DESC:Technical field of the invention
The present invention relates to process for the preparation of a personal care composition(s). More particularly it relates to process for the preparation of soap bars / soap tablets wherein two or more soap formulations, of similar or varying consistencies, compatible or in-compatible, are coextruded to form a single in-separable soap bar. The strength and compactness of the soap bar, so formed, is maintained during use.
Background of the invention and prior art
Soap formulations have been known for centuries. There are various soap formulations available in the art such as moisturizing soaps, conditioning soaps, opaque soaps, translucent soaps, transparent soaps, marbleized soaps, buoyant soaps, dual colored soaps and the like. Benefits and sensorials of a soap are dependent on the form and kind of soap; and on ingredients that constitute these formulations, for example opaque soap bars are capable of providing better conditioning benefits owing to the high amount of FFA which can be easily incorporated into opaque soaps whereas transparent soaps are perceived to be more mild and moisturizing owing to greater amounts of glycerin / moisturizing agents that can be added to their formulation. Similarly on the basis of specific ingredients, soaps that provide characteristics of exfoliation, fairness, softness, smoothness can be prepared. Whereas every soap formulation, be it transparent or opaque, bestows unique set of benefits, it also has its own inadequacies and limitations in delivering the benefits such as enhanced sensory. Hence consumers are forced to make a selection between the benefits that they may receive and hence between the soap formulations that they may buy.
It remains a challenge in the art to provide a soap formulation capable of delivering multiple benefits through a single bar.
Various attempts have been made in the art to serve this unmet need. One such attempt has been in the form of marbleized soap bars which are manufactured through extrusion process wherein two different colored bases are mixed together. The prior arts suggest injection of any Special liquid ingredient (such as dues colors pigments extracts actives and /or emotive) into the main base, during co-extrusion, to enhance the aesthetics or performance. However these marbleized soap differ only in the color and fail to provide differentiated properties and sensorial.
US 4,090,829 teaches introduction of a color dye for color striation of the extruded column which is extruded through a die plate. This prior art further mentions that the special locations for color introduction helps in the production of unique "carrara" marble effect in the bar. ‘829 patent limits itself by adding coloring agents such as dye for color striation on the soaps.
EP 0594077 relates to a method and apparatus for producing striped, multicolored soap. ‘077 patent teaches a method for the manufacture of striped, multicolored soap in various patterns.
Hence the prior arts are related to manufacture of multi colored soap by the aid of dyes of coloring agents. Moreover, it is challenging to affix two or more incompatible formulations into a single product because each formulation has its own characteristics such as viscosity, moisture content, plasticity, processability conditions and requirements, bulk flowability rates etc. There is a need therefore for such a co-extrusion process which can affix two or more incompatible formulations of varying consistencies and features into a single product that provides sensorials, desirable benefits of both its constituents.
The present invention contemplates a multi component soap bar made by co-extruding two or more in-compatible soap formulations. The multi-component soap bar so formed is an industrially viable. Additionally, the co-existence of two compositions together in one product, makes the final soap bar visually distinct and unique.
The present invention also discloses a unique process of co-extruding soap formulations of varying consistencies and as are generally incompatible with each other in a manner that both the soap formulations coexist on the soap in their original form, without loosing their form, shape, special characteristics and features and continue to offer their unique benefits during use. Additionally the combined soap bar also exhibits enhanced aesthetics.
Object of the present invention
It is an objective of the present invention to overcome the drawback of the prior arts.
It is also the objective of the present invention is to provide a co-extrusion process whereby two or more soap formulations (of varying consistencies, properties or features) are affixed together, while retaining their distinctiveness, into a single in-separable soap bar.
Further it is the objective of the present invention is to provide a co-extrusion process whereby two or more soap formulations (which are generally incompatible with each other) are affixed together to provide a single in-separable soap bar with enhanced aesthetics.
Again it is the objective of the present invention to provide a co-extrusion process whereby two or more soap formulations (which are generally incompatible with each other) are affixed together, while retaining their distinctiveness, into a single in-separable soap bar.
Still further it is the objective of the present invention is to provide a co-extrusion process whereby two or more soap formulations (which are generally incompatible with each other) are affixed together to provide a single in-separable soap bar while maintaining strength and in-use compactness.
Yet again it is the objective of the present invention is to provide a co-extrusion process whereby two or more soap formulations (of varying consistencies, properties or features) are affixed together to provide a single in-separable soap bar with enhanced aesthetics.
It is yet another objective of the present invention is to provide a co-extrusion process whereby two or more soap formulations (of varying consistencies, properties or features) are affixed together to provide a single in-separable soap bar while maintaining strength and in-use compactness.
Yet again it is an objective of the invention to provide a soap bar / tablet with at least two different soap formulations conjoined to form a single product.
Another objective of the invention is to provide a soap bar / tablet comprising two or more incompatible soap formulations.
Yet another objective of the invention is to provide a soap bar / tablet comprising two or more incompatible soap formulations wherein the incompatible soap formulation(s) appear to be affixed together.
Still another objective of the present invention is to provide a personal care composition with benefits of multiple formulations. The soap formulation of the present invention provides a combination of benefits obtained from two or more singular formulations in one stage like humidifying skin without creating stickiness and providing good cleansing effect.
Further it is the objective of the invention to provide visually distinct, aesthetically sound soap bar / tablet.
Brief Description of Accompanying Drawings:
Figure 1 illustrates co-extruded soap bar.
Figure 2 illustrates the complete flow chart of the process of co-extrusion
Figure 3 illustrates the schematic representation of the apparatus used for the process of co-extrusion.
Figure 4 illustrates the engineering details of the co extrusion assembly
Figure 5 illustrates exemplary mixing plate design
Figure 6a illustrates soap bar with 50:50 ratio(white: colour) stripes.
Figure 6b illustrates soap bar with 70:30 (white:colour) stripes.
Detailed description of the invention:
The present invention discloses a unique co-extrusion process whereby two or more soap base formulations are coextruded to provide a singe inseparable compact soap bar.
The term ‘co-extrusion’ within the meaning of the present invention can be defined as a process of distribution of different soap bases into multiple smaller non interfering streams flowing together separately and joined back to form a single bar with both the bases co-existing separately in a fixed design pattern.
The term ‘incompatible’ as used in the present invention in relation to formulations can be defined as two or more formulations differing in feature, characteristics, element, ingredient, form, shape or function; in terms of form such as such as transparent, opaque; in terms of characteristics such as moisturizing and conditioning; in terms of functions such as exfoliating vs mild; in terms of elements such as those varying in emollients, cleansing capability and the like; in terms of ingredients such as a formulation comprising an anti-acne active as against a formulation comprising oil soluble actives.
The term ‘cone’ can be defined as a geometrically shaped machine part that may form a separable or inseparable part of equipment.
The soap bar of the present invention is a multi component soap made by the process of Co-extrusion of soap base of two different formulations. The co-existence of two compositions together in one product, in a visually differentiable format makes it unique and helps delivering the consumer desirable benefits of two different formulations from one soap bar. Two different formulations made into one single product format is challenging. This is essentially because different formulation bases, such as translucent an opaque, are incompatible with each other and if joined together to form a single bar tend to separate during use. The invention provides unique solution by way of a co-extrusion process whereby two or more soap bases are joined together such that these remain inseparable during use. The coextruded bar of the present invention is also capable of delivering benefits of the two or more different formulations it is formed of such as translucent/transparent and opaque combination. The soap bar so formed provides individual benefits of the mutually incompatible constituting formulations and maintains it compactness and remains in-separable during use. Additionally the final soap bar is aesthetically pleasing.
The invention discloses a unique co-extrusion process for the production of co-extruded soap bar. The co-extrusion process of the present invention comprises:
a. connecting co-extrusion attachment to the cone of i) at least one plodder (P1) and ii) at least one plodder (P2); while maintaining the temperature of the plodders from about 30 ºC to about 60 ºC;
b. adding the first soap base formulation in P1 and operating the same at a predetermined extrusion rate while maintaining the pressure of the co-extrusion cone from about 10 to about 30 bar; The extrusion rate is 1TPH to 2TPH;
c. adding the second soap base formulation into P2 and operating the same at a predetermined extrusion rate; to obtain a coextruded soap mass;
wherein the first soap base formulation and the second soap base formulation are different and wherein the extrusion rates of P1 and P2 are maintained at a ratio of from about 45:50 to about 50:50.
The coextruded soap mass is then cut and stamped to obtain coextruded soap bars.
The co-extrusion assembly of the present invention comprises:
a. at least two separate plodders;
b. at least one co-extrusion attachment comprising:
i. at least one mixing plate;
ii. at least one piece of non-interfering multi-channel arrangements; and
iii. at least one co-extrusion cone
wherein the at least two plodders are placed mutually perpendicular to each other.

It has been surprisingly found out by the inventors that irrespective of the constituting soap base formulations of the coextruded soap bar which may be varying in consistency, flowability, viscosity, stickness, strechability, performance parameters, such as mildness, exfoliation, conditioning, cleansing capability etc; if the plodder temperatures, extrusion rates and pressure of the co-extrusion cone is maintained, a consistent patterned product, wherein the proportion of constituting parts is controlled, is formed. The critical process parameters are soap extrusion pressure, extrusion rate and plodder temperature.
The plodders as may be used in production of co-extrusion bar of the present invention may be selected from a group comprising but not limited to single or multiple stage with single or double worm such as dual vacuum plodders (DVP), simplex plodders and the like.
In one specific embodiment of the present invention the at least one piece of non-interfering multi-channel arrangements is cut through a cylinder. In another specific embodiment of the present invention the at least one piece of non-interfering multi-channel arrangements is geometrically symmetrical.
The mixing plate as may be used in production of co-extrusion bar of the present invention may comprise at least two partitions. In a specific embodiment of the invention the mixing plate comprises four quadrants.
The extrusion cone as may be used in production of co-extrusion bar of the present invention may be separable or inseparable part of the co-extrusion assembly.
In yet another embodiment of the present invention each of the multi-channel arrangements is non-interfering with each other and positioned throughout the length of the equipment extending form inlet side, where the channel openings are positioned in a different geometric pattern, to the outlet side where the arrangement pattern is different. The pattern in which these channel extend into the mixing plate is varying throughout the length of the mixing plate. The openings at the inlet side are positioned as per the inlet material flow position and depends on the back end machine design and at the outlet side the channel open in an arrangement which is desired on the soap. This way the soap from two different streams are distributed into multiple smaller flow streams separately to the other side of mixing plate and joined back at the forming a bar with both the bases present in the cross section separately in a pattern as desired.
It has been found by the present inventors that plodder temperature; ratio of extrusion rates from DVP1 and DVP2; and pressure of co-extrusion cone is critical to the co-extrusion process of the present invention. Moreover the present inventors have found that when the all the three critical elements (temperature, pressure and extrusion rates) are maintained within the stated limits, then irrespective of the characteristics, features, forms and types of the compatible / incompatible formulations; a compact, in-separable, stable coextruded bar is obtained as an end product, which maintains its in-use identity.
In a specific embodiment of the invention the co-extrusion process of the present invention comprises:
a) connecting co-extrusion attachment to the cone of i) at least one dual vacuum plodder (DVP1) and ii) at least one dual vacuum plodder (DVP2); while maintaining the temperature of the plodders from about 45 ºC;
b) adding the first soap base formulation in DVP1 and operating the same at a predetermined extrusion rate while maintaining the pressure of the co-extrusion cone at about 20 bar;
c) adding the second soap base formulation into DVP2 and operating the same at a predetermined extrusion rate; to obtain a coextruded soap mass;
wherein the first soap base formulation and the second soap base formulation are different and wherein the extrusion rates of DVP1 and DVP2 are maintained at a ratio of 50:50.
The coextruded soap mass is then cut and stamped to obtain coextruded soap bars.
It has been found out that the product of the present invention is beneficial for industrial scale processability; consistent product characteristics (such as product form, shape and sensorials); and maintenance of desired product pattern all through the lot are some of the critical features for marketability of the end product of this invention. Each lot of soap batch may be of 4-5 tons. It is important that each of the 100 g soap bar made out of the 4-5 ton lot be of the same pattern. It is undesirable if the soap bars formed show inconsistent patterns and hence unpredictable performance characteristics to the end user.
Since it is coextruded soap bar the chances of pattern going nonfunctional are high. It has been surprisingly found out by the inventors that irrespective of the constituting soap base formulations of the coextruded soap bar which may be varying in consistency, flowability, viscosity, stickness, strechability, performance parameters, such as mildness, exfoliation, conditioning, cleansing capability etc; if the plodder temperatures, extrusion rates and pressure of the co-extrusion cone is maintained, a consistent patterned product, wherein the proportion of constituting parts is controlled, is formed.
It has been found out that due to the imbalance of the operating conditions the mass flow ratio changes and desired co-extrusion pattern is not obtained. Further when temperature of the plodders is higher than the predetermined temperature range of about 30 ºC to about 60 ºC, the coextruded soap bars are soft and sticky and not processable. The final products “if formed” vary in proportion of the constituting soap bases present. Also if the temperature is lower than the stated range, the coextruded soap, formed from incompatible soap bases, does not remain cohesive.
It is noted that when the ratio of extrusion rate of DVP1: DVP2 is 70:30 the pattern of the final coextruded soap bar is inconsistent and undesired.
It is also noted that when the pressure applied to co-extrusion cone is greater /lower than the predetermined range of from about 10 to 30 bars the coextruded soap bar exhibits undesired features such as unequal stripes and flaking of one half of the soap happens.
As another embodiment of the present invention there is provided process of co-extrusion for preparing a soap bar with at least two incompatible formulations (i.e. a. translucent soap formulation and b. opaque soap formulation), said process comprising steps of:
a) connecting co-extrusion attachment to the cone of i) at least one dual vacuum plodder (DVP1) and ii) at least one dual vacuum plodder (DVP2); while maintaining the temperature of the plodders from about 30ºC to about 60 ºC;
b) adding the translucent soap base formulation in the DVP 1 and operating the same at a predetermined extrusion rate while maintaining the pressure of the co-extrusion cone from about 10 to about 30bar;
c) adding the opaque soap base formulation in the DVP 2 and operating the same at a predetermined extrusion rate; to obtain a coextruded soap mass;
wherein the first soap base formulation and the second soap base formulation are different and wherein the extrusion rates of DVP1 and DVP2 are maintained at a ratio of from about 50:50 to about 45:55.
As yet another embodiment of the present invention there is provided process of co-extrusion for preparing a soap bar with at least two compatible formulations (i.e. two transparent soap formulations or two opaque soap formulations comprising different active ingredients, fragrance, pigment, emotives), said process comprising steps of:
a) connecting co-extrusion attachment to the cone of i) at least one dual vacuum plodder (DVP1) and ii) at least one secondary simplex plodder (DVP2); while maintaining the temperature of the plodders from about 30 ºC to about 50 ºC;
b) adding the first soap base formulation in the DVP1 and operating the same at a predetermined extrusion rate while maintaining the pressure of the co-extrusion cone from about 10 to about 30 bar.;
c) adding the second soap base formulation in to DVP2 and running the same at a predetermined extrusion rate; to obtain a coextruded soap mass comprising transparent and opaque soap bases;
wherein the first soap base formulation and the second soap base formulation are different and wherein the extrusion rates of DVP 1and DVP 2are maintained at a ratio of from about 50:50 to about 45:55.
Using the technique disclosed in the present invention, co-extruded soap bar formulations, comprising multiple and varied patterns such as horizontal, mixed stripes; criss-cross; zig-zag; partitioned such as binary, tertiary, multiple; combinations and various patterns inside the core of the extruded soap, can be formed by suitable varying the mixing plate and the patterns therein. Various mixing plates with varying orifice size and geometric or abstract patterns can be employed for preparation of coextruded soap bars of the present invention. Such modifications as are conventionally used and are known to a person skilled in the art may therefore be considered non-limiting and within the scope of the present invention.
In a specific embodiment of the present invention there is provided process of co-extrusion of a soap bar comprising at least one opaque soap formulation and at least one translucent soap formulation wherein the coextruded bar comprises translucent and opaque soap formulations in the ratio of 50:50 said process comprising steps of:
a) connecting co-extrusion attachment to the cone of i) at least one dual vacuum plodder (DVP1) and ii) at least one secondary duplex plodder (DVP2); while maintaining the temperature of the plodders from about 45 ºC;
b) Placing transparent soap base formulations in to DVP1 and operating the DVP1 at a predetermined extrusion rate while maintaining the pressure of the co-extrusion cone from about 20 bar;
c) Placing the opaque soap base formulation in to DVP2 and operating the DVP2 at a predetermined extrusion rate; to obtain a coextruded soap mass comprising transparent and opaque soap bases;
wherein the extrusion rates of DVP and DVP are maintained at a ratio of from about 50:50.
In yet another specific embodiment of the present invention there is provided process of co-extrusion of a soap bar comprising two different opaque soap formulations wherein the coextruded bar comprises stripes of the two different opaque soap formulations said process comprising steps of:
a) connecting co-extrusion attachment to the cone of i) at least one dual vacuum plodder (DVP1) and ii) at least one secondary duplex plodder (DVP2); while maintaining the temperature of the plodders of about 45 ºC;
b) Placing the first opaque soap base formulation in to DVP1 and operating the DVP 2at at a predetermined extrusion rate while maintaining the pressure of the co-extrusion cone of about 20 bar;
c) Placing the other opaque soap base formulation in to DVP2 and operating the DVP2 at a predetermined extrusion rate; to obtain a coextruded soap mass comprising transparent and opaque soap bases;
wherein the first opaque soap formulation and the second opaque soap formulation differ in colour; and wherein the extrusion rates of DVP1 and DVP2 are maintained at a ratio of 50:50.
The present invention is now illustrated by way of non-limiting exemplary formulations that may be used for the preparation of the co-extruded soap bar of the present invention.
Example 1: Colored Opaque Soap Base Formulation
Table 1:
Orange Color Noodles (50%) Function
Soap Noodles 8020 92.8607 Cleaning Agent
Vitamin E 0.002 Minor Ingredient- Claim substance
Talc 4 Filler
Titanium Dioxide 0.4 Whitener
Triclocarbon (TCC) 0.125 Bacteria Killer(germicide)
Silicones 0.02 Skin Conditioner
PEG 0.02 Emollient
Natural Extract 0.004 Minor Ingredient- Claim substance
Caesin 0.006 Claim Material
Fragrance 1.2 Fragrance
Glycerin 1.3 Humectant
Colorant 1 0.0256 Color
Colorant 2 0.0127 Color
Colorant 3 0.024 Color

Process for preparation:
a) Mixing the raw materials together in appropriate order in an amalgamator;
b) Milling the sufficiently mixed material;
c) Plodding the milled material to form a colored opaque soap base formulations.

This opaque soap base formulation may be coextruded along with other soap base formulation(s) as per the co-extrusion process of the present invention to provide coextruded soap bars.

Example 2: Opaque Soap Base Formulation: formulation 1
Table 2:
White Opaque base (50%) Function
Soap Noodles 8020 78.3415 Cleaning Agent
Talc 4 Filler
Titanium Dioxide 0.4 Whitening Agent
Triclocarbon (TCC) 0.0125 Bacteria Killer ( Germicide)
PEG 0.02 Emollient
Silicones 0.02 Skin Conditioner
Caesin 0.006 Claim Material
Sodium PCA 0.8 Humectant
SLES (70%) 4 Synthetic Detergent
Alpha Olefin Sulphonate 1 Synthetic Detergent
Decyl Glucoside 2 Synthetic Detergent
Lauryl Alcohol 3 Emollient
Glycerin 5 Humectant
Fragrance 1.4 Fragrance
Process for preparation:
a) Mixing the raw materials together in appropriate order in an amalgamator;
b) Milling the sufficiently mixed material;
c) Plodding the milled material to form a opaque soap base formulation.

This opaque soap base formulation may be coextruded along with other soap base formulation(s) as per the co-extrusion process of the present invention to provide coextruded soap bars.

Example 3: Translucent Soap Base Formulation
Table 3:
Colored Translucent base - 50% Function
Soap Noodles 8020 64.4399 Cleaning Agent
Glycerin 9 Humectant
Free Fatty Acids 4 Imparts an oily feeling on skin
Water 13 Aqua
SLES 2 Synthetic Detergent
PEG 2 Skin Conditioner
Color 0.0001 Color
Alpha Olefin Sulphonate 4 Synthetic Detergent
Mica 0.06 Filler and for aesthetics
Fragrance 1.5 Fragrance

Process for preparation:
a) Mixing the raw materials together in appropriate order in an amalgamator;
b) Milling the sufficiently mixed material;
c) Plodding the milled material to form a translucent soap base formulations.

This translucent soap base formulation may be coextruded along with other soap base formulation(s) as per the coextrusion process of the present invention to provide coextruded soap bars.

Another embodiment of the present invention provides non-limiting exemplary co-extruded soap bar formulation of the present invention along with process for preparation of the same.
Example 4: Colored Opaque Soap Base Formulation
Table 4:
Orange Color Noodles (50%) Function
Soap Noodles 8020 89.8607 Cleaning Agent
Vitamin E 0.004 Minor Ingredient- Claim substance
Talc 4 Filler
Titanium Dioxide 0.4 Whitener
Triclocarbon (TCC) 0.0125 Bacteria Killer(germicide)
Silicones 0.02 Skin Conditioner
PEG 0.03 Emollient
Natural Extract 0.004 Minor Ingredient- Claim substance
Caesin 0.006 Claim Material
Fragrance 1.2 Fragrance
Glycerin 1.3 Humectant
Lauryl Alcohol 3 Emollient
Color 0.0256 Color
Color 0.0127 Color
Color 0.024 Color

Process for preparation:
1. Mixing the raw materials together in appropriate order in an amalgamator;
2. Milling the sufficiently mixed material;
3. Plodding the milled material to form a colored opaque soap base formulations.
Example 5: Opaque Soap Base Formulation: formulation 2
Table 5:
White Noodles (50%) Function
Soap Noodles 8020 93.0235 Cleaning Agent
Vitamin E 0.004 Minor Ingredient- Claim substance
Talc 4 Filler
Titanium Dioxide 0.4 Whitener
Triclocarbon (TCC) 0.0125 Bacteria Killer(germicide)
Silicones 0.02 Skin Conditioner
PEG 0.03 Emollient
Natural Extract 0.004 Minor Ingredient- Claim substance
Caesin 0.006 Claim Material
Fragrance 1.2 Fragrance
Glycerin 1.3 Humectant

Process for preparation:
1. Mixing the raw materials of table 4 together in appropriate order in an amalgamator to form a mixture;
2. Milling the sufficiently mixed mixture of step 2 to obtain milled material;
3. Plodding the milled material of step 3 to form an opaque soap base formulation.
4. Mixing the raw materials of table 5 together in appropriate order in an amalgamator to form a mixture;
5. Milling the sufficiently mixed mixture of step 4 to obtain milled material;
6. Plodding the milled material of step 5 to form an opaque soap base formulation.

7. Connecting co-extrusion attachment to the cone of i) at least one dual vacuum plodder (DVP1) and ii) at least one secondary duplex plodder (DVP2); while maintaining the temperature of the plodders of about 45 ºC;
8. Adding the opaque soap base formulation of step 3 in to DVP1 and operating the DVP2 at a predetermined extrusion rate while maintaining the pressure of the co-extrusion cone at about 20 bars.;
9. Adding the opaque soap base formulation of step 6 in to DVP2 and operating the system at a cumulative extrusion rate of about 50:50DVP1:DVP2; to obtain a coextruded soap mass comprising striped opaque soap bases.
10. Cutting the coextruded soap mass of step 10 into bars and stamped to the desired shape.

Example 6: White Opaque base: Formulation 3
Table 6:
White Opaque base (50%) Function
Soap Noodles 8020 78.5315 Cleaning Agent
Talc 4 Filler
Titanium Dioxide 0.4 Whitening Agent
Triclocarbon (TCC) 0.0125 Bacteria Killer ( Germicide)
PEG-75 Lanolin 0.03 Emollient
Silicones 0.02 Skin Conditioner
Milk Cream 0.006 Claim Material
Sodium PCA 0.6 Humectant
SLES (70%) 4 Synthetic Detergent
Alpha Olefin Sulphonate 1 Synthetic Detergent
Decyl Glucoside 2 Synthetic Detergent
Lauryl Alcohol 3 Emollient
Glycerin 5 Humectant
Fragrance 1.4 Fragrance

Example 7: Colored Translucent baseTable 7:
Colored Translucent base - 50% Function
Soap Noodles 80:20 69.1499 Cleaning Agent
Glycerin 8 Humectant
Free Fatty Acids 3 Imparts an oily feeling on skin
Water 12 Aqua
SLES 3 Synthetic Detergent
PEG-400 / Propylene Glycol 1 Skin Conditioner
Color 0.0001 Color
Alpha Olefin Sulphonate 2.5 Synthetic Detergent
Mica 0.05 Filler and for aesthetics
Fragrance 1.3 Fragrance


Example 8: Formulation 1: Opaque Base 50% and Translucent base 50%
Table 8:
Opaque base (50%)
Soap Noodles 80:20 78 - 95
Filler e.g. Talc 0.9 - 4
Opacifier e.g. Titanium Dioxide 0.36-0.44
Conditioner PEG 75 lanolin 0.011-0.014
Anti bacterial – TCC 0.011-0.014
Conditioner - Wacker Silicon 0.011-0.03
Conditioner - Caesin 0.004-0.007
Humectant - Sodium PCA 0.45-0.7
Surfactant - SLES (70%) 2.7-5
Surfactant - - AOS Powder (95%) 0.5-2.2
Surfactant - - Decyl Glucoside 0.9-3
Fatty alcohol - Lauryl Alcohol (C1214) 0.9-4
Humectant - Glycerin CP 2.7-6
Fragrance 1.17-1.5


Translucent base - (50%)
Soap noodles 80/20 63-77
Glycerine 7.2-9.5
Water 10.8-13.5
Free fatty Acids 2.7-4.5
SLES 1.35-2.5
Color1 0.00009-0.00011
AOS 3.15-4.5
Fragrance 1.35-1.65

Process:
a) Mixing the raw materials of Translucent base together in appropriate order in an amalgamator to form a mixture;
b) Milling the sufficiently mixed mixture of step a to obtain milled material;
c) Plodding the milled material of step b to form a translucent soap base formulation.
d) Mixing the raw materials of opaque base together in appropriate order in an amalgamator to form a mixture;
e) Milling the sufficiently mixed mixture of step d to obtain milled material;
f) Plodding the milled material of step e to form an opaque soap base formulation.
g) connecting co-extrusion attachment to the cone of i) at least one dual vacuum plodder (DVP1) and ii) at least one secondary duplex plodder (DVP2); while maintaining the temperature of the plodders from about 45 ºC;
h) Placing translucent soap base of step c in to DVP1 and operating the DVP1 at a predetermined extrusion rate while maintaining the pressure of the co-extrusion cone from about 20 bar;
i) Placing the opaque soap base formulation of step f in to DVP2 and operating the DVP2 at a predetermined extrusion rate; to obtain a coextruded soap mass comprising transparent and opaque soap bases.
wherein the extrusion rates of DVP and DVP are maintained at a ratio of from about 50:50.
Example 9: Formulation 2: White base 50% and Colored base 50% - Stripped Product
Table 9:
White Base-50%
Soap Noodles 8020 85-98
Talc 1.8-5
Titanium Dioxide 0.09-0.5
PEG 0.02-0.05
Natural Extracts 0.001-0.02
TCC 0.011-0..2
Vitamin E Acetate 0.001-0.006
Caesin 0.002-0.008
Lauryl alcohol C1214 1.0-3.5
Silicone 0.01-.04
Glycerin 0.8-2.0

Color noodles-50%
Soap Noodles 8020 85-98
Talc 1.8-5
Titanium Dioxide 0.09-0..5
Color 0.01-0.07
PEG 0.122-0.014
Natural Extracts 0.001-0.02
TCC 0.011-0..2
Vitamin E Acetate 0.001-0.006
Milk Cream 0.002-0.006
Lauryl alcohol C1214 0.45-0.55
Fragrance 1.1-1.8

Example 10: The co-extrusion process with the use of the apparatus
a) connecting co-extrusion attachment to the cone of i) at least one plodder (P1) and ii) at least one plodder (P2); while maintaining the temperature of the plodders from about 30 ºC to about 60 ºC;
b) adding the first soap base formulation in P1 and operating the same at a predetermined extrusion rate while maintaining the pressure of the co-extrusion cone from about 10 to about 30 bar;
c) adding the second soap base formulation into P2 and operating the same at a predetermined extrusion rate; to obtain a coextruded soap mass.
wherein the first soap base formulation and the second soap base formulation are different and wherein the extrusion rates of P1 and P2 are maintained at a ratio of from about 45:50 to about 50:50.

The coextruded soap mass is then cut and stamped to obtain coextruded soap bars.
Example 11: Process for the co-extrusion of at least two formulations
1. Mixing the raw materials of table 4 together in appropriate order in an amalgamator to form a mixture;
2. Milling the sufficiently mixed mixture of step 2 to obtain milled material;
3. Plodding the milled material of step 3 to form an opaque soap base formulation.
4. Mixing the raw materials of table 5 together in appropriate order in an amalgamator to form a mixture;
5. Milling the sufficiently mixed mixture of step 4 to obtain milled material;
6. Plodding the milled material of step 5 to form an opaque soap base formulation.
7. Connecting co-extrusion attachment to the cone of at least one dual vacuum plodder (DVP1) and at least one dual vacuum plodder (DVP2) while maintaining the temperature of the plodders from about 50 ºC to about 60 ºC;
8. Adding the opaque soap base formulation of step 3 in to DVP1 and operating the DVP1 at a predetermined extrusion rate while maintaining the pressure of the co-extrusion cone at about 30bar;
9. Adding the opaque soap base formulation of step 6 in to DVP2 and operating the system at a cumulative extrusion rate of about 50:50DVP1:DVP2; to obtain a coextruded soap mass comprising striped opaque soap bases.
10. Cutting the coextruded soap mass of step 9 into bars and stamped to the desired shape.

Example 12

The multicoloured soap bar of present invention is present in a ratio of 50:50 as shown by way of figure 6a. Figure 6b shows a comparative ratio of 70:30 (white: colour) where the colour stripes become irregular and thinner which is not acceptable according to the present invention.
,CLAIMS:1. A co-extrusion process for production of soap bar with at least two formulation comprising the steps of:
a. connecting co-extrusion attachment to the cone of at least one plodder (P1) and plodder (P2);
b. adding first soap base formulation in said plodder P1 and adding second soap base formulation in said plodder P2;
c. operating said plodder P1 and said plodder P2 at a predetermined extrusion rate;
wherein said first soap base formulation and second soap base formulation are different and said extrusion rates of plodder P1 and plodder P2 are maintained at a ratio ranges from 45:50 to 50:50.
2. The co-extrusion process for production of soap bar as claimed in claim 1, wherein said plodder P1 and said plodder P2 is dual vacuum plodder.
3. The co-extrusion process for production of soap bar as claimed in claim1, wherein temperature of said plodder is maintained at a range of 30oC to 60oC.
4. The co-extrusion process for production of soap bar as claimed in claim1, wherein pressure of said co-extrusion cone is maintained at a range from 10 bar to 30 bar.
5. The co-extrusion process for production of soap bar as claimed in claim1, wherein said extrusion rate is 1TPH to 2TPH.
6. The co-extrusion process for production of soap bar as claimed in claim1, wherein said formulation is an incompatible formulation.
7. The co-extrusion process for production of soap bar as claimed in claim 6, wherein said incompatible formulation comprises at least a translucent formulation and at least an opaque formulation.
8. The co-extrusion process for production of soap bar as claimed in claim1, wherein said formulation is a compatible formulation.
9. The co-extrusion process for production of soap bar as claimed in claim 8, wherein said compatible formulation comprises of at least two opaque formulations or at least two translucent formulations.
10. A multi component soap bar prepared by co-extrusion process of claim 1.