Process to prepare a shaped solid detergent

Abstract

A system for continuous casting of melt-cast products such as soaps, detergents and the like comprising: i) a substantially vertically disposable mould unit to favour solidification/casting of the melt cast composition during an upstream motion through the mould unit; ii) the mould unit operatively connected at it's lower end to a supply source of the melt-cast composition; iii) means for controlling the temperature of the melt in the mould unit to achieve the desired solidification and shaping during traverse of the melt from the bottom of the mould towards the top thereof, which is adapted to eject the formed cast product.

1 . A system for continuous casting of a fatty acid soap melt-cast products comprising:
 i) a substantially vertically disposable mould unit to favour solidification/casting of the melt cast product during an upstream motion through the mould unit;   ii) the mould unit operatively connected at it's lower end to a supply source of the melt-cast product;   iii) means for controlling the temperature of a melt in the mould unit to achieve the desired solidification and shaping during traverse of the melt from the bottom of the mould towards the top thereof, which is adapted to eject the formed cast product; and   iv) wherein the fatty acid soap melt-cast product cannot be readily stamped and shaped into tablets or bars following extrusion.   
     
     
         2 . A system for continuous casting of a melt-cast product as claimed in  claim 1  wherein the mould unit is adapted such that the same subsequent to the upstream solidification/casting of the melt in it's vertically disposed form can be gradually brought to a horizontal disposition to favour ejection of the solid/cast product in the horizontal dimension operatively connected to the downstream finishing means/unit. 
     
     
         3 . A system for continuous casting of a melt-cast products as claimed in  claim 1  comprising a high-surface area heat exchanger provided ahead of the shaping mould to improve the efficiency of cooling and throughput. 
     
     
         4 . A system for continuous casting of a melt-cast product as claimed in  claim 1  comprising:
 i) a substantially vertically disposable mould unit to favour solidification/casting of the melt cast product during an upstream motion through the mould unit; 
 ii) the mould unit operatively connected at it's lower end to a supply source for the melt-cast product; 
 iii) means for controlling the temperature in the mould unit to achieve the desired cooling comprising a cooling jacket on the mould having means for continuous supply of coolant there through, to facilitate on-line cooling to facilitate solidification and shaping of the melt composition during it's traverse from the bottom of the mould to the top to eject as the cast product. 
 
     
     
         5 . A system as claimed in  claim 1  wherein the cooling jacket is adapted to feed in the coolant at the lower end and exit from the top. 
     
     
         6 . A system as claimed in  claim 1  wherein the means for controlling the temperature of the melt in the mould is adapted to produce a selective temperature gradient/distinct temperature zones in the mould through which the soap melt is allowed to traverse, to facilitate selective temperature control of melt during it's traverse in the mould to achieve solidification and shaping based upon the constitution of the soap formulation. 
     
     
         7 . A system as claimed in  claim 1  comprising a heating zone near the exit of the jacketed mould/caster adapted to improve the slip of the product and it's throughput. 
     
     
         8 . A system as claimed in  claim 1  wherein the mould means shaping the product form is adapted for releasable operative connection to facilitate change of the same for forming a variety of product forms. 
     
     
         9 . A system as claimed in  claim 1  comprising means for selective injection of benefit/ aesthetic agents in the soap formulation during the solidification/shaping process while it traverses the mould, optionally under differential temperature gradient. 
     
     
         10 . A system as claimed in  claim 1  comprising means for providing a temperature gradient in the jacketed mould, and plurality of injection means 
     
     
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