind the film with a speed of at least 100m/min,
or even 120 to 700m/min, or even 150 to 500m/mm, or even 250 to 400m/min.
[0096] 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 surface, where there are no moulds, or held down by a belt on the edges
of the surface, where there are no moulds.
[0097] 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 grips, clips rollers or belt), and moreover as to reduce the tension
on the film 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 film in 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 the film width is larger than the surface, so
this system is more flexible-than the use of grips of clips.
[0098] 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.
[0099] Preferably, said surface thereto comprises holes which are connected to a device
which can provide a vacuum, as known 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.
[0100] 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.
[0101] 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 1 to 2mm.
[0102] 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.
[0103] 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.
[0104] 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.
[0105] 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 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 film,
which pulls the film into the moulds, or combinations of all these methods.
[0106] 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 permit 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.
[0107] 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.
[0108] 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 example to temperatures of 50 to 120°C, or even 60 to 90°C,
preferably for example with infra red light.
[0109] 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.
[0110] 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.
[0111] 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.
[0112] 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 control that only a set amount
or volume of product is dispensed during one rotation per nozzle, e.g. thus in one
pouch.
[0113] 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.
[0114] 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 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.
[0115] 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.
[0116] 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.
[0117] 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.
[0118] 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).
[0119] 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 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.
[0120] The filling will then take place through the openings on this surface or belt, such
that the 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.
[0121] The filled, open pouches are then closed, which can be done by any method. Preferably,
this is also done while in horizontal position and in continuous, constant motion,
and preferably on the horizontal portion of the endless surface described above.
[0122] Preferred in the case of the second moving web is that the closing is done by continuously
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
[0123] 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 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.
[0124] 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.
[0125] 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.
[0126] 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.
[0127] 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 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.
[0128] 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.
[0129] The cutting can be done by any known method. It may be preferred that the cutting
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.
[0130] The cutting device can for example be a sharp item or a hot item, whereby in the
latter case, the that 'burns' through the film/ 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.
[0131] 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 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 pouch, the
characteristics required from the pouch to hold, protect and deliver or release the
compositions, the number of compartments in the pouch:
[0132] 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.
[0133] 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 ingress 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. In
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.
[0134] 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 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 referred to as being substantially
insoluble in cold water but soluble in warm water. Sometimes this is abbreviated simply
to "warm water soluble".
[0135] 50 grams ± 0.1 gram of pouch material is added in a pre-weighed 400 ml beaker and
245ml ± 1ml 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 µm. 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.
[0136] Commercially available films 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.
[0137] 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 compartment made of warm water-soluble
material takes longer to dissolve than the compartment made of cold water-soluble
material. This kind of pouch allows for a delayed release of the liquid composition
providing optimised use of the detergent composition. 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 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 soil removal and
spotting benefits in the later stages of the dishwashing process.
[0138] Pouch compartments 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 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 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 interaction between the surfactant and the table/dishware surfaces.
[0139] 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.
[0140] 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 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 compartment by heat sealing.
[0141] 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 main-wash cycle.
[0142] 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 the organic carboxylic acids such as fumaric
acid, maleic acid, malic acid, citric acid; suitable carbonate sources include sodium
salts of carbonate, bicarbonate, percarbonate. 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.
Examples:
Abbreviations used in Examples
[0143] In the examples, the abbreviated component identifications have the following meanings:
- Carbonate :
- Anhydrous sodium carbonate
- STPP :
- Sodium tripolyphosphate
- Silicate :
- Amorphous Sodium Silicate (SiO2:Na2O = from 2:1 to 4:1)
- HEDP :
- Ethane 1-hydroxy-1,1-diphosphonic acid
- Perborate :
- Sodium perborate monohydrate
- Percarbonate :
- Sodium percarbonate of the nominal formula 2Na2CO3.3H2O2
- Carbonate :
- Anhydrous sodium carbonate
- Termamyl :
- α-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 :
- alkyl capped non-ionic surfactant of formula C9/11 H19/23 EO8-cyclohexyl acetal
- C14AO :
- tetradecyl dimethyl amine oxide
- C16AO :
- hexadecyl dimethyl amine oxide
- Duramyl :
- α-amylase available from Novo Nordisk A/S
- DPM :
- dipropylene glycol methyl ether
- DPG :
- dipropylene glycol
- Methocel :
- cellulosic thickener available from Dow Chemical
[0144] In the following examples all levels are quoted as per cent (%) by weight.
Examples 1 to 8
[0145] 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
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 first endless surface and closing the first web of
open pouches with the second web of filled and sealed pouches moving in synchronism
therewith.
[0146] 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.
1. Verfahren zur Herstellung eines wasserlöslichen Beutels, umfassend eine Vielzahl von
Kammern, die sich in einer im Allgemeinen übereinander angeordneten Beziehung befinden,
wobei jede einen Waschmittelwirkstoff oder Hilfsmittelbestandteil umfasst, wobei das
Verfahren die folgendes Schritte umfasst:
a) Bilden einer ersten sich bewegenden Bahn von gefüllten und wahlweise versiegelten
Beuteln, die auf einer ersten sich bewegenden endlosen Oberfläche lösbar angebracht
sind;
b) Bilden einer zweiten sich bewegenden Bahn von gefüllten und versiegelten Beuteln,
die auf einer zweiten sich bewegenden endlosen Oberfläche lösbar angebracht sind;
c) Übereinander Anordnen und Versiegeln oder Befestigen der ersten und der zweiten
sich bewegenden Bahn, um eine übereinander angeordnete und versiegelte Bahn zu bilden;
und
d) Trennen der übereinander angeordneten und versiegelten Bahn in eine Vielzahl von
wasserlöslichen Mehrkammerbeuteln.
2. Verfahren nach Anspruch 1 , wobei sich die zweite sich bewegende endlose Oberfläche
synchron mit der ersten sich bewegenden endloses Oberfläche bewegt.
3. Verfahren nach Anspruch 1 oder 2, wobei die erste Bahn von Beuteln durch Bilden und
Befüllen einer ersten sich bewegenden Bahn offener Beutel, die auf der ersten endlosen
Oberfläche angebracht sind, und durch Schließen der ersten Bahn offener Beutel mit
Bahnverschlussmitteln, die sich synchron damit bewegen, hergestellt wird.
4. Verfahren nach Anspruch 1 oder 2, wobei die erste Bahn von Beuteln durch Bilden und
Befüllen einer ersten sich bewegenden Bahn offener Beutel, die auf der ersten, endlosen
Oberfläche angebracht sind, und durch Schließen der ersten Bahn offener Beutel mit
der zweiten Bahn gefüllter und versiegelter Beutel, die sich synchron damit bewegen,
hergestellt wird,
5. Verfahren nach einem der Ansprüche, 1 bis 4, umfassend den Schritt des Umkchrens der
zweiten sich bewegenden Bahn vor dem übereinander Anordnen und Versiegeln der ersten
und der zweiten sich bewegenden Bahn, um die übereinander angeordnete und versiegelte
Bahn zu bilden.
6. Verfahren nach einem der Ansprüche 1 bis 5, wobei die Beutel der ersten sich bewegendes
Bahn während des Befüllens davon horizontal oder im Wesentlichen horizontal sind.
7. Verfahren nach einem der Ansprüche 1 bis 6, wobei sich die erste endlose Oberfläche
während des Schritts des Befüllens der ersten sich bewegenden Bahn offener Beutel
in kontinuierlicher horizontaler oder im Wesentlichen horizontaler Bewegung bewegt.
8. Verfahren Dach einem der Ansprüche 1 bis 7, wobei sich die erste endlose Oberfläche
während des Schritts des der ersten sich bewegenden Bahn offener Beutel in kontinuierlicher
horizontaler geradliniger Bewegung bewegt und wobei der Schritt des Befüllens mittels
einer Produktfüllstation, die sich mit der ersten endlosen Oberfläche synchron bewegt,
erreicht wird.
9. Verfahren nach Anspruch 8, wobei die Mittel zum Einfüllen von Mengen einer Vielzahl
von Produktzuführströmen in jeden der offenen: Beutel umfasst.
10. Verfahren nach einem der Ansprüche 1 bis 9, wobei die zweite Bahn gebildeter, gefüllter
und versiegelter Beutel durch Bilden und Befüllen einer zweiten sich bewegenden Bahn
offener Beutel, die auf der zweiten endlosen Oberfläche angebracht sind, und durch
Schließen der zweiten Bahn offener Beutel mit Folienverschlussmitteln, die sich synchron
damit bewegen, hergestellt wird.
11. Verfahren nach einem der Ansprüche 1 bis 10, wobei die Beutel der zweiten sich bewegenden
Bahn während des Befüllens davon horizontal oder im Wesentlichen horizontal sind.
12. Verfahren nach Anspruch 11, wobei der Schritt des Befüllens der zweiten sich bewegenden
horizontalen Bahn offener Beutel mittels einer zweiten Produktfüllstation, die sich
synchron mit der zweiten endlosen Oberfläche bewegt, erreicht wird.
13. Verfahren nach Anspruch 12, wobei die zweite Produktfüllstation Mittel zum Einfüllen
von Mengen einer Vielzahl von Produktzführströmen in jeden der offenen Beutel umfasst.
14. Verfahren nach einem der Ansprüche 1 bis 13, wobei sich die erste endlose Oberfläche
während des Befüllens der ersten sich bewegenden Bahn offener Beutel in horizontaler
geradliniger Bewegung bewegt und wobei sich die zweite endlose. Oberfläche während
des Schritts des Befüllens der zweiten sich bewegenden Bahn offener Beutel in im Wesentlichen
horizontaler geradliniger oder krummliniger Bewegung bewegt.
15. Verfahren nach einem der Ansprüche 1 bis 14, wobei sich die zweite endlose Oberfläche
in einer der ersten endlosen Oberfläche entgegengesetzten Richtung dreht.
16. Verfahren zur Herstellung eines wasserlöslichen Beutels, der eine. Vielzahl von Karmmern
umfasst, die im Allgemeinen übereinander angeordnet sind oder angeordnet werden können,
wobei jede einen Waschmittelwirkstoff oder Hilfsmittelbestandteil umfasst, wobei das
Verfahren die folgenden Schritte umfasst:
a) Bilden und teilweises Befüllen einer sich bewegenden Bahn offener Beutel, die auf
einer sich bewegenden endlosen Oberfläche lösbar angebracht sind
b) Schließen und Versiegeln der bewegten Bahn mit Bahnenverschlussmitteln, die sich
synchron damit bewegen, wobei das Bahnenverschlussrmittel in die teilweise gefüllten
Beutel eingeführt wird, so dass eine Vielzahl von geschlossenen und übereinander angeordneten
offenen Kammern gebildet werden;
c) Füllen, Schießen und Versiegeln der übereinander angeordneten offenen Kammern mithilfe
eines zweiten Bahnenverschlussmittels, das sich synchron mit der bewegten Bahn bewegt,
und
d) Trennung der Bahn in eine Vielzahl von wasserlöslichen Mehrkammerbeuteln.
17. Verfahren nach Anspruch 16, wobei die Versiegelungsschritte mittels Lösungsmittelversiegeln
ausgeführt werden.
18. Verfahren zur Herstellung eines wasserlöslichen Beutels, umfassend eine Vielzahl von
Kammern, die im Allgemeinen übereinander angeordnet sind oder übereinander angeordnet
werden können, wobei jede einen Waschmittelwirkstoff oder Hilfsmittelbestandteil umfasst
wobei das Verfahren die folgenden Schritte umfasst:
a) Bilden und teilweises Befüllen einer bewegten Bahn offener Beutel, die lösbar auf
einer sich bewegenden endlosen Oberfläche angebracht ist:
b) Schließen der bewegten Bahn mit Bahnenverschlussmitteln, die sich synchron damit
bewegen, wobei das Bahnenverschlussmittel in die teilweise gefüllten Beutel eingeführt
wird, so dass eine Vielzahl von geschlossenen und übereinander angeordneten offenen
Kammern gebildet werden;
c) Füllen und Schließen der übereinander angeordneten offenen Kammern mithilfe eines
zweiten Bahnenverschlussmittels, das sich synchron mit der bewegten Bahn bewegt;
d) Versiegeln der Bahn und des ersten und zweiten Bahnenverschlussmittels; und
e) Trennung der Bahn in eine Vielzahl von wasserlöslichen Mehrkammerbeuteln.
19. Verfahren nach Anspruch 18, wobei der Versiegelungsschritt mittels Ultraschallverschweißen
ausgeführt wird.
20. Verfahren nach einem der Ansprüche 16 bis 19, wobei in Schritt (a) die Bahn offener
Beutel mit einer ersten Zusammensetzung, die einen Waschmittelwirkstoff oder Hilfsmittelbestandteil
umfasst, gefüllt wird und wobei die Zusammensetzung verdichtet wird oder die Beutel
vergrößert werden, bevor die sich bewegende Bahn in Schritt (b) geschlossen wird.
21. Verfahren nach Anspruch 20, wobei der erste Bestandteil eine Pulverzusammensetzung
ist und wobei die Zusammensetzung durch Verdichtung verdichtet wird.
22. Verfahren zur Herstellung eines wasserlöslichen Beutels, der eine Vielzahl von Kammern
umfasst, die im Allgemeinen übereinander angeordnet sind oder übereinander angeordnet
werden können, wobei jede einen Waschmiltelwirkstoff oder Hilfsmittelbestandteil umfasst,
wobei das Verfahren die folgenden Schritte umfasst:
a) Bilden und Befüllen einer bewegten Bahn offener Beutel, die lösbar auf einer sich
bewegenden endlosen Oberfläche angebracht ist;
b) Schließen und Versiegeln der bewegten Bahn mit einem Bahnenverschlussmittel, das
sich synchron damit bewegt, so dass eine Vielzahl von geschlossenen Kammern gebildet
werden;
c) Bilden einer Aussparung innerhalb einiger oder aller der geschlossenen Kammern,
die in Schritt (b) gebildet werden, um eine Vielzahl von offenen Kammern zu erzeugen,
die über den geschlossenen Kammern übereinander angeordnet sind;
d) Befüllen, Schließen und Versiegeln der übereinander angeordneten offenen Kammern
mithilfe eines zweiten Bahnenverschlussmittels, das sich synchron mit der bewegten
Bahn bewegt; und
e) Trennung der Bahn in eine Vielzahl von wasserlöslichen Mehrkammerbeuteln.
23. Verfahren zur Herstellung eines wasserlöslichen Beutels, umfassend eine Vielzahl von
Kammern, die im Allgemeinen übereinander angeordnet sind oder übereinander angeordnet
werden können, wobei jede einen Waschmittelwirkstoff oder Hilfsmittelbestandtel umfasst,
wobei das Verfahren die folgenden Schritte umfasst:
a) Bilden und Befüllen einer bewegten Bahn offener Beutel, die lösbar auf einer sich
bewegenden endlosen Oberfläche angebracht ist;
b) Schließen der sich bewegenden Bahn mit Babnverschlussmitteln, die sich synchron
damit bewegen, um eine Vielzahl von geschlossenen und übereinander angeordneten Kammern
zu bilden;
c) Bilden einer Aussparung innerhalb einiger oder aller Kammern, die in Schritt (b)
gebildet werden, um eine Vielzahl von offenen Kammern zu erzeugen, die über den geschlossenen
Kammern übereinander angeordnet sind;
d) Füllen und Schließen der übereinander angeordneten offenen Kammern mithilfe eines
zweiten Bahnenverschlussmittels, das sich synchron mit der bewegten Bahn bewegt;
e) Versiegeln der Bahn und des ersten und zweiten Bahnenverschlussmittels; und
f) Trennen der Bahn in eine Vielzahl von wasserlöslichen Mehrkammerbeuteln.
24. Verfahren nach einem der Ansprüche 16 bis 23, wobei sich die endlose Oberfläche während
der Schritte des Befüllens der offenen Beutel und übereinander angeordneten offenen
Kammern in kontinuierlicher horizontaler oder im Wesentlichem horizontaler Bewegung
bewegt.
25. Verfahren nach einem der Ansprüche 16 bis 22, wobei sich die endlose Oberfläche während
der Schritte des Befüllens der offenen Beutel und übereinander angeordneten offenem
Kammern in kontinuierlicher horizontaler geradliniger Bewegung bewegt und wobei die
Schritte des Befüllens mittels einer Produktfüllstation erreicht werden, die sich
synchron mit der endlosen Oberfläche bewegt.
26. Verfahren nach Anspruch 24, wobei die Produktifüllstation Mittel zum Einfüllen von
Mengen einer Vielzahl von Produktzuführströmen in jede der Kammern umfasst.
27. Verfahren nach einem der Ansprüche 1 bis 26, wobei eine Vielzahl von Kammern mit einer
Pulverzusammensetzung gefüllt werden und wobei, eine Vielzahl von übereinander angeordneten
Kammern mit einer flüssigen, Gel- oder einer Pastenzusammensetzung gefüllt werden.
28. Verfahren nach einem der Ansprüche 1. bis 27 zum Bilden einer Vielzahl von Mehrkammerbeuteln
in einer Vielfalt von sensorisch unterscheidbaren Gruppen, wobei das Verfahren das
Befüllen jeder der Vielfalt von Kammergruppen mit einer entsprechenden sensorisch
unterscheidbaren Zusammensetzung umfasst, wodurch die resultierenden Gruppen im Hinblick
auf Farbe, Form, Größe, Muster oder Verzierung unterscheidbar sind, oder wobei die
Gruppen im Hinblick auf das Bereitstellen eines einzigartigen sensorischen Signals
wie Geruch, Klang, Gefühl usw. unterscheidbar sind.
1. Procédé de fabrication d'un sachet hydrosoluble et qui comprend une pluralité de compartiments
dans une relation généralement superposée, chacun comprenant un principe actif détergent
ou un composant auxiliaire, le procédé comprenant les étapes consistant à :
a) former un premier réseau en mouvement de sachets remplis et facultativement scellés
montés de façon libérable sur une première surface en mouvement sans fin ;
b) former un deuxième réseau en mouvement de sachets remplis et scellés montés de
façon libérable sur une deuxième surface en mouvement sans fin ;
c) superposer et sceller ou lesdits premier et deuxième réseaux en mouvement pour
former un réseau superposé et scellé ; et
d) séparer ledit réseau superposé et scellé en une pluralité de sachets hydrosolubles
à compartiments multiples,
2. Procédé selon la revendication 1, dans lequel la deuxième surface en mouvement sans
fin se déplace en synchronisme avec ladite première surface en mouvement sans fin.
3. Procédé selon la revendication 1 on 2, dans lequel ledit premier réseau de sachets
est préparé en formant et en remplissant un premier réseau en mouvement de sachets
ouverts montés sur première surface sans fin et en fermant le premier réseau de sachets
ouverts avec un moyen de fermeture de réseau se déplaçant en synchronisme avec celui-ci.
4. Procédé selon la revendication 1 ou 2, dans lequel ledit premier réseau de sachets
est préparé en formant et en remplissant un premier réseau en mouvement de sachets
ouverts montés sur la première surface sans fin et en fermant le premier réseau de
sachets ouverts avec le deuxième réseau de sachets remplis et scellés se déplaçant
en synchronisme avec celui-ci.
5. Procédé selon l'une quelconque des revendications 1 à 4, incluant l'étape d'inversion
dudit deuxième réseau en mouvement avant de superposer et de sceller lesdits premier
et deuxième réseaux en mouvement pour former ledit réseau superposé et scellé.
6. Procédé selon l'une quelconque des revendications 1 à 5, dans lequel les sachets du
premier réseau en mouvement sont horizontaux ou essentiellement horizontaux pendant
leur remplissage.
7. Procédé selon l'une quelconque des revendications 1 à 6, dans lequel la première surface
sans fin se déplace dans un mouvement horizontal ou essentiellement horizontal continu
pendant l'étape de remplissage du premier réseau en mouvement de sachets ouverts.
8. Procédé selon l'une quelconque des revendications 1 à 7, dans lequel la première surface
sans fin se déplace dans un mouvement rectiligne horizontal continu pendant l'étape
de remplissage du premier réseau en mouvement de sachets ouverts et dans lequel l'étape
de remplissage est accomplie au moyen d'une station de remplissage de produit se déplaçant
en synchronisme avec la première surface sans fin.
9. Procédé selon la revendication 8, dans lequel la station de remplissage du produit
comprend un moyen pour remplir des quantités d'une pluralité de courants d'alimentation
en produit dans chacun desdits sachets ouverts.
10. Procédé selon l'une quelconque des revendications 1 à 9, dans lequel ledit deuxième
réseau de sachets formés, remplis et scellés est préparé en et en remplissant un deuxième
réseau en mouvement de sachets ouverts montés sur la deuxième, surface sans fin et
en fermant le deuxième réseau de sachets ouverts avec un moyen de fermeture par film
se déplaçant en synchronisme avec celui-ci.
11. Procédé selon l'une quelconque des revendications 1 à 10, dans lequel les sachets
du deuxième réseau en mouvement sont horizontaux ou essentiellement horizontaux pendant
leur remplissage.
12. Procède selon la revendication 11, dans lequel l'étape de remplissage du deuxième
réseau en mouvement horizontal de sachets ouverts est accompli en utilisant une deuxième
station de remplissage de produit se déplaçant en synchronisme avec la deuxième surface
sans fin.
13. Procédé selon la revendication 12, dans lequel la deuxième station de remplissage
de produit comprend un moyen pour remplir des quantités d'une pluralité de courants
d'alimentation de produit dans chacun desdits sachets
14. Procédé selon l'une quelconque des revendications 1 à 13, dans lequel la première
surface sans fin se déplace dans un mouvement rectiligne horizontal pendant l'étape
de remplissage du réseau en mouvement de sachets ouverts et dans lequel la deuxième
surfaces sans fin se déplace dans un mouvement rectiligne ou curviligne essentiellement
horizontal pendant l'étape de remplissage du deuxième réseau en mouvement de sachets
ouverts.
15. Procédé selon l'une quelconque des revendications 1 à 14, dans lequel ladite deuxième
surface sans fin tourne dans le sens contraire à ladite première surface sans fin.
16. Procédé de fabrication d'un sachet hydrosoluble qui comprend une pluralité de compartiments
en relation généralement superposée ou superposable, chacun comprenant un principe
actif détergent ou un composant auxiliaire, le procédé comprenant les étapes consistant
à :
a) former et remplir partiellement un réseau en mouvement de sachets ouverts montés
de façon libérable sur une surface en mouvement sans fin ;
b) fermer et sceller ledit réseau en mouvement par un moyen de de réseau se déplaçant
en synchronisme avec celui-ci selon lequel le moyen de fermeture du réseau est introduit
dans les sachets partiellement remplis de façon à former une pluralité de compartiments
ouverts fermés et superposés;
c) remplir, fermer et les compartiments ouverts superposés au moyen d'un deuxième
moyen de fermeture de réseau se déplaçant en synchronisme avec ledit réseau en mouvement
; et
d) séparer ledit réseau en une pluralité de sachets hydrosolubles à compartiments
multiples.
17. Procédé selon la revendication 16, dans lequel les étapes de scellage sont réalisées
par un moyen de scellage par solvant.
18. Procédé de fabrication d'un sachet hydrosoluble et qui comprend une pluralité de compartiments
dans une relation généralement superposée ou superposable, chacun comprenant un principe
actif détergent ou un composant auxiliaire, le procédé comprenant les étapes consistant
à :
a) former et partiellement remplir un réseau en mouvement de sachets ouverts montés
de façon libérable sur une surface en mouvement sans fin ;
b) fermer ledit réseau en mouvement par un moyen de fermeture de réseau se déplaçant
en synchronisme avec celui-ci et selon lequel le moyen de fermeture du réseau est
introduit dans les sachets partiellement remplis de façon à former une pluralité de
compartiments ouverts fermés et superposés ;
c) remplir et fermer les compartiments ouverts superposés au moyen d'un deuxième moyen
de fermeture de réseau se déplaçant en synchronisme avec ledit réseau en mouvement
;
d) sceller ledit réseau et lesdits premier et deuxième moyens de fermeture du réseau
; et
e) séparer ledit réseau en une pluralité de sachets hydrosolubles à compartiments
multiples,
19. Procédé selon la revendication 18, dans lequel l'étape de scellage est entreprise
par un moyen de scellage par ultrasons.
20. Procédé selon l'une quelconque des revendications 16 à 19, dans lequel à l'étape (a),
le réseau de sachets ouverts est rempli avec une première composition comprenant un
principe actif détergent ou un composant auxilliaire et dans lequel la composition
est rendue plus dense ou dans lequel les sachets sont agrandis avant de fermer le
réseau en mouvement à l'étape (b).
21. Procédé selon la revendication 20, dans lequel le premier composant est une composition
en poudre et dans lequel la composition est densifiée par compaction.
22. Procède de fabrication d'un sachet hydrosoluble qui comprend une pluralité de compartiments
dans une relation généralement superposée ou superposable, chacun comprenant un principe
actif détergent ou un composant auxiliaire, le procédé comprenant, les étapes consistant
à :
a) former et remplir un réseau en mouvement de sachets ouverts montés de façon libérable
sur une surface en mouvement sans fin ;
b) fermer et sceller ledit réseau en avec un moyen de fermeture de réseau se déplaçant
en synchronisme avec celui-ci de façon à former une pluralité de compartiments fermés;
c) former une cavité au sein d'une partie ou de tout le compartiment ferme formé à
l'étape (b) de façon à à générer une pluralité de compartiments ouverts superposes
au-dessus des compartiments fermes ;
d) remplir, fermer et sceller les compartiments ouverts superposes au moyen d'un deuxième
moyen de fermeture de réseau se déplaçant en synchronisme avec ledit réseau en mouvement
; et
e) séparer ledit réseau en une pluralité de sachets hydrosolubles à compartiments
multiples.
23. Procédé de fabrication d'un sachet hydrosoluble et qui comprend une pluralité de compartiments
dans une relation généralement superposée ou superposable, chacun comprenant un principe
actif détergent ou un composant auxiliaire, procédé comprenant les étapes consistant
à :
a) former et remplir un réseau en mouvement de sachets ouverts montés de façon libérable
sur une surface en mouvement sans fin ;
b) fermer ledit réseau en mouvement avec un moyen de fermeture de réseau se déplaçant
en synchronisme avec celui-ci de façon à former une pluralité de compartiments fermés
et superposés;
c) former une cavité au sein d'une partie ou de tout le compartiment, fermé formé
à l'étape (b) de façon a générer une pluralité de compartiments ouverts superposés
sur les compartiments fermés;
d) remplir et fermer les compartiments ouverts superposés au moyen d'un deuxième moyen
de fermeture de réseau se déplaçant en synchronisme avec ledit réseau en mouvement
;
e) sceller ledit réseau et lesdits premier et deuxième moyens de fermeture du réseau
; et
f) séparer ledit réseau en une pluralité de sachets hydrosolubles à compartiments
multiples.
24. Procédé selon l'une quelconque des revendications 16 à 23, dans lequel la surface
sans fin se déplace dans un mouvement horizontal ou essentiellement horizontal continu
pendant les étapes de remplissage des sachets ouverts et des compartiments ouverts
superposés.
25. Procédé selon l'une quelconque des revendications 16 à 22, dans lequel la surface
sans fin se déplace dans un mouvement rectiligne horizontal continu les étapes de
remplissage des sachets ouverts et des compartiments ouverts superposés et dans lequel
les étapes de remplissage sont accomplies en utilisant une station de remplissage
de produit se déplaçant en synchronisme avec la surface sans fin,
26. Procédé selon la revendication 24, dans lequel la station de remplissage de produit
comprend un moyen pour remplir des quantités d'une pluralité de courants d'alimentation
en produit dans chacun desdits compartiments.
27. Procédé selon l'une quelconque des revendications 1 à 26, dans lequel une pluralité
de compartiments est remplie avec une composition en poudre et dans lequel une pluralité
de compartiments superposés est remplie avec un liquide, un gel ou une composition
en pâte.
28. Procédé selon l'une quelconque des revendications 1 à 27, pour former une pluralité
de sachets à compartiments multiples dans une multiplicité de groupes sensoriellement
distincts, le procédé comprenant le remplissage de chaque groupe d'une multiplicité
de groupes compartimentés avec une composition sensoriellement distincte correspondante,
selon lequel les groupes résultants sont distincts en termes de couleur, forme, dimension,
motif ou ornement, ou dans lequel les groupes sont distincts en termes de fourniture
d'un signal sensoriel unique au niveau par exemple du goût, de l'ouïe, du toucher,
etc,