TECHNICAL FIELD
[0001] The present invention is in the field of laundry. In particular, it relates to a
method of industrial or institutional laundry for a polyester load using a silicone
suds suppressor during the wash process.
BACKGROUND OF THE INVENTION
[0002] Even though the principles that determine the effectiveness of detergents for household
(or home) and professional (including institutional and industrial) laundries are
similar, detergents for large-scale institutional or industrial use generally differ
insofar as they must be designed to meet the special circumstances associated with
laundry on an industrial scale and/or in an institutional context. Contrary to home
laundry, professional laundries have to deal with large volumes of textile items and
require therefore completely automatic processing with microprocessor-controlled machines
and dosing units. The length of the washing process differs from that of home laundry
and in some cases the washing is performed with soft water. Soil levels can be significantly
lower in certain types of loads of professional laundry (for example towels and bed
linen in a hotel which have ninimal use and soiling before being re-washed) than in
household laundry and the loads and the machines are considerably bigger. The composition
of the loads is more uniform, in terms of both, types of fabrics and soils. For example
a typical commercial laundry load will consist of only towels, only bed linen or only
table linen (tablecloths and napkins).
[0003] Due to the size of the washing equipment, professional laundry involves higher mechanical
action than home laundry and this promotes foaming. Foaming is also promoted in the
case of laundry loads consisting mainly of synthetic fabrics, in particular polyester
fabrics. Polyester items are hydrophobic and they are not capable to absorb surfactants.
During the washing process, polyester items seem to be less densily packed than cotton
items, being more prone to sudsing. Suds negatively affect the laundry cleaning performance
because contributes to the suspension of items in the wash liquor precluding the free
rise and fall of the items, leading to reduction of mechanical action which is one
of the major elements contributing to cleaning.
[0004] Low sudsing in washing polyester loads could be achieved through the selection of
inherently low sudsing surfactants, primarily non-ionics, versus the use of anionics,
for example. However this leads to poor performance on certain varieties of soils,
because this limits the selection to potentially compromised-in-performance surfactants.
An approach to overcome this lost of performance is the addition of high levels of
alkalinity, as alkalinity itself can help drive soil removal. For example, patent
application
Wo 96/24657 discloses highly alkaline solid detergent compositions for use in professional laundry.
But alkalinity can drive (alkaline) hydrolysis of the polyester molecules that comprise
the fibers, and thus damage the very fabrics intended for cleaning. The alkalinity
can also drive mineral salt encrustation and many other issues.
[0005] Some of the professional laundry systems involve the use of soft water. Soft water
also promotes sudsing. Under these circumstances, it is difficult to perform a good
cleaning.
[0006] Fatty acids or fatty soaps are commonly used as suds suppressors in laundry. They
rely on the presence of water hardness ions to work. When water hardness ions are
present they can form salts which can disrupt the suds. If there are no water hardness
ions, as the case is with soft water, then the soap might even cause additional suds.
It has been found that if a load of polyester is washed in soft water, using a normal
amount of detergent, the level of suds can be so high that it can overflow the machine,
this seems to be worse when the level of soil is low.
SUMMARY OF THE INVENTION
[0007] According to a first aspect of the invention, there is provided a method of cleaning
a polyester load in a professional laundry machine as defined in the claims.
[0008] By polyester load is understood a load comprising at least 50%, preferably at least
60%, more preferably at least 80% and more preferably at least 95% by weight of the
load of polyester items.
[0009] It has been found that textile loads containing a high level of polyester items give
rise to high suds that impact negatively in the cleaning process. The method of the
invention provides improved cleaning.
[0010] The level of anionic surfactant is greater than 12%, more preferably greater than
15% and especially greater than 20% by weight of the detergent composition. This provides
an outstanding cleaning over a great range of soils. The detergent composition comprises
non-ionic surfactant and anionic surfactant. The level of anionic surfactant is higher
than the level of non-ionic surfactant, by "higher" is herein meant that the level
of anionic surfactant is at least 1% by weight more than the level of non-ionic surfactant,
preferably at least 5%, more preferably at least 15% and especially at least 20%.
Preferably the level of non-ionic surfactant is less than 10% by weight of the detergent
composition. The method of the invention also allows for flexibility in terms of detergent
formulation.
[0011] Polyester with low level of soil and new polyester items can be even more prone to
sudsing than highly soiled items. The method of the invention performs very well even
in the case of loads with low level of soil (typically towels or bed linen) or new
items. By the term "low soiled items" is herein understood items free from visible
stains. By the term "new items" is herein understood items that have not been subjected
to a washing process.
[0012] As mentioned above, soft water further contributes to aggravate the suds problem.
The water of the wash liquor of the method of the invention, preferably the water
of the liquor of each cycle, has a hardness, i.e., Ca and Mg ions concentration, of
less than 1, preferably less than 0.5 and especially less than 0.2 mmoles/litre.
[0013] Another factor that further aggravates the suds problem is heating by steam means.
The method of the invention involves the step of heating the cleaning water using
steam, in particular steam injection.
[0014] Excellent cleaning is obtained with the method of the invention, even when using
soft water and when the water is heated by steam means.
[0015] Good cleaning performance is obtained when the level of active suds suppressor in
the wash liquor is from 0.1 to 10, more preferably from 0.2 to 5 and especially from
0.8 to 3 ppm. The suds suppressor for use herein is a polydimethlysiloxane compounded
with silica.
[0016] The wash liquor, preferably the wash liquor of the main wash, has a pH of from 7
to 9, preferably from 8 to 9, as measured at room temperature (20°C) this allows not
only for good cleaning but also for good care of the washed articles.
[0017] The detergent composition comprises anionic surfactant, in a level of at least 12%
by weight of the detergent composition, and at least 80% by weight of the anionic
surfactant is sodium lauryl benzene sulfonate. Detergents rich in sodium lauryl benzene
sulfonate, used according to the method of the invention, provide not only good cleaning
but also have a low suds profile.
[0018] In preferred embodiments the method of the invention comprises the step of contacting
the load with a soil release polymer, in any of the wash cycles, preferably during
the main-wash or a rinse cycle. Preferably the soil release polymer is added as part
of an additive rather than as part of a detergent composition. This not only obviates
the process challenges found to make the soil release polymer part of a base detergent
but also eliminates the interaction between some of the base detergent ingredients
and the polymer and gives flexibility in terms of dosing.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The present invention envisages a method of professional laundry of a polyester load.
The method involves contacting the load with a detergent comprising a silicone suds
suppressor. The method provides improved cleaning. It has been found that the problem
of high suds is more acute in the case of a load with low level of soil, ie. a load
with less than 10 g of soil per kilogram of load, preferably with less than 5 g of
soil per kilogram of load. The polyester load used in the method of the present invention
is a load with low level of soil.
[0020] Professional laundry includes institutional and industrial (sometimes also referred
to as commercial) laundry. Institutional laundry refers to textile washing operations
usually run in business sites, normally referred to as On-Premise or In-House Laundry
Operations. Typical businesses can be for instance hotels, restaurants, care homes,
hospitals, spas, health or sport clubs, schools, and similar institutions. Industrial
laundry refers to textile washing operations carried out in dedicated places typically
for the above businesses.
[0021] By "professional laundry machine" is herein meant a laundry machine which a capacity
higher than 25 kg of dry laundry.
[0022] There are two main types of professional laundry machines: front load which operate
in a batch mode or tunnel washing machines that operate in continuous mode. The professional
laundry machines for use herein, in the case of front load have a drum volume of at
least about 0.15 m
3, preferably at least 0.2 m
3, more preferably at least 0.3 m
3 and especially at least 0.5 m
3. The professional laundry machines for use herein, in the case of front load have
a drum diameter of at least about 0.5 m, preferably at least 0.8 m and more preferably
at least 1 m. In the case of tunnel washing machines the tunnel has a diameter of
at least about 1.5 m, preferably at least 3m and more preferably at least 5 m.
[0023] Silicone suds suppressor is defined herein as an antifoam compound that is a polydimethylsiloxane
compounded with silica. The polydimethylsiloxane is a relatively high molecular weight
polymer containing siloxane units and methyl groups that is chemisorbed or fused onto
silica. Silicone suds suppressers are well known in the art and are, for example,
disclosed in
U.S. Pat. No. 4,265,779, and
EP 354 016. Other silicone suds suppressers are disclosed in
U.S. Pat. No. 3,455,839 which relates to compositions and processes for defoaming aqueous solutions by incorporating
therein small amounts of polydimethylsiloxane fluids. Mixtures of silicone and silanated
silica are described, for instance, in German Patent Application DOS
2,124,526. Silicone defoamers and suds controlling agents in granular detergent compositions
are disclosed in
U.S. Pat. No. 3,933,672 and in
U.S. Pat. No. 4,652,392.
[0024] Suitable polydimethylsiloxanes compounded with silica particles are commercially
available from Dow Coming, Wacker Chemie and General Electric.
[0025] The Silicone suds suppressor is utilized in amounts up to about 2% by weight of the
detergent composition. This upper limit is practical in nature, due primarily to concern
with keeping costs minized and effectiveness of lower amounts for effectively controlling
sudsing. Preferably from 0.01 % to 1% of active silicone suds suppressor is used,
more preferably from 0.05% to 0.5% by weight of the detergent composition. As used
herein, the term "active" excludes water and inactive ingredients (in terms of suds
suppression).
Detergent composition
Detersive Surfactant
[0026] Compositions suitable for use herein comprise from 20% to 50% by weight of a certain
kind of detersive surfactant component. Such an essential detersive surfactant component
must comprise a combination of anionic surfactant and nonionic surfactant.
[0027] Suitable anionic surfactants useful herein can comprise any of the conventional anionic
surfactant types typically used in liquid detergent products. These include the alkyl
benzene sulfonic acids and their salts as well as alkoxylated or un-alkoxylated alkyl
sulfate materials.
[0028] Preferred anionic surfactants are the alkali metal salts of C
10-16 alkyl benzene sulfonic acids, preferably C
11-14 alkyl benzene sulfonic acids. Preferably the alkyl group is linear and such linear
alkyl benzene sulfonates are known as "LAS". Alkyl benzene sulfonates, and particularly
LAS, are well known in the art. Such surfactants and their preparation are described
for example in
U.S. Patents 2,220,099 and
2,477,383. Especially preferred are the sodium and potassium linear straight chain alkylbenzene
sulfonates in which the average number of carbon atoms in the alkyl group is from
about 11 to 14. Sodium C
11-C
14, e.g., C
12, LAS is especially preferred. At least 80% by weight of the anionic surfactant is
sodium lauryl benzene sulfonate.
[0029] Another preferred type of anionic surfactant comprises ethoxylated alkyl sulfate
surfactants. Such materials, also known as alkyl ether sulfates or alkyl polyethoxylate
sulfates, are those which correspond to the formula:
R'-O-(C
2H
4O)
n-SO
3M
wherein R' is a C
8-C
20 alkyl group, n is from about 1 to 20, and M is a salt-forming cation. Preferably,
R' is C
10-C
18 alkyl, n is from about 1 to 15, and M is sodium, potassium, ammonium, alkylammonium,
or alkanolammonium. Most preferably, R' is a C
12-C
16, n is from about 1 to 6 and M is sodium.
[0030] The alkyl ether sulfates will generally be used in the form of mixtures comprising
varying R' chain lengths and varying degrees of ethoxylation. Frequently such mixtures
will inevitably also contain some unethoxylated alkyl sulfate materials, i.e., surfactants
of the above ethoxylated alkyl sulfate formula wherein n=0. Unethoxylated alkyl sulfates
may also be added separately to the compositions of this invention and used as or
in any anionic surfactant component which may be present.
[0031] Preferred unalkoyxylated, e.g., unethoxylated, alkyl ether sulfate surfactants are
those produced by the sulfation of higher C
8-C
20 fatty alcohols. Conventional primary alkyl sulfate surfactants have the general formula:
ROSO
3-M
+
wherein R is typically a linear C
8-C
20 hydrocarbyl group, which may be straight chain or branched chain, and M is a water-solubilizing
cation. Preferably R is a C
10-C
15 alkyl, and M is alkali metal. Most preferably R is C
12-C
14 and M is sodium.
[0032] Suitable nonionic surfactants useful herein can comprise any of the conventional
nonionic surfactant types typically used in liquid detergent products. These include
alkoxylated fatty alcohols, ethylene oxide (EO)-propylene oxide (PO) block polymers,
and amine oxide surfactants. Preferred for use in the liquid detergent products herein
are those nonionic surfactants which are normally liquid.
[0033] Preferred nonionic surfactants for use herein include the alcohol alkoxylate nonionic
surfactants. Alcohol alkoxylates are materials which correspond to the general formula:
R
1(C
mH
2mO)
nOH
wherein R
1 is a C
8 - C
16 alkyl group, m is from 2 to 4, and n ranges from about 2 to 12.
[0034] Preferably R
1 is an alkyl group, which may be primary or secondary, that contains from about 9
to 15 carbon atoms, more preferably from about 10 to 14 carbon atoms. Preferably also
the alkoxylated fatty alcohols will be ethoxylated materials that contain from about
2 to 12 ethylene oxide moieties per molecule, more preferably from about 3 to 10 ethylene
oxide moieties per molecule.
[0035] The alkoxylated fatty alcohol materials useful in the liquid detergent compositions
herein will frequently have a hydrophilic-lipophilic balance (HLB) which ranges from
about 3 to 17. More preferably, the HLB of this material will range from about 6 to
15, most preferably from about 8 to 15. Alkoxylated fatty alcohol nonionic surfactants
have been marketed under the tradenames Neodol and Dobanol by the Shell Chemical Company.
[0037] Yet another suitable type of nonionic surfactant useful herein comprises the amine
oxide surfactants. Amine oxides are mateials which are often referred to in the art
as "semi-polar" nonionics. Amine oxides have the formula: R(EO)
x(PO)
y(BO)
zN(O)(CH
2R')
2.qH
2O. In this formula, R is a relatively long-chain hydrocarbyl moiety which can be saturated
or unsaturated, linear or branched, and can contain from 8 to 20, preferably from
10 to 16 carbon atoms, and is more preferably C
12-C
16 primary alkyl. R' is a short-chain moiety preferably selected from hydrogen, methyl
and -CH
2OH. When x+y+z is different from 0, EO is ethyleneoxy, PO is propyleneneoxy and BO
is butyleneoxy. Amine oxide surfactants are illustrated by C
12-14 alkyldimethyl amine oxide.
[0038] In the liquid detergent compositions herein, the weight ratio of anionic surfactant
to nonionic surfactant is from 20:1 to 1:20.
Laundry washing adjuncts
[0039] The detergent compositions herein, which are in liquid form, comprise from 0.1% to
30% by weight, preferably from 0.5% to 20% by weight, more preferably from 1% to 10%
by weight, of one or more of certain kinds of laundry washing adjuncts. Such laundry
washing adjuncts can be selected from detersive enzymes, builders, chelants, soil
release polymers, soil suspending polymers, optical brighteners, dye transfer inhibition
agents, bleach, whitening agents, suds suppressors, fabric care benefit agents, solvents,
stabilizers, buffers, structurants, dyes and perfumes and combinations of these adjunct
types. All of these materials are of the type conventionally utilized in laundry detergent
products.
Soil release polymer
[0040] Soil release polymers enhance the laundry cleaning efficacy by improving release
of grease and oil during the laundry process. See soil release agents' definition,
p.278-279, "Liquid Detergents" by Kuo-Yann Lai. For use herein, preferred level of soil release polymer per kilogram of load is
from about 0.01 to about 0.8 grams, more preferably the level of polymer is less than
0.2 grams especially from about 0.05 to about 0.15 grams. Contrary to what one would
expect higher levels of soil release polymer do not enhance removal. In some cases
removal is worse than with lower levels.
[0041] Improved stain removal is achieved when the soil release polymer is a copolymer having
the formula:

wherein :
- each R1 moieties is a 1,4-phenylene moiety;
- the R2 moieties are each selected from the group consisting of ethylene moieties, 1,2-propylene
moieties, 1,2 butylene moieties, 1,2 hexylene moieties, 3-methoxy-1,2 propylene moieties
or mixture thereof, provided that said R2 are not exclusively 1,2 butylene moieties, 1,2 hexylene moieties, 3-methoxy-1,2 propylene
moieties or mixture thereof; preferably R2 is a 1,2-propylene moiety.
- the R3 moieties are each selected from the group consisting of substituted 1,3-phenylene
moieties having the substituent

at the 5 position;
- the R4 moieties are R1 or R3 moieties, or mixtures thereof;
- each X is C1-C4 alkyl; each n is from 12 to 43;
- when w is 0, u+v is from 3 to 10;
- when w is at least 1, u+v+w is from 3 to 10.
[0042] Preferably w is 0.
[0043] Preferred soil release polymer for use herein is a copolymer comprising propylene
glycol derived moieties, terephthalate moieties and capped polyethylene glycol derived
moieties. Preferably the capped polyethylene glycol used is CH3O(CH2CH2O)nOH, wherein
n is an integer from 12 to 44, preferably from 20 to 42 and more preferably from 25
to 41 and especially 40. Improved performance is obtained with this kind of copolymers.
[0044] The preferred copolymer for use herein has the following formula:

[0045] Preferably the soil release polymer has a molecular weight above about 2,000, more
preferably above about 3,000 and more preferably above about 4,000. Methods in which
soil release polymers having molecular weight above 4,000 have been used provide outstanding
results in terms of stain removal. Preferably the molecular weight is below about
20,000. With reference to the polymers described herein, the term "molecular weight"
is the weight-average molecular weight as determined using gel permeation chromatography
according to the protocol found in
Colloids and Surfaces A. Physico Chemical & Engineering Aspects, Vol. 162, 2000, pg.
107-121. The units are Daltons.
[0046] Preferably the soil release polymer is added as part of an additive. The additive
is in liquid form so it can be easily delivered by means of a displacement pump, for
example a peristaltic pump. The additive is preferably an aqueous structured liquid,
usually the soil release polymer is insoluble in aqueous solution and it is suspended
by means of an external structurant. Structured liquids can either be internally structured,
whereby the structure is formed by primary ingredients (e.g. surfactant material)
and/or externally structured by providing a three dimensional matrix structure using
secondary ingredients (e.g. polymers, clay and/or silicate material). The additive
comprises the soil release polymer, preferably in an amount of from about 1% to about
50%, more preferably from about 5% to about 20% by weight of the additive. The additive
can further comprise an external structurant to keep the soil release polymer suspended.
Levels of external structurants of from about 0.05 to about 5%, more preferably from
about 0.1 to about 2% and especially from about 0.1 to about 1% by weight of the additive
have been found particularly suitable to keep the polymer suspended. Preferred external
structurant for use herein is xanthan gum. Preferably the additive comprises a preservative,
more preferred in a level of from about 0.05 to about 3% and especially from about
0.1 to about 1% by weight of the additive. A dye is another prefer component of the
additive of the invention. Preferably the additive is free of builders and/or surfactants.
Detersive Enzymes
[0047] Examples of suitable enzymes include, but are not limited to, hemicellulases, peroxidases,
proteases, cellulases, xylanases, lipases, phospholipases, esterases, cutinases, pectinases,
keratanases, reductases, oxidases, phenoloxidases, lipoxygenases, ligninases, pullulanases,
tannases, mannanases, pentosanases, malanases, β-glucanases, arabinosidases, hyaluronidase,
chondroitinase, laccase, and known amylases, or combinations thereof. A preferred
enzyme combination comprises a cocktail of conventional detersive enzymes like protease,
lipase, cutinase and/or cellulase in conjunction with amylase. Detersive enzymes are
described in greater detail in
U.S. Patent No. 6,579,839.
[0048] If employed, enzymes will normally be incorporated into the base detergent compositions
herein at levels sufficient to provide up to 10 mg by weight, more typically from
about 0.01 mg to about 5 mg, of active enzyme per gram of the composition. Stated
otherwise, the aqueous liquid detergent compositions herein can typically comprise
from 0.001% to 5%, preferably from 0.01% to 1% by weight, of a commercial enzyme preparation.
Protease enzymes, for example, are usually present in such commercial preparations
at levels sufficient to provide from 0.005 to 0.1 Anson units (AU) of activity per
gram of detergent composition.
[0049] The detergent may also include from about 0.05 to about 0.5% of preservatives non-limiting
examples of which include didecyl dimethyl ammonium chloride which is available under
the tradeneme UNIQUAT (from Lonza of Basel Switzerland), 1,2-benzisothiozolin-3-one,
which is available under the tradename PROPEL (from Arch Chemicals of Norwalk, Connecticut),
dimethylol-5,5-dimethylhydantoin which is available under the tradeneme DANTOGUARD
(from Lonza of Basel Switzerland), 5- Chloro-2- methyl-4- isothiazolin-3-one / 2-methyl-4-isothiazolin-3-one,
which is available under the tradename KATHON (from Rohm and Haas of Philadelphia,
Pennsylvania), and mixtures thereof.
Other Fabric Care Benefit Agents
[0050] The detergent composition for use herein may also comprise additional fabric care
or benefit agents which can be deposited onto fabrics being laundered and which thereupon
provide one or more types of fabric care or treatment benefits. Such benefits can
include, for example, fabric softness, anti-static effects, ease-of-ironing benefits,
anti-abrasion benefits, anti-pilling effects, color protection, wrinkle removal or
improved resistance to wrinkling, fabric substantive perfume or odor benefits, malodor
protection benefits, and the like.
[0051] A wide variety of materials which are suitable for providing such benefits and which
can be deposited onto fabrics being laundered are known in the art. Such materials
can include, for example, clays; starches; polyamines; un-functionalized and functionalized
silicones such as aminosilicones and quaternary nitrogen-containing cationic silicones;
cellulosic polymers, and the like. Materials of these types are described in greater
detail in one or more of the following publications:
US 6,525,013;
US 4,178,254;
WO 02/40627;
WO 02/18528;
WO 00/71897;
WO 00/71806;
WO 98/39401; and
WO 98/29528.
[0052] If employed, such additional fabric care benefit agents polymers can typically be
incorporated into the liquid laundry detergent compositions herein in concentrations
ranging from 0.05% to 20%, by weight, depending upon the nature of the materials to
be deposited and the benefit(s) they are to provide. More preferably, such fabric
care benefit agents can comprise from 0.1% to 10%, by weight of the composition.
Example:
[0053] 45 pounds of a polyester load was washed in a Milnor commercial washing machine (model
# 30022V6J (55-60 pound capacity)) at 60°C and using soft water (0 mmoles/liter).
[0054] The detergent used had the following composition and it was used at a dosage of 48
grams/ machine (or 9.6 ml/kg fabric). The detergent was delivered into the main-wash
cycle.
Table 1
| Ingredient |
% by weight |
| C12-alkylbenxene sulfonic acid |
12.2 |
| Non-ionic surfactant |
8.75 |
| C12-alkyl trimethyl amine N-oxide |
1.5 |
| C12-14 fatty acid |
8.3 |
| Citric acid |
3.4 |
| Triethyleneimine penta phosphonic acid |
0.19 |
| Ethoxylated polymine polymer |
1.1 |
| Enzyme |
0.53 |
| 1,2 propandiol |
4.9 |
| Ethanol |
2.8 |
| Monethanolamine |
0.83 |
| Monoethanaolamine borate |
2.4 |
| Cumene sulfonic acid |
1.9 |
| BF20 plus silicone suds suppressor Ex Dow Coming |
0.13 |
| Hydrogenated castor oil |
0.10 |
| Perfume and minors |
0.5 |
| Sodium hydroxide |
to pH 8.0 |
| water |
Balance |
[0055] A low suds profile was obtained using the exemplified detergent.
[0056] The dimensions and values disclosed herein are not to be understood as being strictly
limited to the exact numerical values recited. Instead, unless otherwise specified,
each such dimension is intended to mean both the recited value and a functionally
equivalent range surrounding that value. For example, a dimension disclosed as "40
mm" is intended to mean "about 40 mm"