Patent Application
20160186107
The invention discloses a multiphase detergent tablet, a method of manufacturing a multi-phase detergent tablet, and use of such a multiphase detergent tablet to clean kitchen appliances, particularly in commercial kitchens.
Various types of detergent are available for cleaning heavily soiled surfaces and cooking appliances, based on different active ingredients. Often, these active ingredients are caustic, toxic, or irritate the skin so that such detergents should only be handled with appropriate safety precautions. For example, high-alkaline detergent tablets (for example as disclosed in German patent application 10 2013 100 195.5), usually intended for commercial applications, are labelled “caustic” and may only be handled with gloves according to the safety precautions.
Water-soluble protective film coatings, for example polyvinyl alcohol films, have a relatively short shelf-life on account of their high alkalinity and the films harden, become brittle and lose their water-soluble properties after only a short storage time, often after only a few weeks.
Since it cannot be ensured that all users always follow the safety precautions of the handling regulations, it is an object of the invention to provide a detergent tablet that allows a very highly alkaline component but at the same time reliable use and safe handling thereof. A further object of the invention is to provide a method of manufacturing such detergent tablets.
These and further objects are achieved by the multiphase detergent tablet of claim 1, the method according to claim 9 of manufacturing such a multiphase detergent tablet, and by the use according to claim 14 of such a multiphase detergent tablet.
According to the invention, such a multiphase detergent tablet comprises a first detergent phase with an alkali system of one or more components, of which at least one contact-unsuitable component comprises sodium hydroxide (caustic soda), and a second detergent phase to cover the first detergent phase, whereby the second detergent phase essentially does not contain any contact-unsuitable components, in particular does not contain any caustic, toxic or hygroscopic components, and optionally does not contain any irritants.
In the context of the invention, contact-unsuitable components are elements that either should not come into contact with skin because they are either a health hazard or highly irritant, for example the highly alkaline component sodium hydroxide mentioned above, or other caustic, toxic or irritant compounds; or because they contain elements that undergo chemical or physical change upon contact with skin, for example hygroscopic bonds. In other words, contact-unsuitable components are compounds that should be prevented as far as possible from coming into contact with the skin or surrounding areas.
The term toxic is to be understood to apply to substances or mixtures that are poisonous or harmful to humans upon contact with the skin or when inhaled or swallowed.
The term caustic is to be understood to apply to substances or mixtures that can cause chemical burns to humans, primarily burns of the skin or mucous membranes. Highly irritant is to be understood to apply to substances or mixtures that can cause severe eye injuries. In both cases, this is given at pH values less than 2 or greater than 11.
The term irritant is to be understood to apply to substances or mixtures that irritate the eyes, the respiratory organs or the skin. This is the case at pH values less than 4 or greater than 10. Mildly irritant is to be understood to apply to compounds or materials that at most can lead to minor skin irritations, for example at a pH value of 8 to 10, or 4 to 5.
Hygroscopic compounds are compounds which, upon contact with water or moisture such as humidity, absorb the water to a large degree and may even incorporate it in their crystal lattice or form hydrates. Strongly hygroscopic compounds are compounds which can absorb at least one third of their own weight in water and/or are also used as a desiccant on account of their deliquescent properties, for example table salt (sodium chloride), calcium chloride, silica gel, sodium hydroxide, potassium hydroxide, methyl glycine diacetic acid, soda, phosphate, metasilicate and many acids also exhibit hygroscopic behavior.
In contrast, contact-suitable components are compounds and substances that cause little or no damage and that undergo little or no alteration upon contact with the skin or surrounding areas. Mildly irritant compounds that cause no lasting damage or only mild skin irritation can also be counted among them. The second detergent phase comprising “essentially” no contact-unsuitable components is therefore to be understood to mean that the components in that detergent phase are preferably not present, or at least only in such quantities as to fulfil the above requirements relating to contact with the detergent phase.
In the context of the invention, a multiphase detergent tablet is a detergent tablet with three or more layers or levels arranged one above the other in order to give a detergent tablet with a layered construction of the first and second detergent phases and further optional detergent phases. Such horizontal layer structures are often referred to as sandwich structures. According to the invention, the detergent tablet comprises at least three stacked layers, with a first layer of the second detergent phase, a second middle layer of the first detergent phase, and a third layer of the second detergent phase. The first and third layers can have a similar or identical second detergent phase composition, or can comprise completely different components, as long as these fall under the definition of being essentially entirely or mostly contact-suitable or essentially do not contain any contact-unsuitable components. For example, a preferred embodiment of the invention comprises a three-layered detergent tablet with a first layer of the second detergent phase; a second middle layer of the first detergent phase and a third layer of the second detergent phase that has a different composition than the second detergent phase of the first layer. The compositions of the two outer layers can differ chemically as well as physically. Such a layered composition favorably allows the first detergent phase to be covered from two sides that are preferably chosen such that the two largest faces are covered by the second detergent phase. In this way, only the side faces of such a layered detergent tablet reveal an incompletely covered first detergent phase with contact-unsuitable components, i.e. specifically caustic, irritant or toxic components. This outwardly uncovered first detergent phase, for example on the sides of a detergent tablet, has a comparatively small surface area compared to the covered faces. This provides a straightforward way of a covering the first detergent phase and its contact-unsuitable components from two opposite sides, which will usually be sufficient to ensure a safe use, for example without any gloves or other safety precautions.
A colored design of the second detergent phase can visually indicate to the user the layers of the second detergent phase that contain no caustic or toxic, preferably also no irritant components. A different color, for example a warning color, can be used to identify the first detergent phase with which any contact should be avoided.
According to another aspect of the invention, a method of manufacturing such a multi-phase detergent tablet is provided, comprising the step of manufacturing a multi-layered detergent tablet of at least three layers, including a first detergent phase with at least one component that contains sodium hydroxide (caustic soda), and a second detergent phase in the form of a covering of the first detergent phase on at least two opposing faces of the first detergent phase.
The step of covering provides, in an advantageous manner, a detergent tablet in which the two outer layers are made of the second detergent phase. These can be handled without any elaborate safety measures, for example without gloves, since they do not contain any caustic or toxic components, optionally also no irritant components. During the usual use of this detergent tablet, the user will not come into contact with the caustic, toxic or irritant components in the centrally arranged first detergent phase. The advantageous distribution of the various elements in the different compartments of an inventive multi-phase detergent tablet allows a simple and economic provision of a detergent tablet that is safe to use. The relevant tableting procedures will be known to the skilled person.
A further aspect of the invention describes the use of this inventive detergent tablet to clean kitchen appliances, particularly in a commercial kitchen, such as industrial dishwashers, ovens, broilers, combi-steamers, food warmers, degreasers. The improved handling can achieve an increased safety of the user compared to the known detergent tablets that, for reasons of good solubility, often contain highly alkaline components, i.e. caustic and also irritant detergent components specifically also in their outer layers.
Further preferred embodiments and variations of the inventive detergent tablet and the inventive manufacturing method, as well as the use of such a detergent tablet are given in the dependent claims as well as the following description of preferred embodiments and the examples. The method of manufacture or the use can be realized according to the dependent claims relating to the inventive detergent tablet or the manufacturing method.
In a further preferred embodiment of the invention, the detergent tablet comprises a cylindrical or rectangular form. Cylindrical or block-shaped tablets are usually less high than they are wide, so that the edges or lateral faces are preferably smaller than the two opposing main faces. Due these basic underlying shapes of detergent tablet, it is preferable to assign the main faces as the faces that will be covered by the second detergent phase. In this way, it is possible to achieve an essentially complete coverage of the first detergent phase by the second detergent phase, so that handling can be improved.
To improve user safety, it is advantageous when at least part of a region of the contact-unsuitable first detergent phase, not covered by a second detergent phase layer, is given a water-soluble protective coating, preferably a rapidly soluble protective coating. This applies particularly to regions of the boundary faces of the detergent tablet, i.e. the outer tablet faces that are perpendicular to the layers. The water-soluble protective film preferably comprises a set or hardened liquid coating mass that is stable relative to the first and second detergent phases and which dissolves quite quickly during use, i.e. at the beginning of a cleaning procedure. The additional covering of the sides or boundary faces of the detergent tablet provides protection against accidental contact with the first detergent phase with its component containing caustic soda during handling of the detergent tablet; but does not delay—or only slightly delays—the dissolution of the first and second detergent phase during use. For the coating, water-soluble materials can be used which can be applied in liquid form (as a solution or a liquefied mass) and which then form a water-soluble protective coating. Preferred examples are sucrose compounds, polyethylene glycol and solid or meltable tensides or polymers.
In a further preferred embodiment of the invention, the first detergent phase comprises a metasilicate. This additional component can impart a high alkalinity to the first detergent phase. Like sodium hydroxide, metasilicates are classified as highly irritant or caustic components that are subject to mandatory labelling. An alkali detergent phase in the context of the invention is a phase that gives a pH value greater than 10, preferably greater than 12, when dissolved in water (in a 1% solution). One such alkali component, or a combination of several such alkali components, possibly also in combination with additional alkali means, can be deployed in the alkaline detergent tablet to set the appropriate alkalinity (also referred to as “basicity”). Setting the pH value is often sufficient to release grease and proteins from soiled surfaces, whereby alkali-based detergents can also exhibit a cleaning effect based on sequestrant groups or surfactant groups as long as these are able to develop their effectiveness in an alkaline milieu (pH value greater than 10). The alkaline components and an additional detergent component can be combined in one substance, but can equally well be separate substances, as long as they are incorporated in the first detergent phase.
The detergent tablet according to the invention preferably contains alkali detergent components by a fraction of up to 20 to 80 wt %, particularly preferably 40 to 70 wt %. In the case of the first detergent phase, in which the strongly alkaline components are concentrated, the amount of alkali detergent components can be up to 100 wt %.
Examples of toxic, caustic or irritant components for the first detergent phase that can be used instead of or in addition to the alkaline components (caustic soda and, as the case may be: metasilicate, soda) can be referred to as biocides (e.g. quaternary ammonium compounds). Their proportions lie in the previously mentioned ranges, or the skilled person will be aware of the concentration to which each substance can be used. Biocides can be used in relatively low concentrations of less than 10%, preferably less than 5%, to achieve a desired sanitizing effect.
In a further preferred embodiment, the second detergent phase of the inventive detergent tablet comprises a weak alkali system, for example containing soda and/or disilicates, in a composition that is irritant at most (i.e. with a pH value of 10 to 11 in a 1% aqueous solution), preferably with only a pH value in a weakly alkaline range (about 8-10 in a 1% solution). These mildly irritant or non-irritant alkali components are suited for use in the second detergent phase since they can be handled without requiring any significant safety precautions.
The second detergent phase comprises the alkali detergent components preferably to a total amount of not more than about 40 wt %, preferably to a total amount of about 10-30 wt % of the second detergent phase.
Preferably, these alkali components of the first or second detergent phase are added to the tablet blend, and the invention also covers the eventuality that these completely or partially transform into more stable products such as hydrates or oxides in the tablet blend or during the tableting process, as long as the transformation is reversible during use of the detergent tablet in water, so that the desired alkalinity or basicity is achieved. The tablet blend can also be assembled from the alkali components alone. To remove grease and protein from soiled surfaces, it is usually sufficient to set the pH value, whereby alkali-based detergents can also exhibit a cleaning effect based on complexing agent groups or surfactant groups. Protein-denaturing alkali substances can also be used as detergent components as long as they can develop their effectiveness in an alkaline environment.
In a further preferred embodiment of the invention, the first and/or second detergent phase can comprise at least one further detergent substance. Examples of such substances are complexing agents whose additional detergent action is due to the property of chelation. Tensides may also be candidates for such additional detergents. Exemplary compounds may be chosen from the group of ionic or non-ionic tensides or complexing agents, in particular phosphates, polyphosphates, phosphonates, polymers, layer silicates, sodium methyl glycine diacetic acid, poly epoxy succinic acid and gluconates. All of these detergents foam as little as possible to prevent excessive foaming from the outset. Preferred tensides are fatty alcohol ethoxylates, in particular terminally capped Plurafac® types (BASF), Glucoside (Akzo) or fatty amines. While anionic tensides are conceivable, they are less relevant since they often tend to foam strongly. Alkali-stable phosphonates are for example salts of nitrile trimethylene phosphonic acid of the Sequion type (Polygon) or Cublen type (Zschimmer & Schwarz). Preferred polymers are polycarboxlyates (BASF).
Complexing agents are preferably deployed in the detergent tablet to a proportion of not more than 10 to 40 wt %, particularly preferably to a proportion of about 15 to 25 wt %. Tensides are preferably deployed in the detergent tablet to an amount of about 0.2 to 20 wt %, particularly preferably to an amount of about 0.5 to 5 wt %. These amounts apply to the entire detergent tablet as well as to the first or second detergent phases.
In a further preferred embodiment, the first and/or second detergent phase can comprise a tablet blend with the usual matrix components. They can also comprise one or more builders (for example water-soluble sulfates such as sodium sulfate) and/or excipients, in particular for example binding agents, tableting excipients, disintegrants, dissolution retardants, retarding agents or lubricants.
The builders are preferably added to the detergent tablet by an amount of not more that 20 wt %, particularly preferably by an amount of not more than 10 wt %. The excipients are preferably added to the detergent tablet by an amount of not more that 20 wt %, particularly preferably by an amount of about 3 to 10 wt %. The amount proportions apply equally to the entire detergent tablet as well as to the first or second detergent phase.
Excipients for tablets fulfil various purposes and are described in the prior art. In principle, distinctions are made between the following categories of the various excipients on the basis of their different functions. Examples of binding agents or direct tableting excipients are starches, celluloses, polyethylene glycol, calcium compounds, bentonite, polysaccharides, sugar compounds, proteins or synthetic polymers.
Examples of disintegrants are starches, (microcrystalline) cellulose, alginic acid, polysaccharides, proteins, cross-connected polyvinyl pyrrolidine, polymethacrylate derivatives or bentonite.
Exemplary dissolution retardants or retarding means can be waxes, ethyl cellulose, lipids, polyvinyl acetate, carboxymethyl cellulose, polyacrylic acid, polyethylene glycol, gels or stearates.
Examples of lubricants are fatty acid esters, talcum, oils and fats or fatty acids, or pyrogenic silicic acid.
Depending on the desired properties of the detergent tablets, for example as regards hardness and solubility as well as to ensure moldability, an appropriate combination of the various excipients and builders is chosen on the basis of the intended field of application.
In addition, further functional compartments or substances such as a descaling agent, a rinse aid, an ion exchanger, a specific detergent for further contaminations etc., can be incorporated in the detergent tablet. This can be achieved for example by using dedicated layers or regions.
An adhesive agent can preferably be deployed to bond together the individual layers of the first and second detergent phase. For example, polyethylene glycol can be used for this purpose. During the manufacturing procedure of the inventive detergent tablet, this is applied in melted form to the opposite faces of the first detergent phase which is then pressed between previously prepared and hardened second detergent phases in order to form a three-layered detergent tablet. Alternatively, the three-layered tablets can be pressed in a carousel-type machine with an integrated form into rectangular or round shapes, with a typical detergent tablet weight between 10 g and 100 g. In this approach, polyethylene glycol (PEG) for example can be added in powder form to the tablet blend.
The inventive detergent tablets can be packaged individually or in groups of a predetermined number in a sealed plastic bag, a so-called flowpack (a tubular bag into which items are inserted horizontally for packaging) so that they can be dispensed as required in a precise and straightforward manner. An individual packaging of each detergent tablet is preferred, but not strictly necessary owing to the improved handling already described in the above, since the strongly alkaline ingredients in the central layer are covered and therefore pose significantly less risk to the user. For this reason, the detergent tablets can be packed in a tightly sealed container, loosely or stacked, without additional secondary packaging such as a tubular bag.
In a further preferred embodiment, the detergent tablet comprises holes and/or recesses that extend through one or more layers of the first and/or second detergent phase. The holes or recesses are in particular in the upper (or also in the lower) surface of the second detergent phase and either extend all the way through the detergent tablet, or at least to the middle layer, i.e. into the first detergent phase, in order to increase the surface area of the exposed first detergent phase. As a result, the rate of dissolution of the first detergent phase layer, i.e. the middle layer, can be increased, even though it has been covered by other detergent layers in order to improve handling. Even though these holes or recesses cannot be touched on the inside on account of their size, their inner surfaces or edges can also be coated with a water-soluble coating if desired.
The method of manufacturing a multiphase detergent tablet, for example for cleaning kitchen appliances particularly in commercial kitchens, comprises amongst others the step of manufacturing an at least three-layered detergent tablet with a first detergent phase with at least one contact-unsuitable component containing sodium hydroxide, and a second detergent phase in the form of a cover of the first detergent phase on at least two opposite sides of the first detergent phase, whereby the second detergent phase essentially does not contain any contact-unsuitable components, specifically not containing caustic, toxic or hygroscopic components, optionally also not containing irritant components.
With straightforward process steps and the usual manufacturing facilities, the inventive manufacturing method according to the second aspect of the invention can ensure an improved handling of the detergent tablet. by placing the caustic, irritant and toxic components in the middle layer of an at least three-layered detergent tablet, the detergent tablets can be handled without any problems.
To further improve the handling or safety during handling, in a further method step a liquid coating is applied to at least a part of the outer faces or edges of the previously manufactured multiphase detergent tablet that are not covered by the second detergent phase. In this way, a water-soluble and non-hazardous protective coating is formed on these edges or outer faces. Apart from saving material, a coating that is applied exclusively to the outer faces or edges of the detergent tablet has the advantage that the two outer detergent phases are to a large extent free of any coating, and can therefore dissolve quicker than they would if the detergent tablet were completely coated. After manufacturing the multi-phase detergent tablet, for example in a customary carousel tableting facility, the detergent tablets travelling on the conveyor belt can then pass by laterally positioned nozzles or other mechanical arrangements for applying a liquid coating mass.
During the step of applying the coating mass on the detergent tablet, the detergent tablet is advantageously rotated about its own axis continually or intermittently while the coating mass is applied—particularly preferably by spraying, rolling and/or painting—on the edges or sides of the detergent tablet. Alternatively, the coating mass can be applied to the faces by dipping the faces into an immersion bath filled with the liquid coating mass and turning or rolling the detergent tablet. It is hereby advantageous to continually or intermittently convey the tablets to the immersion bath on a conveyor belt arranged slightly above the immersion bath and to dip the detergent tablets into the immersion bath in order to apply the coating mass to the faces.
In the case of rectangular (block) tablets, it is advantageous to rotate these by 90° after applying the coating to one side (or two opposite sides), in order to apply the coating mass to all sides. Preferably in this case, a second, third or fourth arrangement for applying the coating mass is positioned along the conveyor belt. In the case of a cylindrical tablet, it is advantageous to rotate it about its axis of rotation while applying the coating mass, preferably by at least 360°. The coating mass, applied as a liquid or in solution, is then allowed to cool down or harden.
To speed up the cooling or hardening, the manufacturing method advantageously comprises an additional step of cooling the liquid coating mass (liquefied) by a cooling airflow or by evaporation of the solvent using a cold air blower or hot air blower to harden the coating mass.
Subsequently, the finished tablets are packaged, for example in tubular bags. As indicated above, the particular placement of the hazardous components in the multi-phase detergent tablets permits the use of other types of packaging. For example, the detergent tablets are preferably packaged without any tubular bags, loosely or stacked, in a hermetically sealed plastic container for storage or retail.
To improve the solution rate of the middle layer with its high proportion of strongly alkaline, caustic, toxic, irritant or hygroscopic components, it can be helpful to increase the water contact surface for dissolving the middle layer by means of specific solution accelerants or by constructional means.
In a particular embodiment, the surface area of the middle layer can be increased by forming one or more recesses or through-holes in the outer layers of the detergent tablet as described above. To this end, according to a further preferred embodiment of the manufacturing method, an additional step is carried out, i.e. the forming of holes or recesses that extend through one or more layers of the first detergent phase, and the second detergent phase as the case my be. For example, one or more recesses can be formed in the detergent tablet, extending as far inward as possible, by means of a pin (e.g. in a press mould). This ensures that water can penetrate into the tablet from the middle of the tablet also or from several points, dissolving it more quickly.
The inventive detergent tablet can be used to clean kitchen appliances, particularly in the field of commercial kitchens that are usually cleaned with alkaline or strongly alkaline detergents. Examples are industrial dishwashers, ovens, automatic rotisseries, combi-steamers, food warmers, degreasers and strongly soiled surfaces in commercial kitchens, in particular such ovens, automatic rotisseries, combi-steamers, food warmers, and degreasers that have a built-in cleaning program. Of course, this does not exclude the use of the detergent tablets for domestic kitchen appliances or for soiled items, pots, utensils etc. that are cleaned frequently or after each use.
Chloric ingredients in detergent tablets are also classified as toxic or corrosive substances that can be implemented in the first detergent phase. Multiphase detergent tablets of this type can be used for instance as sanitary detergents for lavatories.
Another possible use of the inventive multiphase detergent tablet in automatic dispensing systems follows from the particular layered construction of the three-layered tablet. When the tablets are to be used in an automatic dispenser, in which the tablets cannot be individually wrapped in tubular bags (so-called flowpacks), the exposed tablets lie directly beside or on top of each other. The tablets are stacked in the dispensing arrangement, and usually the lowermost tablet can be dispensed by a mechanical feeder. Since the outer layers do not contain strongly alkaline ingredients, which are usually strongly hygroscopic, humidity will not result in the outer layers sticking to each other. A reliable dispensing of single tablets is therefore ensured. The term “contact-unsuitable” may therefore also be understood to mean that the relevant components of the first detergent phase are not suitable for contact with adjacent tablets because of the undesirable effects that might arise, specifically the agglutination of strongly hygroscopic components of two tablets.
In the case of a stacked tablet application, in which there is no contact between the tablet outer sides (the sides perpendicular to the layering), the step of coating the edges is optional and may be left out. The detergent strength is not affected by the particular construction, since the strongly alkaline ingredients are present in the middle layer, and are released quickly upon dissolution of the detergent tablet.
For this reason, it may be preferred that not only the outer two layers of the detergent tablet rapidly dissolve in water, but that the middle layer—with its high proportion of strongly alkaline, caustic, toxic or irritant components—also dissolves quickly. Since the working surface of the water for dissolving the middle layer is relatively small on account of the particular construction of multiphase detergent tablet, it is advantageous to increase the rate of dissolution of the middle layer by means of either specific solution accelerators or design features.
According to a particular embodiment, for the case that the middle layer of the detergent tablet should dissolve quickly enough in water, the surface of the middle layer can be increased as described above by one or more holes, preferably through-holes in the first detergent phase and/or the second detergent phase. To this end, in a straightforward embodiment, one or more recesses, preferably as deep as possible, are formed in the tablet by a fixed pin, preferably with a movable pin. This ensures that water can penetrate into the tablet from the center of the tablet also, or from multiple directions, and the shorter diffusion paths make the tablet dissolve more quickly.
The principle of the invention will be explained in more detail in the following with the aid of the diagrams:
The detergent tablet 1 comprises a first layer 10 of a second detergent phase, a second layer 12 of a first detergent phase, and a third detergent layer 14 also of the second detergent phase.
The detergent tablet 1 has a rectangular underlying shape, whereby the two large surfaces of the first detergent phase are covered by the second detergent phase layers. In this way, the first detergent phase with its contact-unsuitable substances, i.e. caustic, toxic, irritant or hygroscopic, is only exposed along the side faces 20, so that the detergent tablet can be safely touched on the second detergent phase faces, in spite of the substances exposed along the side faces.
The detergent tablets described in detail above are merely several possible embodiments, and can be modified in the usual manner by the skilled person without departing from the scope of the invention. In particular, there may be specific embodiments of the detergent tablets in other shapes and for other applications than those described herein. Equally, the detergent tablet formulations can be modified by the skilled person in the context of the specific exemplary embodiments described above. It shall be emphasized again that the upper and lower layers of a three-layered multiphase detergent tablet can have different compositions, i.e. the two outer layers of second detergent phase can be chemically different as long as they contain essentially no contact-unsuitable components or comprise essentially only contact-suitable components. The skilled person will also know how to adjust the individual weight percentages within the scope of the inventive solution to the problem. Use of the indefinite article “a” or “an” does not exclude a plurality of the feature being discussed.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2013 108 814.7 | Aug 2013 | DE | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2014/066475 | 7/31/2014 | WO | 00 |
