Field of the invention:
The present invention relates to a bathing bar composition. More particularly it relates
to bathing bar composition that does not stick to metal moulds, and provides superior
finish, without compromising on bar aesthetics.
Background of the invention:
Two methods are used traditionally for producing soap or non-soap formulations,
namely shear working/homogenization of the soap followed by its extrusion and
stamping, and direct casting method. For shear sensitive formulations direct casting
method is widely used, where in the formulation is initially subjected to higher
temperatures and drawn to fluid state, which is then filled into casting moulds and
cooled subsequently to obtain soaps of desired shape. Soaps can be casted using various
kinds of moulds such as moulds made up of silicone, metal or different kinds of
polymers. The most commonly used and preferred moulds in soap industry for soap
making are silicone moulds. This is due to their excellent demoulding property which
eliminates bar sticking to moulds during demoulding, and thereby provides good bar
aesthetics.
However it is noteworthy that solidification of soap in silicone moulds takes a longer
time due to lower heat transfer rate, moreover it generally requires lower temperature
during cooling of the soap, in order to improve the yield throughput which translates
into more energy consumption.
Hence there is a need for soaps moulding by the direct cast based approach or bathing
bars moulded from materials other than silicone (eg. metal moulds). The prominent
feature of the metal moulds is their high heat transfer rate in turn the cooling effect that
will be faster. In addition to this, metal moulds are cheaper and provide more cost
effective operation. These are known to provide superior surface finish as compared to
silicone moulds. Silicone moulds have a much lower shelf life which means more
replacement which associates with capital cost. Therefore formulating soap
compositions that do not stick in metal moulds is a continuous challenge.

EP0983336B1 discloses a mould for individual casting of soft solid articles, wherein
the said mould is a split cavity mould comprising of at least two complimentary rigid
dies which upon engagement define a cavity corresponding to a desired shape of the
cast article, wherein the engaged dies form a reservoir which on one side is open to
receive cast melt and on another side is open to the cavity. In one embodiment the
invention provides a process for casting a melt in the said moulds for individually
producing shaped articles of soap and/or non-soap detergents. The dies of the mould are
manufactured from rigid material with high thermal conductivity preferably from metals
such as aluminum and its alloys and the mould was heated to 75 °C in an oven, after
which it is taken out of the oven and the molten mixture was poured into the mould such
that the reservoir was also filled with the molten solution. The mould was allowed to
cool at an air temperature of 25-30°C for a period of 15 minutes. The soap solidified in
the reservoir was chopped off and the resultant soap tablet was allowed to mature for
10-12 weeks to obtain required transparency after which it was ready to be packed. The
process eliminates several manufacturing operations such as casting of molten soap into
long bars, Schist cooling, bar ejection, bar maturation, billeting, chamfering, billet
maturation and stamping involved in the conventional process.
EP1325104 provides a suitable type and combination of fatty acid(s) to form soap for
obtaining melt-cast solid shaped detergent compositions comprising very high levels of
water or liquid benefit agents. This prior art ascertains that all combinations of
neutralized fatty acids chosen to form the soap to be incorporated into the detergent bars
will not result in a solid product when cooled during casting, from elevated
temperatures to ambient temperatures in the range 20- 35°C and it is therefore necessary
to optimize the combination of fatty acid soap in order to obtain a detergent bar at
ambient temperatures with sufficient rigidity such that it can be conveniently held
during use. It is also essential that the bar retains rigidity over the natural environmental
temperatures generally encountered during storage and transport. Accordingly this
invention provides required fatty acid combination to form the soap in melt cast
detergent bar compositions comprising very high levels of water or liquid benefit

agents, such that the detergent composition forms a rigid tablet at temperatures greater
than 20°C and retains rigidity at least up to 40°C.
WO2001030959 relates to a melt-cast solid shaped detergent composition comprising
of 2-60% of a water insoluble structurant; 2-50% of a detergent active species; 0.5-30%
of a salting-in electrolyte; 30-80% water; and other liquid benefit agents. This prior art
discloses the disadvantages with manufacturing of non-transparent detergent tablets by
casting process and expresses the difficulty that the typical compositions do not form a
pourable liquid at elevated temperatures. Accordingly this prior art provides a process
for obtaining solid shaped detergent compositions by incorporation of low amounts of
salting-in electrolytes in melt-cast detergent compositions comprising very high levels
of water or liquid benefit agents. The process disclosed involves the steps of: making a
melt of the soap composition, pouring the said melt into a mould to obtain the desired
shape, and cooling the mould under quiescent conditions to bring about solidification.
The rigid solid shaped articles thus prepared exhibits an yield stress greater than 75 kPa
and the compositions can be held in hand, economical, high foaming and demonstrate
good in-use properties.
Prior art reported many bathing bar formulations prepared using metal moulds by melt
cast method but none of these methods disclosed a formulation that enables the
demoulding process to be carried out within 10 minutes after casting and avoids the
problem of bar sticking, often seen in soap moulding using metal moulds.
Therefore there is a need to develop bathing bar formulation that can be casted using
metal moulds, having appreciable surface finish equivalent to that achieved from
silicone moulds and at the same time avoids the problems posed by casting the soap in
metal moulds.
Object of invention:
An object of the present invention is to overcome the drawbacks of the prior art.

Another object of the present invention to provide a unique bathing bar formulation that
does not stick to metal moulds while demoulding and provides superior finish, without
compromising on bar aesthetics.
Yet another object of the present invention is to provide a bathing bar composition that
allows very fast cooling and offers demoulding at higher process temperatures
compared to the process temperature applied for silicone moulds.
Summary of the present invention;
An aspect of the present invention is to provide a soap bar composition comprising:
a. at least one hydrophilic components;
b. at least one hydrophobic components;
c. cosmetically acceptable excipients;
wherein the ratio of the at least one hydrophobic component: the least one hydrophilic
component is maintained from about 7:1 to about 3:1;
such that the soap bar demoulds at higher process temperatures.
Another aspect of the present invention is to provide a process for the preparation of a
soap bar composition comprising steps of:
a. melting solidifying agent and free fatty acids to obtain a molten mass;
b. adding soap to the said molten mass and homogenizing to obtain a
homogenized melt;
c. adding add hydrophilic emollients and other surfactants to said homogenized
melt of step b and homogenizing to obtain another homogenized mass;
d. adding hydrophobic emollients and other adjuvants to said homogenized
melt of step c and holding the mass;
e. casting said mass to desired shape; and
f. cooling the mold to 5 - 10°C so as to reduce the soap temperature directly to
about 44.5°C and demolding the solidified soap bar.

wherein the ratio of the at least one hydrophobic component : the least one hydrophilic
component is maintained from about 7:1 to about 3:1;
wherein said soap bar does not stick to metal moulds while demoulding and provides
superior finish; and
wherein said soap bar demoulds at higher process temperatures.
Brief description of the Accompanying drawings:
Figure 1 illustrates the cooling profile comparison
Figure 2 illustrates that the soap bar of the present invention provides superior surface
smoothness, bar glide on skin, superior bar surface finish and desired slipperiness of
bar. When compared to its negative example.
Detailed description of the invention:
The present invention relates to a soap composition comprising a unique ratio of
hydrophobic: hydrophilic components, which does not stick to metal moulds even at
high operation temperature and the final product maintains excellent surface
smoothness, provides improved bar glide of naked bathing bar during application. The
said composition also allows very fast cooling and offers demoulding at higher process
temperatures that are greater than 40°C, while the silicone mould demoulding happens
at 35°C.
An embodiment of the present invention provides a soap bar composition that can be
easily demoulded from a metal mould comprising:
a. At least one hydrophilic components; and
b. At least one hydrophobic components
wherein the ratio of the at least one hydrophobic component: the least one hydrophilic
component is maintained from about 7:1 to about 3:1
Hydrophillic component of the present invention may be selected from a group
comprising hydrophilic binders, hydrophilic emollients, water.
Hydrophillic Emollients are substance which are was miscible and as soften or improve
the elasticity, appearance, and youthfulness of the skin (stratum corneum) by increasing

its water content, and keeps it soft by retarding the decrease of its water content.
Hydrophillic Emollients that may be used in the present invention include but are not
limited to polyols such as glycerol, sorbitol higher alcohols such as lauryl, cetyl, stearyl,
oleyl, behenyl and 2-hexydecanol alcohol and mixtures of any of the foregoing
components, and the like. Advantageously hydrophilic emollients may be used from
about 1 to 6%, preferably from 1 to 3 % by weight in the final product.
The amount of water used in the composition of the present invention ranges from 1 to
5% wt, preferably from 2 to 4 % wt.
Hydrophillic binders as may be used in the present invention. Hydrophilic binders
according to the present invention includes high molecular weight PEGs like PEG 6000,
PEG 8000, high molecular weight poly-ox, fatty alcohols, lanolin, sugars and mixtures
thereof. Binders can be present in amounts 0.2 to 4 % by weight in the final product.
Hydrophobic component of the present invention may be selected from a group
comprising hydrophobic binder, solidifying agents, Free Fatty acids, hydrophobic
emollients and combinations thereof.
Hydrophobic Binders according to the present invention includes silicone, silica, silica
gel and mixtures thereof. Other plastic binders are identified in the published literature,
such as J. Amer. Oil Chem. Soc. 1982, 59, 442.Binders can be present in amounts 0.2 to
4 % by weight in the final product.
The solidifying agents as may be used in the preparation of the bathing bar of the
present invention may be selected from a group comprising waxes such as paraffin wax,
paraffin oil (the blends of C8 to C28), microcrystalline wax, carnauba, spermaceti,
beeswax, lanolin; higher chain fatty acids (C16 - C18), and derivatives and
combinations thereof. The amount of solidifying agent Paraffin present in the
composition of the present invention ranges from 15 to30 % wt, particularly from 18 to
24 % wt.

The term "free fatty acids" as used herein refers to fatty acids with alkyl chain lengths
of from C8 - C18. These may be selected from group of linear chained fatty acids,
branched chain fatty acids, saturated and unsaturated fatty acids such as Caprylic,
Capric, Laurie, Myristic, Palmitic, Stearic, Oleic, etc and mixtures thereof. The amount
of free fatty acids required ranges from 10 to 22 % wt, preferably from 12to 18 % wt.
Hydrophobic emollients are substance as are miscible in oil and which soften or
improve the elasticity, appearance, and youthfulness of the skin (stratum corneum) by
increasing its water content, and keeps it soft by retarding the decrease of its water
content. Hydrophobic emollients that may be used in the present invention include but
are not limited to silicone oils and modifications thereof such as linear and cyclic
polydimethylsiloxanes; amino, alkyl, alkylaryl, and aryl silicone oils; fats and oils
including natural fats and oils such as jojoba, soybean, sunflower, rice bran, avocado,
almond, olive, sesame, persic, castor, coconut, mink oils; cacao fat; beef tallow, lard;
hardened oils obtained by hydrogenating the aforementioned oils; and synthetic mono,
di and triglycerides such as myristic acid glyceride and 2-ethylhexanoic acid glyceride;
waxes such as carnauba, spermaceti, beeswax, lanolin, and derivatives thereof;
hydrophobic plant extracts; hydrocarbons such as liquid paraffin, petrolatum,
microcrystalline wax, ceresin, squalene, pristan and mineral oil; higher fatty acids such
as lauric, myristic, palmitic, stearic, behenic, oleic, linoleic, linolenic, lanolic, isostearic,
arachidonic and poly unsaturated fatty acids (PUFA); esters such as cetyl octanoate,
myristyl lactate, cetyl lactate, isopropyl myristate, myristyl myristate, isopropyl
palmitate, isopropyl adipate, butyl stearate, decyl oleate, cholesterol isostearate, glycerol
monostearate, glycerol distearate, glycerol tristearate, alkyl lactate, alkyl citrate and
alkyl tartrate; essential oils and extracts thereof such as mentha, jasmine, camphor,
white cedar, bitter orange peel, ryu, turpentine, cinnamon, bergamot, citrus unshiu,
calamus, pine, lavender, bay, clove, hiba, eucalyptus, lemon, starflower, thyme,
peppermint, rose, sage, sesame, ginger, basil, juniper, lemon grass, rosemary, rosewood,
avocado, grape, grapeseed, myrrh, cucumber, watercress, calendula, elder flower,
geranium, linden blossom, amaranth, seaweed, ginko, ginseng, carrot, guarana, tea tree,
jojoba, comfrey, oatmeal, cocoa, neroli, vanilla, green tea, penny royal, aloe vera,
menthol, cineole, eugenol, citral, citronelle, borneol, linalool, geraniol, evening

primrose, camphor, thymol, spirantol, penene, limonene and terpenoid oils; and
mixtures of any of the foregoing components, and the like. Advantageously hydrophilic
emollients may be used from about 0.1 to 6 % wt, preferably from 1 to 3 % by weight in
the finai product.
The bathing bar composition of the present invention may further comprise surfactants,
soaps, preservative, pH regulators, fragrances, emotives, active ingredients.
Soap according to the present invention includes alkali metal salts of fatty acids such as
sodium palmitate and sodium oleate (i.e. anionic surfactants). Among the soaps that are
used herein may be saponified glycerides from plant or animal sources such as sodium
palmate, sodium palm kernelate, sodium cocoate, sodium tallowate, potassium
tallowate, sodium lardate and other alkali metal salt of C8-C22 single chained and
branched carboxylic acids. The amount of the soaps ranges from 10 to 18 % wt,
particularly from 11 to 15 % wt.
The surfactants as may be used in the bathing bar of the present invention may be
selected from anionic surfactants, amphoteric surfactants, nonionic surfactants and
cationic surfactants and combinations thereof. As it is well known in the art that
surfactant materials can also be an emulsifier, the term "surfactant" does not exclude
materials which also have emulsification properties.
The anionic surfactants that may be used in the present invention include but are not
limited to acyl isethionates, Sodium cocoyl isethionate, sodium isethionate, sodium
lauroyl isethionate, Sodium lauroyl methyl isethionate, sodium methyl cocoyl taurate,
and the series, sodium alkyl sulfate, alkyl sulfates, anionic acyl sarcosinates, methyl
acyl taurates, N-acyl glutamates, acyl isethionates, alkyl ether sulfates, alkyl
sulfosuccinates, alkyl phosphate esters, ethoxylated alkyl phosphate esters, trideceth
sulfates, protein condensates, mixtures of ethoxylated alkyl sulfates and the like. Alkyl
chains for these surfactants are C8-22, preferably C10-18 and, more preferably, C12-14

alkyls. More preferably, anionic surfactant that may be used for making the bathing bar
of the present invention may ranges from 1 to 55 % wt, preferably from 10 to 40 wt%.
The amphoteric surfactants which can be used in the compositions of the present
invention are those which can be broadly described as derivatives of aliphatic secondary
and tertiary amines in which the aliphatic radical can be straight chain or branched and
wherein one of the aliphatic substituents contains from about 8 to about 18 carbon
atoms and one contains an anionic water solubilizing group, e.g., carboxy, sulfonate,
sulfate, phosphate, or phosphonate. Examples of compounds falling within this
definition are CDMA, sodium 3-dodecylaminopropionate, sodium 3-
dodecylaminopropane sulfonate. Other amphoterics such as betaines are also useful in
the present composition. Examples of betaines useful herein include the high alkyl
betaines such as coco dimethyl carboxymethyl betaine, lauryl dimethyl carboxy-methyl
betaine, lauryl dimethyl alpha-carboxyethyl betaine, cetyl dimethyl carboxymethyl
betaine, lauryl bis-(2-hydroxyethyl) carboxy methyl betaine, stearyl bis-(2-
hydroxypropyl)carboxymethyl betaine, oleyl dimethyl gamma-carboxypropyl betaine,
lauryl bis-(2-hydro-xypropyl)alpha-carboxyet-hyl betaine, etc. The sulfobetaines may
be represented by coco dimethyl sulfopropyl betaine, stearyl dimethyl sulfopropyl
betaine, amido betaines, amidosulfobetaines, and the like. The amount of amphoteric
surfactant as may be used in making the bathing bar of the present invention ranges
from 1 to 4 % wt preferably from 1 to 2 % wt.
The nonionic surfactants useful in this invention can be broadly defined as compounds
produced by the condensation of alkylene oxide groups (hydrophilic in nature) with an
organic hydrophobic compound, which may be aliphatic or alkyl aromatic in nature.
Non-limiting examples of preferred nonionic surfactants for use herein are those
selected form the group consisting of glucose amides, alkyl polyglucosides, sucrose
cocoate, sucrose laurate, alkanolamides, ethoxylated alcohols and mixtures thereof. In a
preferred embodiment the nonionic surfactant is selected from the group consisting of
glyceryl monohydroxystearate, isosteareth-2, trideceth-3, hydroxystearic acid,
propylene glycol stearate, PEG-2 stearate, sorbitan monostearate, glyceryl laurate,

laureth-2, cocamide monoethanolamine, lauramide monoethanolamine, decyl glucoside
and mixtures thereof. The composition of the present invention may also comprise one
or more sugar based surfactants selected from but not limited to condensation products
of long chain alcohols with sugar or starch polymers (e.g. decyl polyglucoside and
lauryl polyglucoside), amides (e.g. cocoamide diethanolamine and cocoamide
monoethanolamine), alkylene oxide derived surfactants (e.g. ceteth-6, cetearefh-6,
steareth-6, PEG-12 stearate, and PEG-200 glyceryl tallowate), Maltooligosyl
Glucoside/Hydrogenated Starch Hydrolysate and mixtures thereof. The amount of non-
ionic surfactant as may be used in making the bathing bar of the present invention
ranges from 1 to 5 wt%, preferably from 1 to 3 wt%.
Preservatives according to the present invention include BHT, EDTA, phenoxy ethanol.
Preservatives can be present in amounts 0.01 to 0.2 % by weight in the final product.
pH regulator according to the present invention includes citric acid, lactic acid, oxalic
acid, acetic acid etc. pH regulator can be present in amounts 0.5 to 5 % by weight in the
final product.
Active ingredients according to the present invention include lipophilic or hydrophilic
active ingredients. As used herein an 'active ingredient' is meant to comprise a
compound that has a cosmetic or therapeutic effect on the skin, hair, or nails, e.g.,
lightening agents, darkening agents such as self-tanning agents, anti-acne agents, shine
control agents, anti-microbial agents, anti-inflammatory agents, anti-aging agents, in
particular anti-wrinkle agents, anti-mycotic agents, anti-parasite agents, external
analgesics, sunscreens, photoprotectors, antioxidants, keratolytic agents,
detergents/surfactants, moisturizers, nutrients, vitamins, energy enhancers, anti-
perspiration agents, astringents, deodorants, hair removers, firming agents, anti-callous
agents, and agents for hair, nail, and/or skin conditioning.
Examples of active ingredients are hydroxy acids, benzoyl peroxide, sulfur resorcinol,
ascorbic acid, D-panthenol, hydroquinone, octyl methoxycinnimate, titanium dioxide,

octyl salicylate, homosalate, avobenzone, polyphenolics, carotenoids, free radical
scavengers, spin traps, retinoids such as retinol and retinyl palmitate, ceramides,
polyunsaturated fatty acids, essential fatty acids, enzymes, enzyme inhibitors, minerals,
hormones such as estrogens, steroids such as hydrocortisone, 2-dimethylaminoethanol,
copper salts such as copper chloride, peptides containing copper such as Cu:Gly-His-
Lys, coenzyme Q10, peptides such as those disclosed in WO-00/15188, lipoic acid,
amino acids such a proline and tyrosine, vitamins, lactobionic acid, acetyl-coenzyme A,
niacin, riboflavin, thiamin, ribose, electron transporters such as NADH and FADH2,
and other botanical extracts such as aloe vera and soy, and derivatives and mixtures
thereof. The cosmetically active agent will typically be present in the formulation of the
invention in an amount of from about 0.001 % to about 20% by weight of the
formulation, e.g., about 0.01% by weight to about 10% by weight, more preferably
0.1% to about 5%.
Examples of vitamins include, but are not limited to, vitamin A, vitamin Bs such as
vitamin B3, vitamin B5, and vitamin B12, vitamin C, vitamin K, and vitamin E and
derivatives thereof.
Emotives are selected from group comprising fragrance and/or botanical extract.
Fragrances and botanicals are often liquids. Non limiting examples of botanical extracts
as may be used in the present invention include those extracted from chamomile,
jasmine, lavender, horse chestnut, sage, thyme, yucca, coltsfoot and mixtures thereof.
In the context of this invention, fragrance, means any mixture, i.e. more than one
chemical species, including materials which act as malodor counteractants. A wide
variety of odiferous materials are known for use as a fragrance composition, including
materials such as alkenes, alcohols, aldehydes, ketones, esters, ethers, nitrites, amines,
oximes, acetals, ketals, thiols, thioketones, imines, etc. Without wishing to be limited,
the ingredients of the fragrance composition will have molecular weights of less than
325 atomic mass units, preferably less than 300 atomic mass units and more preferably
less than 275 atomic mass units to ensure sufficient volatility to be noticeable when the
capsules release. Furthermore the fragrance compounds will have molecular weights of

greater than 100 atomic mass units, preferably greater than 120 atomic mass units as
lower masses may be too volatile or too water soluble.
Naturally occurring plant and animal oils and exudates comprising complex mixtures of
various chemical components are also known for use as fragrances, and such materials
can be used herein. The principal chemical components of most naturals are known
(within ranges), and thus for the most part they can be assessed in the same way as
synthetic aroma chemicals. Fragrance of the present invention can be relatively simple
in their composition with a minimum of two fragrance or fragrance ingredients, or can
comprise highly complex mixtures of national and synthetic chemical components,
chosen to provide any desired odor. Fragrance ingredients are described more fully in S.
Arctander, Perfume Flavors and Chemicals. Vols. I and II, Montclair, N.J., and the
Merck Index, 8th Edition, Merck & Co., Inc. Rahway, N.J.
Further the composition of the present invention may comprise 0.5 to 1.5 % by weight
of fragrance, 0.005 to 0.5 % by weight of emotives.
The soap bar composition of the present invention provides a unique hydrophobic:
hydrophilic components maintained from about 7:1 to about 3:1.
The hydrophobic: hydrophilic components should be maintained from about 7:1 to
about 3:1 for an easy demolding process and to get superior surface finish in the metal
molds as illustrated in Table 3.
The composition of the present invention uses a specific hydrophobic to hydrophilic
ratio to prevent the sticking of the soap to metal mould during demoulding process and
there by maintains good bar aesthetics.
The characteristic features of the formulation of the present invention are:

• Soap composition comprises of unique ratio of hydrophobic: hydrophilic
components, which does not stick to metal moulds even at high operation
temperature. The temperature ranges from 40 - 50°C.
• The final product maintains excellent surface smoothness and provides
improved bar glide of naked bathing bar during application.
• The composition allows very fast cooling and offers de-molding at higher
process temperatures that are greater than 40°C, when compared to the silicone
mould demoulding temperature which requires 35°C.
Another embodiment of the present invention provides a process for the preparation of
the formulation of the present invention prepared by direct cast route comprising steps
of:
1. Melt the solidifying agent and free Fatty acids to obtain a molten mass;
2. To the molten mass of step 1 add soap and homogenize for 10 - 15 min to obtain
a homogenized melt;
3. To the homogenized melt of step 2 add hydrophilic emollients and other
surfactants and homogenize for 10 - 15 min to obtain homogenized mass;
4. To the homogenized mass of step 3 add hydrophobic emollients and other
adjuvants; and hold the mass for 30 minutes followed by casting the mass in to
desired shape molds
5. Cool the molds of step 4 at 5 - 10°C and demold the solidified soap tablets
The present invention is now illustrated by way of non-limiting examples.
Example-1: (Working Example): Ratio of the hydrophobic and hydrophilic components
is 6.7:1


Inference: The above composition resulted in stable formulation with smooth surface
finish.
Process for the preparation of the opaque soap bar of the present invention comprises:
1. Melting the Paraffin wax and free Fatty acids;
2. Adding soap in to the hot melt and homogenizing the mass for 15 min;
3. Adding glycerin and other surfactants and homogenizing the mass for 10
min;
4. Adding silicone and fragrance & mix the mass for 10 min;
5. Holding the mass for 30 min for foam settling and casting the mass in to
desired shape molds; and
6. Cooling the molds at 7°C and demolding the solidified soap tablets.


Inference: Demoulding was very difficult due to sticky surface.
In the above mentioned non -working example the ratio of the hydrophobic and
hydrophilic components is 2.8:1
Process for the preparation:
1. Melt the Paraffin wax and free Fatty acids;
2. Adding soap in to the hot melt and homogenizing the mass for 15 min;
3. Adding Glycerin and other surfactants and homogenizing the mass for 10
min;
4. Adding Silicone and fragrance & mixing the mass for 10 min;
5. Holding the mass for 30 min for foam settling and casting the mass in to
desired shape molds; and
6. Cooling the molds at 7°C and demold the solidified soap tablets.

Example 3: data demonstrating demoulding property and surface finish of the
soap bar composition of the present invention when compared to the soap bar
composition of the prior art.

Result and observation: Soaps as detailed in example 1 and 2 were prepared as per the
procedure mentioned. After solidification the soaps were demolded and evaluated by 5
expert panel on a scale of 1-5. Score card: Demolding of soap from molds on a scale of
1-5.
Example 4: Data demonstrating the fast cooling property of the bathing bar of the
present invention.
The present invention provides a formulation which solidifies in metal mold faster than
the Silicon mold.

Result and observation: As may be inferred from the above data the metal mould
allowed cooling and demolding of the composition of the working example within 12.5
minutes whereas the same mould required at least 31 minutes to allow cooling and
demolding as illustrated in figure 1.
Example 5: Data substantiating the specific ratio of hydrophobicrhydrophilic
components helps in solving the problem of stickiness of the bar to the metal
mould during demoulding process.


Result and observation: The unique ratio of hydrophobic and hydrophilic components
i.e. 7:1 to 3:1 to be maintained for easy demolding and better surface finish. If the ratio
is out of the prescribed range, then the time required for cooling the material for
demolding increases & also the stickiness of the material to the mold increases & due to
this the surface finish becomes very rough.
Example 6: Comparative data demonstrating the properties of surface smoothness
and improved bar glide of naked bathing bar during application:


Result and observation: As may be inferred from the above table and graph working
example of the present invention provides superior surface smoothness, bar glide on
skin, superior bar surface finish and desired slipperiness of bar as illustrated in figure 2.

WE CLAIM:
1. A soap bar composition comprising:
a) at least one hydrophilic component;
b) at least one hydrophobic component;
c) cosmetically acceptable excipients;
wherein the ratio of the at least one hydrophobic component : the least one
hydrophilic component is maintained from about 7:1 to about 3:1; and
wherein said soap bar demoulds at higher process temperatures.
2. The soap bar composition as claimed in claim 1, wherein said hydrophilic
components are selected from a group comprising hydrophilic binders,
hydrophilic emollients, water.
3. The soap bar composition as claimed in claim 1, wherein said hydrophobic
components are selected from hydrophobic binder, solidifying agents, free fatty
acids, hydrophobic emollients and combinations thereof.
4. The soap bar composition as claimed in claim 1, wherein said cosmetically
acceptable excipients are chosen from surfactants, soaps, preservative, pH
regulators, fragrances, emotives and active ingredients.
5. The soap bar composition as claimed in claim 2, wherein said hydrophilic
binders are selected from a group comprising high molecular weight PEGs like
PEG 6000, PEG 8000, high molecular weight poly-ox, fatty alcohols, lanolin,
sugars and mixtures thereof.
6. The soap bar composition as claimed in claim 2, wherein said hydrophilic
binders are present in amounts 0.2 to 4 % by weight in the final product.
7. The soap bar composition as claimed in claim 2, wherein hydrophillic emollients
include but are not limited to polyols such as glycerol, sorbitol higher alcohols
such as lauryl, cetyl, stearyl, oleyl, behenyl and 2-hexydecanol alcohol and
mixtures thereof.

8. The soap bar composition as claimed in claim 2, wherein said hydrophilic
emollients are present in amounts ranging from 1 to 6%, preferably from 1 to 3
% by weight in the final product.
9. The soap bar composition as claimed in claim 2, wherein said water ranges from
1 to 5% wt, preferably from 2 to 4 % wt.
10. The soap bar composition as claimed in claim 3, wherein said hydrophobic
binders are selected from a group comprising silicone, silica, silica gel and
mixtures thereof.
11. The soap bar composition as claimed in claim 3, wherein said hydrophobic
binders are present in amounts ranging from 0.2 to 4 % by weight in the final
product.
12. A process for the preparation of a soap bar composition comprising steps of:

a) melting solidifying agent and free fatty acids to obtain a molten mass;
b) adding soap to the said molten mass and homogenizing to obtain a
homogenized melt;
c) adding add hydrophilic emollients and other surfactants to said homogenized
melt of step b and homogenizing to obtain another homogenized mass;
d) adding hydrophobic emollients and other adjuvants to said homogenized
melt of step c and holding the mass;
e) casting said mass to desired shape; and
f) cooling the mold to 5 - 10°C so as to reduce the soap temperature directly to
about 44.5°C and demolding the solidified soap bar.
wherein the ratio of the at least one hydrophobic component : the least one
hydrophilic component is maintained from about 7:1 to about 3:1;
wherein said soap bar does not stick to metal moulds while demoulding and
provides superior finish;
wherein said soap bar demoulds at higher process temperatures.

13. The process as claimed in claim 12, wherein said process of homogenizing is
carried out for 10 - 15 minutes.

ABSTRACT

A bathing bar composition that can be demoulded using metal moulds, while retaining
superior finish and without compromising on bar aesthetics. The bathing soap bar
comprising hydrophilic components, hydrophobic components and other cosmetically
acceptable excipients and wherein the ratio of the hydrophobic component and
hydrophilic component is maintained from about 7:1 to about 3:1 to facilitate
demoulding at higher process temperatures using moulds, essentially without
compromising on bar aesthetics and surface finish.