FILED OF INVENTION
[001] The present disclosure broadly relates to the field of soap bars for personal wash and particularly relates to composition and process for preparing a soap bar having desired sensorial features.
BACKGROUND OF INVENTION
[002] There are many types of soap bars available in the market and the soap bars differ from each other in many aspects according to the preferences of the consumers. For e.g. bathing soap bars can be broadly categorized into transparent, translucent, and opaque according to their appearances. All kinds of soap bars contain certain essential constituents including soap (sodium salt of fatty acids), moisture, humectants, preservatives, structurants, fillers, colourants and fragrances. The concentration of the constituents and their varieties need to be optimized for manufacturing a good quality soap, while ensuring low cost of preparation and ease of processing.
[003] In order to make soaps more cost effective, one of the preferable routes is to increase the amount of structurants or fillers added in the soaps. Fillers can be selected from inorganic ingredients such as talc, inorganic salts such as citrates, sulfates, silicates, and also from organic ingredients such as starch and acrylates. However, available prior art evidences that soap bars containing high amount of fillers and liquid content suffer from cracks and mush (high wear rate) issues. Another desirable feature of soaps that is adversely impacted while making high filler content soap bars is moisture retention capability. Moisture retention capability is the capacity of final soap bar to retain moisture when it is on-shelf, decreases significantly when preparing high filler content-based soap. Thus, leading to undesirable cracks in the soaps.
[004] Other drawbacks observed in case of soaps comprising high amount of fillers is that they suffer from poor processability when manufactured using conventional routes such as extrusion, cutting and stamping. It further adversely affects the conversion rate of soap during stamping, leading to loss in production yield. To avoid such issues high structurant/filler containing soap bars can be prepared using cast

route methods. However, casting is comparatively a more time consuming, labour intensive and expensive process. Therefore, a cost-effective soap bar comprising higher amount of structurants/fillers that does not compromise on other essential parameters of mushiness, water retention capacity among others is lacking.
SUMMARY OF THE INVENTION
[005] In an aspect of the present invention, there is provided an extrudable low total fatty matter soap bar comprising: (a) at least one alkali metal salt of fatty acid having weight percentage in the range of 35 - 45 % with respect to the soap bar; (b) at least two structurants having a combined weight percentage in the range of 25 - 40 % with respect to the soap bar; and (c) water having weight percentage in the range of 20 - 25 % with respect to the soap bar.
[006] In another aspect of the present invention, there is provided a process for preparing an extrudable low total fatty matter soap bar comprising: (i) at least one alkali metal salt of fatty acid having weight percentage in the range of 35 - 45 % with respect to the soap bar; (ii) at least two structurants comprising a first structurant and a second structurant having a combined weight percentage in the range of 25 -40 % with respect to the soap bar; (iii) at least one surfactant selected from the group consisting of alpha olefin sulphonate, sodium alkyl sulfate, anionic acyl sarcosinates, N-acyl glutamates, alkyl ether sulfates, sodium cocoyl apple amino acids surfactants, sodium lauryl sarcocinate, and combinations thereof, having weight percentage in the range of 6 - 12% with respect to the soap bar; (iv) at least one cosmetically acceptable excipient selected from the group consisting of chelating agent, humectant, preservative, colorant, fragrance, and combinations thereof; and (v) water having weight percentage in the range of 20 - 25 % with respect to the soap bar, the process comprising the steps of: (a) contacting the first structurant and water to obtain a premix I; (b) contacting the premix I to the at least one alkali metal salt of fatty acid to obtain a soap noodle; (c) contacting the soap noodle, the second structurant, at least one surfactant, at least one preservative, at least one humectant, at least one chelating agent, optionally at least one colorant, and at least one fragrance

to obtain a soap mix; and (d) processing the soap mix to obtain the extrudable soap bar.
[007] These and other features, aspects, and advantages of the present subject matter will be better understood with reference to the following description and appended claims. This summary is provided to introduce a selection of concepts in a simplified form. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
DETAILED DESCRIPTION OF THE INVENTION
[008] Those skilled in the art will be aware that the present disclosure is subject to
variations and modifications other than those specifically described. It is to be
understood that the present disclosure includes all such variations and modifications.
The disclosure also includes all such steps, features, compositions, and compounds
referred to or indicated in this specification, individually or collectively, and any and
all combinations of any or more of such steps or features.
Definitions
[009] For convenience, before further description of the present disclosure, certain
terms employed in the specification, and examples are delineated here. These
definitions should be read in the light of the remainder of the disclosure and
understood as by a person of skill in the art. The terms used herein have the meanings
recognized and known to those of skill in the art, however, for convenience and
completeness, particular terms and their meanings are set forth below.
[0010] The articles "a", "an" and "the" are used to refer to one or to more than one
(i.e., to at least one) of the grammatical object of the article.
[0011] The terms "comprise" and "comprising" are used in the inclusive, open sense,
meaning that additional elements may be included. It is not intended to be construed
as "consists of only".
[0012] Throughout this specification, unless the context requires otherwise the word
"comprise", and variations such as "comprises" and "comprising", will be

understood to imply the inclusion of a stated element or step or group of element or steps but not the exclusion of any other element or step or group of element or steps. [0013] The term "including" is used to mean "including but not limited to". "Including" and "including but not limited to" are used interchangeably. [0014] Structurants and fillers, for the purposes of the present document have been used interchangeably. Structurants/fillers refers to substances that add mass and provides physical structure to the soap that enhance the properties of the soap. [0015] Total fatty matter refers to the total content of alkali salt of fatty acids that is present in a composition. The alkali salts of fatty acids are also referred to as soaps. In the present disclosure, fatty acids with carbon chain length ranging from Cs to C22 have been considered in the process of soap preparation. For the purposes of this document, the terms soap and fatty matter has been used interchangeably. [0016] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the disclosure, the preferred methods, and materials are now described. All publications mentioned herein are incorporated herein by reference.
[0017] The present disclosure is not to be limited in scope by the specific embodiments described herein, which are intended for the purposes of exemplification only. Functionally-equivalent products, compositions, and methods are clearly within the scope of the disclosure, as described herein. [0018] Preparing a soap composition in an economical manner and at the same time adhering to the desired parameters for making a successful product is challenging. The present document discloses a unique composition comprising high amount of liquids, fillers/structurants which in spite of having higher amounts of aforementioned components can be manufactured using conventional extrusion process. Thereby, preventing the additional charges of using cast route methods during conventional processing of such compositions. The unique soap composition comprises at least two structurants added at different processing steps. The compositions disclosed in the document also performs better in terms of physical

parameters. The soap bar so formed is crack free, displays less mush and retains moisture for a longer duration. Furthermore, the amount of soap / fatty matter is effectually reduced in the final soap bar as described herein. Thus, resulting in a cost-effective soap bar composition capable of being manufactured using conventional techniques.
[0019] The present document discloses composition and processes for preparing a crack free soap containing high moisture content. The soap composition as disclosed herein comprises sodium salt of at least one fatty acid having weight percentage in the range of 35-45%, and at least two structurants having a combined weight percentage in the range of 25-40% with respect to the total composition. The composition further comprises at least one surfactant having a weight percentage in the range of 6-12% with respect to the total composition, and at least one cosmetically acceptable excipient selected from the group consisting of chelating agent, humectant, preservative, colorant, fragrance and combinations thereof. [0020] The process of preparing the soap bar composition comprises adding a first surfactant during noodle making stage and a second structurant during mixing stage. The soap bar can be prepared by the conventional extrusion and stamping route. [0021] In an embodiment of the present disclosure, there is provided an extrudable low total fatty matter soap bar comprising: (a) at least one alkali metal salt of fatty acid having weight percentage in the range of 35 - 45 % with respect to the soap bar; (b) at least two structurants having a combined weight percentage in the range of 25
- 40 % with respect to the soap bar; and (c) water having weight percentage in the
range of 20 - 25 % with respect to the soap bar.
[0022] In an embodiment of the present disclosure, there is provided an extrudable low total fatty matter soap bar comprising: (a) at least one alkali metal salt of fatty acid having weight percentage in the range of 37 - 42 % with respect to the soap bar; (b) at least two structurants having a combined weight percentage in the range of 27
- 37 % with respect to the soap bar; and (c) water having weight percentage in the
range of 21 - 24 % with respect to the soap bar.
[0023] In an embodiment of the present disclosure, there is provided an extrudable low total fatty matter soap bar comprising: (a) at least one alkali metal salt of fatty

acid having weight percentage in the range of 35 - 45 % with respect to the soap bar; (b) at least two structurants having a combined weight percentage in the range of 25
- 40 % with respect to the soap bar; and (c) water having weight percentage in the
range of 20 - 25 % with respect to the extrudable soap bar, wherein the at least one
alkali metal salt of fatty acid to the at least two structurants weight ratio is in the
range of 1:1.15 to 1:0.5.
[0024] In an embodiment of the present disclosure, there is provided an extrudable low total fatty matter soap bar comprising: (a) at least one alkali metal salt of fatty acid having weight percentage in the range of 37 - 42 % with respect to the soap bar; (b) at least two structurants having a combined weight percentage in the range of 27
- 37 % with respect to the soap bar; and (c) water having weight percentage in the
range of 21 - 24 % with respect to the soap bar, wherein the at least one alkali metal
salt of fatty acid to the at least two structurants weight ratio is in the range of 1:1.15
to 1:0.5.
[0025] In an embodiment of the present disclosure, there is provided an extrudable low total fatty matter soap bar comprising: (a) at least one alkali metal salt of fatty acid having weight percentage in the range of 35 - 45 % with respect to the soap bar; (b) at least two structurants having a combined weight percentage in the range of 25
- 40 % with respect to the soap bar; and (c) water having weight percentage in the
range of 20 - 25 % with respect to the soap bar, wherein the at least one alkali metal
salt of fatty acid to the at least two structurants weight ratio is in the range of 1:1.0
to 1:0.75. In another embodiment, the at least one alkali metal salt of fatty acid to the
at least two structurants weight ratio is in the range of 1:0.95 to 1:0.80.
[0026] In an embodiment of the present disclosure, there is provided an extrudable low total fatty matter soap bar comprising: (a) at least one alkali metal salt of fatty acid having weight percentage in the range of 35 - 45 % with respect to the soap bar; (b) at least two structurants having a combined weight percentage in the range of 25
- 40 % with respect to the soap bar; and (c) water having weight percentage in the
range of 20 - 25 % with respect to the soap bar, wherein the soap bar further
comprises at least one surfactant selected from the group consisting of alpha olefin
sulphonate, sodium alkyl sulfate, anionic acyl sarcosinates, N-acyl glutamates, alkyl

ether sulfates, sodium cocoyl apple amino acids surfactants, sodium lauryl sarcocinate, and combinations thereof, and has weight percentage in the range of 6 -12 % with respect to the soap bar. In another embodiment of the present disclosure the at least one surfactant is alpha olefin sulphonate.
[0027] In an embodiment of the present disclosure, there is provided an extrudable low total fatty matter soap bar comprising: (a) at least one alkali metal salt of fatty acid having weight percentage in the range of 35 - 45 % with respect to the soap bar; (b) at least two structurants having a combined weight percentage in the range of 25 - 40 % with respect to the soap bar; and (c) water having weight percentage in the range of 20 - 25 % with respect to the soap bar, wherein the soap bar further comprises at least one surfactant selected from the group consisting of alpha olefin sulphonate, sodium alkyl sulfate, anionic acyl sarcosinates, N-acyl glutamates, alkyl ether sulfates, sodium cocoyl apple amino acids surfactants, sodium lauryl sarcocinate, and combinations thereof, and has weight percentage in the range of 7 -11 % with respect to the soap bar.
[0028] In an embodiment of the present disclosure, there is provided an extrudable low total fatty matter soap bar comprising: (a) at least one alkali metal salt of fatty acid having weight percentage in the range of 35 - 45 % with respect to the soap bar; (b) at least two structurants having a combined weight percentage in the range of 25 - 40 % with respect to the soap bar; and (c) water having weight percentage in the range of 20 - 25 % with respect to the soap bar, wherein the at least one alkali metal salt of fatty acid is selected from the group consisting of caprylic acid, capric acid, lauric acid, myristic acid, palmitic acid, stearic acid, arachidic acid, behenic acid, myristoleic acid, palmitoleic acid, sapienic acid, oleic acid, elaidic acid, vaccenic acid, linoleic acid, linoelaidic acid, alpha-linolenic acid, arachidonic acid, ecosapentaenoic acid, erucic acid, docosahexaenoic acid, and combinations thereof. In another embodiment, the at least one alkali metal salt of fatty acid is having weight percentage in the range of 37 - 42 % with respect to the soap bar. In another embodiment of the present disclosure the at least one alkali metal salt of fatty acid is selected from sodium salts of Cs to C22 fatty acids.

[0029] In an embodiment of the present disclosure, there is provided an extrudable low total fatty matter soap bar comprising: (a) at least one alkali metal salt of fatty acid having weight percentage in the range of 35 - 45 % with respect to the soap bar; (b) at least two structurants having a combined weight percentage in the range of 25 - 40 % with respect to the soap bar; and (c) water having weight percentage in the range of 20 - 25 % with respect to the soap bar, wherein the soap bar further comprises at least one surfactant selected from the group consisting of alpha olefin sulphonate, sodium alkyl sulfate, anionic acyl sarcosinates, N-acyl glutamates, alkyl ether sulfates, sodium cocoyl apple amino acids surfactants, sodium lauryl sarcocinate, and combinations thereof, and has weight percentage in the range of 6 -12 % with respect to the soap bar, and wherein the at least one alkali metal salt of fatty acid is selected from the group consisting of caprylic acid, capric acid, lauric acid, myristic acid, palmitic acid, stearic acid, arachidic acid, behenic acid, myristoleic acid, palmitoleic acid, sapienic acid, oleic acid, elaidic acid, vaccenic acid, linoleic acid, linoelaidic acid, alpha-linolenic acid, arachidonic acid, ecosapentaenoic acid, erucic acid, docosahexaenoic acid, and combinations thereof. [0030] In an embodiment of the present disclosure, there is provided an extrudable low total fatty matter soap bar comprising: (a) at least one alkali metal salt of fatty acid having weight percentage in the range of 35 - 45 % with respect to the soap bar; (b) at least two structurants having a combined weight percentage in the range of 25 - 40 % with respect to the soap bar; and (c) water having weight percentage in the range of 20 - 25 % with respect to the soap bar, wherein the at least two structurants comprises a first structurant and a second structurant.
[0031] In an embodiment of the present disclosure, there is provided an extrudable low total fatty matter soap bar comprising: (a) at least one alkali metal salt of fatty acid having weight percentage in the range of 35 - 45 % with respect to the soap bar; (b) at least two structurants having a combined weight percentage in the range of 25 - 40 % with respect to the soap bar; and (c) water having weight percentage in the range of 20 - 25 % with respect to the soap bar, wherein the at least two structurants comprises a first structurant and a second structurant, and wherein the at

least one alkali metal salt of fatty acid to the at least two structurants weight ratio is in the range of 1:1.15 to 1:0.5.
[0032] In an embodiment of the present disclosure, there is provided an extrudable low total fatty matter soap bar comprising: (a) at least one alkali metal salt of fatty acid having weight percentage in the range of 35 - 45 % with respect to the soap bar; (b) at least two structurants having a combined weight percentage in the range of 25 - 40 % with respect to the soap bar; and (c) water having weight percentage in the range of 20 - 25 % with respect to the soap bar, wherein the at least two structurants comprises a first structurant and a second structurant, and wherein the first structurant is selected from the group consisting of sodium sulphate, sodium silicate, talc, sodium chloride, sodium carbonate, clays, dolomite, bentonite, polyoxide, and combinations thereof. In another embodiment, the first structurant is selected from the group consisting of sodium sulphate, sodium silicate, talc, polyoxide, and combinations thereof.
[0033] In an embodiment of the present disclosure, there is provided an extrudable low total fatty matter soap bar comprising: (a) at least one alkali metal salt of fatty acid having weight percentage in the range of 35 - 45 % with respect to the soap bar; (b) at least two structurants having a combined weight percentage in the range of 25 - 40 % with respect to the soap bar; and (c) water having weight percentage in the range of 20 - 25 % with respect to the soap bar, wherein the at least two structurants comprises a first structurant and a second structurant, and wherein the second structurant is selected from the group consisting of sodium sulphate, sodium silicate, talc, sodium chloride, sodium carbonate, clays, dolomite, bentonite, polyoxide, and combinations thereof. In another embodiment, the second structurant is selected from the group consisting of sodium sulphate, sodium silicate, talc, polyoxide, and combinations thereof.
[0034] In an embodiment of the present disclosure, there is provided an extrudable low total fatty matter soap bar comprising: (a) at least one alkali metal salt of fatty acid having weight percentage in the range of 35 - 45 % with respect to the soap bar; (b) at least two structurants having a combined weight percentage in the range of 25 - 40 % with respect to the soap bar; and (c) water having weight percentage in

the range of 20 - 25 % with respect to the soap bar, wherein the at least two structurants comprises a first structurant and a second structurant, and wherein the first structurant and the second structurant independently is selected from the group consisting of sodium sulphate, sodium silicate, talc, sodium chloride, sodium carbonate, clays, dolomite, bentonite, polyoxide, and combinations thereof, and wherein the at least one alkali metal salt of fatty acid to the at least two structurants weight ratio is in the range of 1:1.15 to 1:0.5.
[0035] In an embodiment of the present disclosure, there is provided an extrudable low total fatty matter soap bar comprising: (a) at least one alkali metal salt of fatty acid having weight percentage in the range of 35 - 45 % with respect to the soap bar; (b) at least two structurants having a combined weight percentage in the range of 25 - 40 % with respect to the soap bar; and (c) water having weight percentage in the range of 20 - 25 % with respect to the soap bar, wherein the soap bar further comprises at least one surfactant selected from the group consisting of alpha olefin sulphonate, sodium alkyl sulfate, anionic acyl sarcosinates, N-acyl glutamates, alkyl ether sulfates, sodium cocoyl apple amino acids surfactants, sodium lauryl sarcocinate, and combinations thereof, and has weight percentage in the range of 6 -12 % with respect to the soap bar, and wherein the soap bar further comprises at least one cosmetically acceptable excipient selected from the group consisting of chelating agent, humectant, preservative, colorant, fragrance and combinations thereof.
[0036] In an embodiment of the present disclosure, there is provided an extrudable low total fatty matter soap bar comprising: (a) at least one alkali metal salt of fatty acid having weight percentage in the range of 35 - 45 % with respect to the soap bar; (b) at least two structurants having a combined weight percentage in the range of 25 - 40 % with respect to the soap bar; and (c) water having weight percentage in the range of 20 - 25 % with respect to the soap bar, wherein the soap bar further comprises at least one surfactant selected from the group consisting of alpha olefin sulphonate, sodium alkyl sulfate, anionic acyl sarcosinates, N-acyl glutamates, alkyl ether sulfates, sodium cocoyl apple amino acids surfactants, sodium lauryl sarcocinate, and combinations thereof, and has weight percentage in the range of 6 -

12 % with respect to the soap bar, and wherein the soap bar further comprises at least one cosmetically acceptable excipient selected from the group consisting of chelating agent, humectant, preservative, colorant, fragrance and combinations thereof, and wherein the chelating agent is selected from the group consisting of ethylenediaminetetraacetic acid (EDTA), citric acid, ethane 1-hydroxy-1,1-diphosphonate (EHDP), and combinations thereof, and has a weight percentage in the range of 0.001 - 0.1 % with respect to the soap bar, the humectant is selected from the group consisting of glycerin, sorbitol, PEG 400, propylene glycol, and combinations thereof, and has a weight percentage in the range of 1 - 10 % with respect to the soap bar; the preservative is selected from the group consisting of hydantoin, butylated hydroxytoluene (BHT), citrates, phenoxy ethanol and combinations thereof, and has a weight percentage in the range of 0.001 -1.0 % with respect to the soap bar; the colorant is selected from the group consisting of dyes, pigments and combinations thereof, and has a weight percentage in the range of 0.00001 - 1 % with respect to the soap bar; the fragrance is selected from the group consisting of natural and synthetic fragrances and combinations thereof, and has a weight percentage in the range of 0.0001 - 2 % with respect to the soap bar; with respect to the extrudable soap bar.
[0037] In an embodiment of the present disclosure, there is provided an extrudable low total fatty matter soap bar comprising: (a) at least one alkali metal salt of fatty acid having weight percentage in the range of 37 - 42 % with respect to the soap bar; (b) at least two structurants having a combined weight percentage in the range of 27 - 37 % with respect to the soap bar; and (c) water having weight percentage in the range of 20 - 25 % with respect to the soap bar, wherein the soap bar further comprises at least one surfactant selected from the group consisting of alpha olefin sulphonate, sodium alkyl sulfate, anionic acyl sarcosinates, N-acyl glutamates, alkyl ether sulfates, sodium cocoyl apple amino acids surfactants, sodium lauryl sarcocinate, and combinations thereof, and has weight percentage in the range of 7 -11 % with respect to the soap bar, and wherein the soap bar further comprises at least one cosmetically acceptable excipient selected from the group consisting of chelating agent, humectant, preservative, colorant, fragrance and combinations thereof. In

another embodiment, the chelating agent is selected from the group consisting of ethylenediaminetetraacetic acid (EDTA), citric acid, ethane 1-hydroxy-1,1-diphosphonate (EHDP), and combinations thereof, and has a weight percentage in the range of 0.001 - 0.1 % with respect to the soap bar, the humectant is selected from the group consisting of glycerin, sorbitol, PEG 400, propylene glycol, and combinations thereof, and has a weight percentage in the range of 1 - 10 % with respect to the soap bar; the preservative is selected from the group consisting of hydantoin, butylated hydroxytoluene (BHT), citrates, phenoxy ethanol and combinations thereof, and has a weight percentage in the range of 0.001 -1.0 % with respect to the soap bar; the colorant is selected from the group consisting of dyes, pigments and combinations thereof, and has a weight percentage in the range of 0.00001 - 1 % with respect to the soap bar; the fragrance is selected from the group consisting of natural and synthetic fragrances and combinations thereof, and has a weight percentage in the range of 0.0001 - 2 % with respect to the extrudable soap bar; with respect to the soap bar.
[0038] In an embodiment of the present disclosure, there is provided a process for preparing an extrudable low total fatty matter soap bar comprising: (i) at least one alkali metal salt of fatty acid having weight percentage in the range of 35 - 45 % with respect to the soap bar; (ii) at least two structurants comprising a first structurant and a second structurant having a combined weight percentage in the range of 25 -40 % with respect to the soap bar; (iii) at least one surfactant selected from the group consisting of alpha olefin sulphonate, sodium alkyl sulfate, anionic acyl sarcosinates, N-acyl glutamates, alkyl ether sulfates, sodium cocoyl apple amino acids surfactants, sodium lauryl sarcocinate, and combinations thereof, having weight percentage in the range of 6 - 12% with respect to the soap bar; (iv) at least one cosmetically acceptable excipient selected from the group consisting of chelating agent, humectant, preservative, colorant, fragrance, and combinations thereof; and (v) water having weight percentage in the range of 20 - 25 % with respect to the soap bar, the process comprising the steps of: (a) contacting the first structurant and water to obtain a premix I; (b) contacting the premix I to the at least one alkali metal salt of fatty acid to obtain a soap noodle; (c) contacting the soap noodle, the second

structurant, at least one preservative, at least one surfactant, at least one humectant, at least one chelating agent, optionally at least one colorant, and at least one fragrance to obtain a soap mix; and (d) processing the soap mix to obtain the soap bar. [0039] In an embodiment of the present disclosure, there is provided a process for preparing an extrudable low total fatty matter soap bar as described herein, wherein (a) contacting the first structurant and water is carried out at a temperature in the range of 25 °C - 40 °C for a period in the range of 1 - 30 minutes to obtain a premix I; (b) contacting the premix I and the at least one alkali metal salt of fatty acid is carried out at a temperature in the range of 80 °C - 110 °C for a period in the range of 1 - 30 minutes to obtain a soap noodle; (c) contacting the soap noodle, the second structurant, at least one surfactant, at least one humectant, at least one chelating agent, at least one colorant, and at least one fragrance, is carried out at a temperature in the range of 20°C - 45 °C for a period in the range of 10 - 30 minutes at a stirring speed in the range of 40 - 80 rpm to obtain a soap mix; (d) processing the soap mix comprises extruding, cutting, and stamping to obtain the soap bar. [0040] In an embodiment of the present disclosure, there is provided a process for preparing an extrudable low total fatty matter soap bar as described herein, wherein (a) contacting the first structurant and water is carried out at a temperature in the range of 30 °C - 35 °C for a period in the range of 10 - 20 minutes to obtain a premix I; (b) contacting the premix I and the at least one alkali metal salt of fatty acid is carried out at a temperature in the range of 90 °C - 100 °C for a period in the range of 10 - 20 minutes to obtain a soap noodle; (c) contacting the soap noodle, the second structurant, at least one surfactant, at least one humectant, at least one chelating agent, at least one colorant, and at least one fragrance, is carried out at a temperature in the range of 25°C - 40 °C for a period in the range of 15 - 25 minutes at a stirring speed in the range of 40 - 80 rpm to obtain a soap mix; (d) processing the soap mix comprises extruding, cutting, and stamping to obtain the soap bar. [0041] In an embodiment of the present disclosure, there is provided a process for preparing a soap bar as described herein, wherein the at least one alkali metal salt of fatty acid to the at least two structurants weight ratio is in the range of 1:1.15 to 1:0.5.

[0042] In an embodiment of the present disclosure, there is provided a process for preparing a soap bar as described herein, wherein the at least one alkali metal salt of fatty acid is selected from the group consisting of caprylic acid, capric acid, lauric acid, myristic acid, palmitic acid, stearic acid, arachidic acid, behenic acid, myristoleic acid, palmitoleic acid, sapienic acid, oleic acid, elaidic acid, vaccenic acid, linoleic acid, linoelaidic acid, alpha-linolenic acid, arachidonic acid, ecosapentaenoic acid, erucic acid, docosahexaenoic acid, and combinations thereof. In another embodiment, the at least one alkali metal salt of fatty acid to the at least two structurants weight ratio is in the range of 1:1.15 to 1:0.5. [0043] In an embodiment of the present disclosure, there is provided a process for preparing a soap bar as described herein, wherein the first structurant is selected from the group consisting of sodium sulphate, sodium silicate, talc, sodium chloride, sodium carbonate, clays, dolomite, bentonite, polyoxide, and combinations thereof. [0044] In an embodiment of the present disclosure, there is provided a process for preparing a soap bar as described herein, wherein the second structurant is selected from the group consisting of sodium sulphate, sodium silicate, talc, sodium chloride, sodium carbonate, clays, dolomite, bentonite, polyoxide, and combinations thereof. [0045] In an embodiment of the present disclosure, there is provided a process for preparing a soap bar as described herein, wherein the first structurant is selected from the group consisting of sodium sulphate, sodium silicate, talc, sodium chloride, sodium carbonate, clays, dolomite, bentonite, polyoxide, and combinations thereof and the second structurant is selected from the group consisting of sodium sulphate, sodium silicate, talc, sodium chloride, sodium carbonate, clays, dolomite, bentonite, polyoxide, and combinations thereof. In another embodiment, the at least one alkali metal salt of fatty acid to the at least two structurants weight ratio is in the range of 1:1.15 to 1:0.5.
[0046] In an embodiment of the present disclosure, there is provided a process for preparing a soap bar as described herein, wherein the chelating agent is selected from the group consisting of ethylenediaminetetraacetic acid (EDTA), citric acid, ethane l-hydroxy-l,l-diphosphonate (EHDP), and combinations thereof, and has a weight percentage in the range of 0.001 - 0.1 % with respect to the soap bar, the humectant

is selected from the group consisting of glycerin, sorbitol, PEG 400, propylene glycol, and combinations thereof, and has a weight percentage in the range of 1 - 10 % with respect to the soap bar; the preservative is selected from the group consisting of hydantoin, butylated hydroxytoluene (BHT), citrates, phenoxy ethanol and combinations thereof, and has a weight percentage in the range of 0.001 -1.0 % with respect to the soap bar; the colorant is selected from the group consisting of dyes, pigments and combinations thereof, and has a weight percentage in the range of 0.00001 - 1 % with respect to the soap bar; the fragrance is selected from the group consisting of natural and synthetic fragrances and combinations thereof, and has a weight percentage in the range of 0.0001 - 2 % with respect to the soap bar; with respect to the extrudable soap bar.
[0047] In an embodiment of the present disclosure, there is provided a process for preparing an extrudable low total fatty matter soap bar comprising: (i) at least one alkali metal salt of fatty acid selected from the group consisting of lauric acid, palmitic acid, oleic acid, and combinations thereof and having weight percentage in the range of 35 - 45 % with respect to the soap bar; (ii) at least two structurants comprising a first structurant and a second structurant, wherein the first structurant and the second structurant independently is selected from the group consisting of sodium sulphate, sodium silicate, talc, poly oxide, and combinations thereof and having a combined weight percentage in the range of 25 - 40 % with respect to the soap bar; (iii) at least one surfactant, wherein the surfactant is alpha olefin sulphonate having weight percentage in the range of 6 - 12% with respect to the soap bar; (iv) at least one cosmetically acceptable excipient selected from the group consisting of chelating agent, humectant, preservative, colorant, fragrance, and combinations thereof; and (v) water having weight percentage in the range of 20 - 25 % with respect to the soap bar, the process comprising the steps of: (a) contacting sodium sulphate and water to obtain a premix I; (b) contacting the premix I to sodium salts of lauric acid, palmitic acid, and oleic acid to obtain a soap noodle; (c) contacting the soap noodle, sodium silicate, poly oxide, alpha olefin sulphonate, glycerin, EDTA, EHDP, BHT, optionally at least one colorant, and at least one fragrance to obtain a soap mix; and (d) processing the soap mix to obtain the soap bar.

[0048] In an embodiment of the present disclosure, there is provided an extrudable low total fatty matter soap bar comprising: (i) at least one alkali metal salt of fatty acid having weight percentage in the range of 35 - 45 % with respect to the soap bar; (ii) at least two structurants comprising a first structurant and a second structurant having a combined weight percentage in the range of 25 - 40 % with respect to the soap bar; (iii) at least one surfactant selected from the group consisting of alpha olefin sulphonate, sodium alkyl sulfate, anionic acyl sarcosinates, N-acyl glutamates, alkyl ether sulfates, sodium cocoyl apple amino acids surfactants, sodium lauryl sarcocinate, and combinations thereof, having weight percentage in the range of 6 - 12% with respect to the soap bar; (iv) at least one cosmetically acceptable excipient selected from the group consisting of chelating agent, humectant, preservative, colorant, fragrance, and combinations thereof; and (v) water having weight percentage in the range of 20 - 25 % with respect to the soap bar, wherein the soap bar is obtained by a process comprising the steps of: (a) contacting the first structurant and water to obtain a premix I; (b) contacting the premix I to the at least one alkali metal salt of fatty acid and at least one preservative to obtain a soap noodle; (c) contacting the soap noodle, the second structurant, at least one surfactant, at least one chelating agent, at least one humectant, optionally at least one colorant, and at least one fragrance to obtain a soap mix; and (d) processing the soap mix to obtain the soap bar.
[0049] In an embodiment of the present disclosure, there is provided an extrudable low total fatty matter soap bar comprising: (i) at least one alkali metal salt of fatty acid having weight percentage in the range of 35 - 45 % with respect to the extrudable soap bar; (ii) at least two structurants comprising a first structurant and a second structurant having a combined weight percentage in the range of 25 - 40 % with respect to the soap bar; (iii) at least one surfactant selected from the group consisting of alpha olefin sulphonate, sodium alkyl sulfate, anionic acyl sarcosinates, N-acyl glutamates, alkyl ether sulfates, sodium cocoyl apple amino acids surfactants, sodium lauryl sarcocinate, and combinations thereof, having weight percentage in the range of 6 - 12% with respect to the soap bar; (iv) at least one cosmetically acceptable excipient selected from the group consisting of chelating agent,

humectant, preservative, colorant, fragrance, and combinations thereof; and (v) water having weight percentage in the range of 20 - 25 % with respect to the soap bar, wherein the soap bar is obtained by a process comprising the steps of: (a) contacting the first structurant and water to obtain a premix I; (b) contacting the premix I to the at least one alkali metal salt of fatty acid and at least one preservative to obtain a soap noodle; (c) contacting the soap noodle, the second structurant, at least one surfactant, at least one chelating agent, at least one humectant, optionally at least one colorant, and at least one fragrance to obtain a soap mix; and (d) processing the soap mix to obtain the extrudable soap bar, and wherein the at least one alkali metal salt of fatty acid to the at least two structurants weight ratio is in the range of 1:1.15 to 1:0.5.
[0050] In an embodiment of the present disclosure, there is provided an extrudable low total fatty matter soap bar comprising: (i) at least one alkali metal salt of fatty acid having weight percentage in the range of 37 - 42 % with respect to the soap bar; (ii) at least two structurants comprising a first structurant and a second structurant having a combined weight percentage in the range of 27 - 37 % with respect to the soap bar; (iii) at least one surfactant having weight percentage in the range of 6 - 11% with respect to the soap bar; (iv) at least one cosmetically acceptable excipient selected from the group consisting of chelating agent, humectant, preservative, colorant, fragrance, and combinations thereof; and (v) water having weight percentage in the range of 20 - 25 % with respect to the soap bar, wherein the soap bar is obtained by a process comprising the steps of: (a) contacting the first structurant and water to obtain a premix I; (b) contacting the premix I to the at least one alkali metal salt of fatty acid and at least one preservative to obtain a soap noodle; (c) contacting the soap noodle, the second structurant, at least one surfactant, at least one humectant, at least one chelating agent, optionally at least one colorant, and at least one fragrance to obtain a soap mix; and (d) processing the soap mix to obtain the extrudable soap bar. In another embodiment, the at least one alkali metal salt of fatty acid to the at least two structurants weight ratio is in the range of 1:1.15 to 1:0.5.

[0051] In an embodiment of the present disclosure, there is provided an extrudable low total fatty matter soap bar comprising: (i) at least one alkali metal salt of fatty acid having weight percentage in the range of 37 - 42 % with respect to the soap bar; (ii) at least two structurants comprising a first structurant and a second structurant having a combined weight percentage in the range of 27 - 37 % with respect to the soap bar; (iii) at least one surfactant having weight percentage in the range of 6 - 11% with respect to the soap bar; (iv) at least one cosmetically acceptable excipient selected from the group consisting of chelating agent, humectant, preservative, colorant, fragrance, and combinations thereof; and (v) water having weight percentage in the range of 20 - 25 % with respect to the soap bar, wherein the soap bar is obtained by a process comprising the steps of: (a) contacting the first structurant and water to obtain a premix I; (b) contacting the premix I to the at least one alkali metal salt of fatty acid and at least one preservative to obtain a soap noodle; (c) contacting the soap noodle, the second structurant, at least one surfactant, at least one humectant, at least one chelating agent, optionally at least one colorant, and at least one fragrance to obtain a soap mix; and (d) processing the soap mix to obtain the extrudable soap bar. In another embodiment, the at least one alkali metal salt of fatty acid to the at least two structurants weight ratio is in the range of 1:0.95 to 1:0.80.
[0052] Although the subject matter has been described in considerable detail with reference to certain examples and implementations thereof, other implementations are possible. EXAMPLES
[0053] The disclosure will now be illustrated with working examples, which is intended to illustrate the working of disclosure and not intended to take restrictively to imply any limitations on the scope of the present disclosure. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice of the disclosed methods and compositions, the exemplary methods, devices and materials are described herein. It is to be understood

that this disclosure is not limited to particular methods, and experimental conditions described, as such methods and conditions may apply.
[0054] To overcome the challenges posed during processing of the soaps vast experimentation needs to be carried out to deliver the desired product. The soap composition needs to be optimised in such a manner so as to deliver in all fronts. The examples section discloses a table mentioning the working range of all the essential components used in the preparation of the soap bar as described in the document. The working ranges succeed by another table mentioning the working and non-working examples of the soap bar composition. The working examples comprises all the essential components used within the working range, whereas the non-working examples comprises the structurants having weight percentage outside the working range, and another prototype comprises water content outside of the working range. Example 1
Working range of essential components
[0055] An opaque soap bar as described in the present document comprises sodium salt of fatty acids, structurants/fillers, surfactants, preservatives, water and humectants. The working range of the afore mentioned essential components is described in Table 1.



[0056] The subsequent examples display working and non-working prototypes based on the working ranges of different ingredients as depicted in Table 1. The examples further display that the process of preparation of soap as disclosed herein is equally important as that of the composition so as to result in a working prototype.
Example 2

Working and Non-working examples
[0057] The Table 2 depicts one working example (A) having all the ingredients within the working range as described in Example 1. Furthermore, the table depicts three non-working examples - B, C, and D, comprising lower amount of structurant, higher amount of structurant, and higher amount of moisture content respectively as compared to the working range (Table 1). The examples have been assessed based on the parameters of:
1. Processing ability of the soap;
2. Cracks observed;
3. Mush; and
4. Moisture retention ability.


[0058] The working example A is prepared using all the essential ingredients within the working range. It can be appreciated from the table (Table 2) that the example A does not display any cracks, further displays lesser mush as compared to non-working examples and displays minimal moisture loss over a period of 24 months. Non-working examples
[0059] The non-working example B is non-working with respect to the concentration of structurants. The example B comprises 22.32% weight percentage of the structurants with respect to the soap bar which is lesser than the working range of 25-40% (Table 1). It can be observed from Table 2 that in example B cracks can be seen on the soap bar which is undesirable. The mush index is also higher and loss of moisture is significantly higher as compared to the working example. Thus, lowering the weight percentage of structurants is undesirable in formulating the soap bar composition.
[0060] The non-working example C is non-working with respect to the concentration of structurants. The example C comprises 40.32%) weight percentage of the structurants with respect to the soap bar which is higher than the upper limit of 40%o as depicted in Table 1. As can be observed from Table 2, the example C cannot be processed into a desirable soap bar by conventional extrusion methods. For checking the properties, the example C was processed by manual foot stamping method which is not a desirable processing method. Further, the example is not acceptable in terms of mushiness and ability for moisture retention, additionally cracks also developed which is again undesirable.
[0061] The non-working example D comprises water in a concentration higher than the upper limit of the working range (20-25%) with respect to the soap bar (Table 1). The example D is non-working because of the inability of processing through conventional extrusion methods. For checking the properties, the example D was processed by manual foot stamping method which is not a desirable processing method. Also, the percentage of moisture loss is the highest among all the examples which is undesirable, and cracks can be observed in the soap bar along with higher mush index.

[0062] Overall, it is distinctly displayed that all the essential elements need to be within the working range for production of a soap bar which is desirable with respect to all parameters. Even slight deviation from the working range is not desirable for formulating the soap bar using the ingredients as disclosed in the present document.
Example 3
Working process and non-working process for preparing a soap bar
[0063] The process for preparing the soap bar as disclosed in the document is of prime importance. To further substantiate the importance of processing steps, a working example and a non-working example is described in this section. As was observed in Example 2, that slight deviation from the working range of all the essential elements fail to result in a soap bar having all the sensorial features, likewise the process also should be followed in a manner as disclosed in the subsequent paragraphs of working process to result in production of the desired soap bar. The process is explained using another working model of the soap as depicted in Table 3.
[0064] The process for preparing a soap bar comprising the ingredients as depicted in Table 3 is disclosed in the present document.


[0065] Among the ingredients listed in Table 3, sodium sulphate, sodium silicate,
talc are the structurants, alpha olefin sulphonate is a surfactant, glycerine is a solvent,
EDTA (ethyl enediaminetetraacetic acid), EHDP (ethane 1-hydroxy-1, 1-
diphosphonate), are chelating agents and BHT (butylated hydroxytoluene) is
preservatives, and colour and fragrance are added as per the working ranges listed in
Table 1. Sodium salts of lauric acid, palmitic acid, and oleic acid are used to
constitute soap in the present composition.
Working process for preparation of an extrudable low TFM soap bar
[0066] Process for preparing the soap bar as disclosed in the present document
comprises two essential phases of soap noodle making stage and extrusion stage. The
detailed process for preparing the soap is as described in the following paragraph:
Premix I - A premix I is prepared by dissolving a first structurant - sodium sulphate
in water at a temperature in the range of 25°C - 40°C.
Premix II - A premix II is prepared by melting the salt of fatty acids (soaps) at a
temperature in the range of 80°C - 110°C.
Soap noodle making stage - The premix I was mixed with premix II at a temperature
in the range of 80°C - 110°C at the present stage to obtain soap noodle.
Soap bar and extrusion stage - The obtained soap noodle is mixed with at least one
second structurant - talc, sodium silicate, and poly oxide along with alpha olephin
sulphonate, glycerine, preservatives, colour, and fragrance at a speed of 40-80 rpm
to obtain a soap mass. The soap mass thus obtained is extruded, cut, and stamped to
obtain the desired soap bar.
Non-working process for preparation of an extrudable low TFM soap bar
[0067] It is noted that if both the structurants are added during mixing stage, i.e. post
noodle preparation stage, the desired characteristics of processability and moisture
retention not obtained. For example, soap bar composition of Table 3 was processed
using the following detailed method:
Premix stage: A premix is prepared by melting salt of fatty acids (soaps) at a
temperature in the range of 80°C - 110°C.

Soap noodle making stage - The premix I was cooled and extruded to obtain soap noodle.
Soap bar and extrusion stage - The obtained soap noodles are mixed with structurants - talc, sodium silicate, sodium sulphate and poly oxide along with alpha olephin sulphonate, glycerine, preservatives, colour, and fragrance at a speed of 40-80 rpm to obtain a soap mass.
The soap mass so formed is not processable at high speed processing machines, it suffers from sticking issues. The moisture retention (% moisture loss) of the soap is in the range of 9 to 14.
[0068] The most important feature of the working process as described herein is the addition of at least one structurant during the stage of noodle preparation from molten soap. It is to be noted that altering the process of preparation by adding all the structurant/fillers at the stage of mixing of solid soap mix with other ingredients instead of adding at least one structurant at the molten stage (soap noodle stage) renders the soap bar unfit for processing thus not resulting in the desirable soap bar. Thus, addition of structurants at two different stages of soap preparation leads to the production of soap having desirable features which can be conveniently produced by the conventional process of extrusion, and stamping. Advantages of the present disclosure:
[0069] The present disclosure reveals an extrudable low total fatty matter soap bar composition and process for preparing the extrudable soap bar. The soap bar thus prepared is crack-free, contains more than 25% of fillers/structurants, has high moisture retention capacity over a long shelf period, displays less mush, and can be prepared using conventional soap making technique involving the steps of extrusion, cutting, and stamping. The unique process as disclosed in the present document imparts the ease of processing of the soap having high filler content through conventional route and provides a strategy to manufacture soaps with low TFM content which adds the economic benefit to its production. Thus, the composition and process as described herein helps in manufacturing soaps with high filler content using the conventional process therefore, proving to be economical, while retaining all the desired sensorial features of a soap bar.

I/We Claim:
1. An extrudable low total fatty matter soap bar comprising:
a) at least one alkali metal salt of fatty acid having weight percentage in the range of 35 - 45 % with respect to the soap bar;
b) at least two structurants having a combined weight percentage in the range of 25 - 40 % with respect to the soap bar; and
c) water having weight percentage in the range of 20 - 25 % with respect to the soap bar.

2. The soap bar as claimed in claim 1, wherein the at least one alkali metal salt of fatty acid to the at least two structurants weight ratio is in the range of 1:1.15 to 1:0.5.
3. The soap bar as claimed in claim 1, further comprises at least one surfactant selected from the group consisting of alpha olefin sulphonate, sodium alkyl sulfate, anionic acyl sarcosinates, N-acyl glutamates, alkyl ether sulfates, sodium cocoyl apple amino acids surfactants, sodium lauryl sarcocinate, and combinations thereof, and has weight percentage in the range of 6 - 12 % with respect to the soap bar.
4. The soap bar as claimed in claim 1, wherein the at least one alkali metal salt of fatty acid is selected from the group consisting of caprylic acid, capric acid, lauric acid, myristic acid, palmitic acid, stearic acid, arachidic acid, behenic acid, myristoleic acid, palmitoleic acid, sapienic acid, oleic acid, elaidic acid, vaccenic acid, linoleic acid, linoelaidic acid, alpha-linolenic acid, arachidonic acid, ecosapentaenoic acid, erucic acid, docosahexaenoic acid, and combinations thereof.
5. The soap bar as claimed in claim 1, wherein the at least two structurants comprises a first structurant and a second structurant.
6. The soap bar as claimed in claim 5, wherein the first structurant is selected from the group consisting of sodium sulphate, sodium silicate, talc, sodium chloride, sodium carbonate, clays, dolomite, bentonite, polyoxide, and combinations thereof.

7. The soap bar as claimed in claim 5, wherein the second structurant is selected from the group consisting of sodium sulphate, sodium silicate, talc, sodium chloride, sodium carbonate, clays, dolomite, bentonite, polyoxide, and combinations thereof.
8. The soap bar as claimed in any of the claims 1-3, further comprises at least one cosmetically acceptable excipient selected from the group consisting of chelating agent, humectant, preservative, colorant, fragrance and combinations thereof.
9. The soap bar as claimed in claim 8, wherein the chelating agent is selected from the group consisting of ethylenediaminetetraacetic acid (EDTA), ethane l-hydroxy-l,l-diphosphonate (EHDP), citric acid, and combinations thereof, and has a weight percentage in the range of 0.001 -0.1 % with respect to the soap bar, the humectant is selected from the group consisting of glycerin, sorbitol, PEG 400, propylene glycol, and combinations thereof, and has a weight percentage in the range of 1 - 10 % with respect to the soap bar; the preservative is selected from the group consisting of hydantoin, butylated hydroxytoluene (BHT), citrates, phenoxy ethanol and combinations thereof, and has a weight percentage in the range of 0.001 - 1.0 % with respect to the soap bar; the colorant is selected from the group consisting of dyes, pigments and combinations thereof, and has a weight percentage in the range of 0.00001 -1 % with respect to the soap bar; the fragrance is selected from the group consisting of natural, and synthetic fragrances, and combinations thereof, and has a weight percentage in the range of 0.0001 - 2 % with respect to the soap bar.
10. A process for preparing the soap bar as claimed in any of the claims 1-9, the process comprising the steps of:

(a) contacting the first structurant and water to obtain a premix I;
(b) contacting the premix I to the at least one alkali metal salt of fatty acid to obtain a soap noodle;
(c) contacting the soap noodle, the second structurant, the at least one
surfactant, the at least one preservative, the at least one humectant, at least

one chelating agent, optionally the at least one colorant, and the at least one
fragrance to obtain a soap mix; and
(d) processing the soap mix to obtain the soap bar.
11. The process for preparing the soap bar as claimed in claim 10, wherein (a) contacting the first structurant and water is carried out at a temperature in the range of 25 °C - 40 °C for a period in the range of 1 - 30 minutes to obtain a premix I; (b) contacting the premix I and the at least one alkali metal salt of fatty acid is carried out at a temperature in the range of 80 °C - 110 °C for a period in the range of 1 - 30 minutes to obtain a soap noodle; (c) contacting the soap noodle, the second structurant, the at least one surfactant, the at least one humectant, the at least one chelating agent, the at least one colorant, and the at least one fragrance, is carried out at a temperature in the range of 20°C - 45 °C for a period in the range of 10 - 30 minutes at a stirring speed in the range of 40 - 80 rpm to obtain a soap mix; and (d) processing the soap mix comprises extruding, cutting, and stamping to obtain the soap bar.
12. An extrudable low total fatty matter soap bar as claimed in any of the claims 1-9, obtained by the process as claimed in claim 10 or 11.