DESC:Field of invention
The present invention relates to re-use of soap composition as is or its diminished part during the end of the soap used. More particularly, the present invention relates to syndet bar composition, which user can easily melt at low temperature using microwave or like within very less time to re-use remaining syndet at any point of time and achieve various shapes or size based on their requirements.
Background and prior art of the invention
Conventional syndet bar, combi bar or soaps get used up after some washes and remaining will be a thin piece which cannot be used further as it breaks off and does not form well.
Bars, which gradually become smaller and lose their formability along with use, are switched to new ones before being completely used, resulting in wastage of soap.
US7737096 relates to a toilet bar, including but not limited to the following:
a) 0 to about 30% by wt. of a fatty acid soap; and
b) about 15 to 75% wt. of a blend of C8-C18 diacyl and monoacyl isethionates; wherein the ratio of the diacyl to monoacyl is in the range of about 1:100 to 1:1.
The present invention helps in reducing wastage of soap without any external device or object like wood, plastic etc and does not require any special design in soap shape or form (e.g. hollow surface, cavities, and insertions etc). The present invention provides a “Syndet formulation” which user can easily melts at low temperature (compare to melting point of any other conventional soap) using microwave or like within very less time (30 sec-5mins) to re-use remaining syndet at any point of time and achieve various shapes or size based on their like.
Objects of the invention
It is an object of the present invention to overcome the drawbacks of the prior art.
It is another object of the present invention to provide a reusable syndet bar composition for eliminating wastage of soap without any external device or object like wood, plastic.
It is yet another object of the present invention that it does not require any special design on soap like hollow surface, cavities and insertions.
Summary of the present invention

An aspect of the present invention provides a re-useable syndet soap composition comprising

a. solid component;
b. liquid component;
c. emulsifiers; and
d. cosmetically acceptable components;

wherein the ratio of solid and liquid components ranges from 4:1 to 10:1.

Another aspect of the present invention is to provide a kit for recast of the re-melt syndet bar comprising:
a) crude syndet bar of the present invention;
b) mould;
c) optionally one or many fragrances;
d) optionally one or many emotive(in liquid form);
e) optionally one or many colorants; and
f) manual detailing the procedure to recast the re-melt syndet bar;

such that kit is employed to make customized soap in-house.

Detailed description of the present invention
The present invention relates to syndet bar composition that enables reuse of soap and can be repeatedly used without being wasted so as to solve the following problems associated with conventional opaque soap/ syndet bars.
This invention helps in reducing wastage of soap without any external device or object like wood, plastic etc and does not required any special design in soap shape or form (hollow surface, cavities, and insertions etc).
This invention provides a “Syndet formulation” which user can easily melts at low temperature (compare to melting point of any other conventional soap) using microwave or like within very less time (30 sec -5mins) to re-use remaining syndet at any point of time and achieve various shapes or size based on their requirements.
The present invention provides a syndet bar composition comprising
· Solid: Liquid in a ratio of (4:1) to (10:1), preferable (6:1) to (7:1)
· Emulsifiers in the range of 1-9%

The syndet bar composition of the present invention comprises of:
Surfactant in the concentration range of 35-55%w/w and most preferably in the range of 38-45 %w/w;
1. Added Free fatty acid in the concentration range of 3-8%w/w and most preferably in the range of 4-6%w/w;
2. Emulsifiers in the concentration range of 1-9%w/w and most preferably in the range of 3-5%w/w;
3. Polymers in the concentration range of 1-5%w/w and most preferably in the range of 2-3%w/w;
4. Soap in the concentration range of 5-18%w/w and most preferably in the range of 10-15%w/w;
5. Binders in the concentration range of 0.5-4 %w/w and most preferably in the range of 2-3 %w/w;
6. Oil in the concentration range of 0.3-3.0%w/w and most preferably in the range of 0.5-2%w/w;
7. Emollient in the concentration range of 0.5-4%w/w and most preferably in the range of 0.5-2%w/w and
8. Wax in the concentration range of 8-20 %w/w and most preferably in the range of 11-16%w/w.

According to the present invention, preferred solid components include fatty acids, surfactants (based on commercially available physical form of surfactant), polymers, emulsifiers, soap, minerals and wax.

Preferred liquid components include surfactants (based on commercially available physical form of surfactant), oil, polymers and aqua.

The synthetic surfactants used in the present invention may be selected from a group comprising anionic surfactants, amphoteric surfactants, nonionic surfactants, and any 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 alkyl sulfates, anionic acyl sarcosinates, anionic alkyl 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.
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 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 betaine, 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 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, ceteareth6, steareth-6, PEG-12 stearate, and PEG-200 glyceryl tallowate), Maltooligosyl Glucoside/Hydrogenated Starch Hydrolysate and mixtures thereof. Preferred sugar based surfactants include Maltooligosyl Glucoside/Hydrogenated Starch Hydrolysate and Alkyl polyglucoside. Surfactant that are used in the soap bar compositions of the present invention may be present in an amount from approximately from 35-55%w/w and most preferably in the range of 38-45 %w/w.
The “free fatty acids” as used herein are selected from 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, Lauric, Myristic, Palmitic, Stearic, Oleic, etc and mixtures thereof. The free fatty acids that are used in the soap bar compositions of the present invention may be present in an amount from approximately from 3-8%w/w and most preferably in the range of 4-6%w/w.

Emulsifiers of the present invention can be selected from the list of sodium lauryl ether sulfate (1EO, 2EO, 3EO), Cocomonoethanolamide (CMEA), Cocamidopropyl betaine (CAPB), Alpha Olefin Sulfonate (AOS), decyl glucoside (DG) and the like. Preferred emulsifier is selected from sodium lauryl ether sulfate 1EO, CMEA or CAPB. Emulsifiers that are used in the soap bar compositions of the present invention may be present in an amount from approximately from 1-9%w/w and most preferably in the range of 3-5%w/w.

According to the present invention polymers are starches such as corn starch, silicone polymers; water soluble polymers such as polyurethanes, polyacrylates, polyalkylene glycol with molecular weight between 200 and 20,000, preferably between 400 and 10,000 such as PEG 200, PEG 400, PEG600, PEG 1500, PEG 4000, PEG 6000, PEG 8000 and the like; anionic, zwitterionic, amphoteric and nonionic polymers that can be used are, for example, vinylacetate/crotonic acid-copolymers, vinylpyrrolidone/vinylacrylate-copolymers, vinylacetate/butylmaleate/ isobornylacrylate-copolymers, methylvinylether/maleic acid anhydride-copolymers and their esters, which are not cross-linked and with polyoles linked polyacrylacids which are cross-linked, acrylamidopropyltrimethylammonium chloride/ acrylate-copolymers, octylacrylamide/ methylmethacrylate/tert. Butylaminoethy lmethacrylate/ 2-hydroxypropylmethacrylate -copolymers, polyvinylpyrrolidone, vinylpyrrolidone/vinylacetate-copolymers, vinylpyrrolidone/ dimethy laminoethylmethacrylate/ vinyl caprolactam-terpolymers as well as optionally derivatized cellulose ethers and silicones. Polymers that are used in the soap bar compositions of the present invention may be present in an amount from approximately from 1-5%w/w and most preferably in the range of 2-3%w/w;

Binders according to the present invention include high molecular weight poly acrylates, high molecular weight poly-ox, silicates, fatty alcohols, lanolin, sugars, tallow alcohol ethoxylates, and mixtures thereof. Other plastic binders are identified in the published literature (J. Amer. Oil Chem. Soc. 1982, 59, 442). Binders that are used in the soap bar compositions of the present invention may be present in an amount from approximately from 0.5-4 %w/w and most preferably in the range of 2-3%w/w;
Emollients are substance 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. 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; polyols such as glycerol, sorbitol; 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); higher alcohols such as lauryl, cetyl, stearyl, oleyl, behenyl, cholesterol and 2-hexydecanol alcohol; 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; and mixtures of any of the foregoing components, and the like. Emollient that are used in the soap bar compositions of the present invention may be present in an amount from approximately from 0.5-4%w/w and most preferably in the range of 0.5-2%w/w.
Preferred wax is selected from hydrocarbon wax like paraffin wax. Wax that are used in the soap bar compositions of the present invention may be present in an amount from approximately from 8-20 %w/w and most preferably in the range of 11-16%w/w.
Preferred soap is selected from 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 such as sodium palmate, sodium palm kernelate and sodium cocoate. Soap that are used in the soap bar compositions of the present invention may be present in an amount from approximately from 5-18%w/w and most preferably in the range of 10-15%w/w
Preferred oil is selected from propylene glycol, glycerin, sorbitol, paraffin oil and the preferred oil is glycerin. Oil that are used in the soap bar compositions of the present invention may be present in an amount from approximately from 0.3-3.0%w/w and most preferably in the range of 0.5-2%w/w.
Above combination provides a bar which can be re-melted and reused by users themselves with no difficulties.
Due to formulations unique flow properties, bar can be casted into any shape using silicone/plastic/glass/metal etc moulds.
Components of the bar composition is designed in such a way that it contains high liquid content but still can be processed through bar format, this unique feature is helping the syndet bar to melt completely (below 90°C, preferably at 75-90°C) without any other aids. The component combination as such does not exhibit any synergy the essential feature of present invention lies in the unique ratio of solid and liquid.
Ratio of solid: liquid in present invention is higher compare to conventional soaps. Liquid components are present in higher amount when compared to conventional soap and not solid component.
The liquid solvent can be achieved at a higher amount by using soluble organic structurant in the higher amount i.e. =3%w/w.
The present invention further provides a kit for recast of the re-melt syndet bar that can be used repeatedly in-home in order to prepare soap by melting and molding it so as to make customized soap. The kit can also be used in order to re-use the leftover pieces of soap. The kit comprises:
1. Crude syndet bar of the present invention;
2. Mould; and
3. manual detailing the standard operating procedure to recast the re-melt syndet bar;
wherein, the kit can be employed to make customized soap in-house.

According to another embodiment of the present invention, there is provided a kit for recast of the re-melt syndet bar comprising:
1. Crude syndet bar of the present invention;
2. Mould;
3. Optionally one or many fragrances;
4. Optionally one or many emotive(in liquid form);
5. Optionally one or many colorants; and
6. Manual detailing the procedure to recast the re-melt syndet bar;
wherein, the kit can be employed to make customized soap in-house.

The present invention further provides a method for making soaps having various shapes, colors, fragrance and benefits using the kit.
Non limiting example of mould that can be used in present invention:
Mould comprises an upper portion and upper plate and a sidewall extending downward from the entire edge of the upper plate, wherein, the upper plate has a plurality of mould cavities of different shapes opened upward.
Process for using the kit to make customized soaps:
Step 1: Melting the crude syndet bar by heating in general or in microwave.
Step 2: Mixing the melted syndet with the desired set of fragrances, colorants and emotive.
Step 3: Pouring the melted syndet mixture in the mould cavity provided above the upper portion of kit.
Step 4: Allowing the syndet to cool and solidifying and then taking out the newly formed soap.
Process for using the left over portion of soaps:
Step 1: Melting the left over pieces of syndet by heating in general or in microwave.
Step 2: Pouring the melted syndet in the mould cavity provided above the upper portion of kit.
Step 3: Allowing the syndet to cool and solidifying and then taking out the newly formed soap.
The present invention is described by way of non-limiting illustrative examples.
Example 1
6 wt% of fatty acids, 3 wt% of polymer, 13 wt% of waxes, 1.5 wt% of oil, 4 wt% emulsifier are mixed in a mixer at a temperature of 65-75°C. After mixing the components for a time period of 20-30 minutes, 13 wt% of soap is added to the said mixture at a temperature of 85-90°C. Thereafter to the said mixture, 1.5 wt% of pH regulator is added followed by surfactants and the temperature of maintained between 90-95°C. Once soap and surfactants are mixed completely, other additives such as TiO2, EDTA, fragrance, binders, emollients and mineral are added at a high mixing speed followed by homogenization. The final mass is maintained at a temperature of 85-90°C to achieve pouring consistency in mixer. The mass is then poured into moulds to yield the desired shape.
Example 1 (Working)
Table 1
S.No. Ingredient Exact Wt / wt %
1 Surfactant 42
2 Free Fatty Acid/ plasticizer 5
3 Emulsifiers 3
4 Polymer 3.5
5 Soap 13
6 Binders 2
7 Oil 1.0
8 Emollient 1.5
9 Preservatives 0.2
10 Color / Fragrance / Emotive 1.2
11 pH Regulator 1.5
12 Wax 15
13 Minerals 3
14 Structurant 8

The ratio of solid and liquid component of the above composition is 4:1

Example 2 (non-working example)
Table 2
S.No. Ingredient Exact Wt / wt %
1 Surfactant 70.0
2 Free Fatty Acid/ plasticizer 5.0
3 Emulsifiers 0.1
4 Polymer 0.2
5 Soap 3.0
6 Binders 12.0
7 Oil 0.1
8 Emollient 1.0
9 Preservatives 0.01
10 Color / Fragrance / Emotive 0.1
11 pH Regulator 1.0
12 Wax 5.0
13 Minerals 1.0
14 Structurant 3.6

The ratio of solid and liquid component of the above composition is 13.7:1.

Example 3 (non-working example)
Table 3

S.No. Ingredient Exact Wt / wt %
1 Surfactant 3.0
2 Free Fatty Acid/ plasticizer 2.5
3 Emulsifiers 4.0
4 Polymer 4.0
5 Soap 65
6 Binders 5.0
7 Oil 1.0
8 Emollient 0.7
9 Preservatives 0.3
10 Color / Fragrance / Emotive 1.0
11 pH Regulator 1.0
12 Wax 2.5
13 Minerals 10
14 Structurant 0

The ratio of solid and liquid component of the above composition is 19:1.

Table 4: Comparative data for demonstrating the criticality of the specific ratio of solid: liquid solvent

Table 4
Direct Re-Melting
Parameters Example 1(Working) Example-2(Non-working) Example-3(Non-working)
Solid : Liquid ratio 4:1 13.7:1 19:1
Bar Format Solid Bar Very Soft bar Solid Bar
Bar Hardness (PV in mm) 2-4 18-25 3-5
Flow property (post melting) Smooth, freely flow able Flow able Thick, Non-Flow able
Surface finish Smooth and even Smooth and even Uneven
Solidification Time @ RT in 0C for 100gm mass 1-2hrs overnight 1-2hrs
Foam Amount (in ml) 250-300ml 100-150ml 200-265ml

From table 4 it is demonstrated that the desired re-usable bar is not achieved outside the specific ratio of solid: liquid solvent of the present invention.
Table 5: Comparison between the results obtained post using web/internet stated method with the present invention.
Parameters Present Invention (example-1)(direct melting) Prior art method (blending with extra water (soap:water) (40:60) Formulation-A Prior art method (blending with extra water (soap:water) (80:20) Formulation-A’
Melting time for 100gm bar (secs) 30-40 60-80 60-120
Bar surface after casting Very smooth and shiny smooth Uneven
Bar Format Hard bar Very Soft Bar Very Brittle Bar
Bar Hardness (PV in mm) 2-4 20-25 8-10
Solidification Time @ RT in 0C for 100gm mass 1-2hrs 10-12hrs still very soft 4-5hrs
Mush (gm/50cm2) 2-4 8-11 9-12

Accordingly, the present invention does not use water for blending the soap bar unlike the prior arts and the desired re-usable bar is achieved with improved properties.
Example 6: process of using the kit of the present invention

Step 1: Melting the crude syndet bar by heating in general or in microwave.
Step 2: Mixing the melted syndet with the desired set of fragrances, colorants and emotive.
Step 3: Pouring the melted syndet mixture in the mould cavity provided above the upper portion of kit.
Step 4: Allowing the syndet to cool and solidifying and then taking out the newly formed soap.
Example 7: Process for using the left over portion of soaps
Step 1: Melting the left over pieces of syndet by heating in general or in microwave.
Step 2: Pouring the melted syndet in the mould cavity provided above the upper portion of kit.
Step 3: Allowing the syndet to cool and solidifying and then taking out the newly formed
,CLAIMS:1. A re-useable syndet soap bar composition comprising

a. solid component;
b. liquid component; and
c. emulsifiers;

wherein the ratio of solid and liquid components ranges from 4:1 to 10:1.

2. The soap composition as claimed in claim 1, wherein the ratio of solid and liquid components preferably ranges from 6:1 to 7:1.

3. The soap composition as claimed in claim 1, wherein solid components are chosen from a group comprising fatty acids, surfactants, polymers, emulsifiers, soap, minerals and wax.

4. The soap composition as claimed in claim 1, wherein liquid components are chosen from a group comprising surfactants, oil, polymers and aqua.

5. The soap composition as claimed in claim 1, wherein said emulsifiers range from 1 to 9 %wt.

6. The soap composition as claimed in claim 1, wherein said soap composition melts below 90°C, preferably at 75-90°C.

7. A kit for recast of the re-melt syndet bar comprising:
a. crude syndet bar of the present invention;
b. mould;
c. optionally one or many fragrances;
d. optionally one or many emotive(in liquid form);
e. optionally one or many colorants; and
f. manual detailing the procedure to recast the re-melt syndet bar;

such that said kit is employed to make customized soap in-house.

8. A process for using said kit as claimed in claim 7 to make re-useable syndet soaps comprising steps of
a) melting the crude syndet bar by heating;
b) mixing the melted syndet soap bar with the desired set of fragrances, colorants and emotive (optionally);
c) pouring the melted syndet soap bar mixture in the mould cavity provided above the upper portion of kit; and
d) allowing the syndet soap bar to cool and solidifying and then taking out the newly formed soap.