CA2277139C - Alkaline detergent containing mixed organic and inorganic sequestrants resulting in improved soil removal - Google Patents

Abstract

Detergents, especially solid block alkaline detergent compositions, are disclosed comprising a source of alkalinity, and other detergent additives including sequestrants. The detergents of the invention use a mixed condensed phosphate and organic phosphonate sequestrant composition that sucessfully softens service water used in manufacturing aqueous detergents from the composition, but also obtains substantially improved organic soil removal on dishware or flatware. The solid block detergents of the invention comprises large masses of the chemical ingredients having a weight of greater than about 500 grams in a solid block product format that is typically dispensed using a spray on water dispenser that creates an aqueous concentrate that is used in a washing machine.

Description

1.
ALKALINE DETERGENT CONTAINING MIXED
ORGANIC AND INORGANIC ~SEQUES'rRnN'rS RESULTING
IN IMPROVED SOIL REMOVAL

FIELD OF THE INVENTION

The invention relates to alkaline laundry or warewashing detergents. More particularly the invention relates to detergents in the form of a powder, liquid, pellet, solid block detergent:, etc. composition containing a source of alkalinity and a variety of other detergent additive materials.. The ingredients used in making the detergent cooperate to provide a variety of useful functions in the aqueous cleaning medium made from the improved detergent.

BACKGROUND OF THE INVENTION

Alkaline cleaning mater:Lals have been the source of intensive research and development for many years. Such products take the form of aqueous liquids, powders, pellets and solid blocks. In a number of markets such as warewashing and laundry, where safety and efficiency are paramount, solid block detergents have become a detergent of choice. Solid block compositions offer unique advantages over conveiitional detergents including improved handling and safety, elimination of component segregation during transportation and storage and increased concentration of active components within the composition. Further, the materials can be made in a hydrated form which produces less heat of hydration when dispensed. The materials disclosed in Fernholz, U.S.
Reissue Patent Nos. 32,763 and 32,818 quickly replaced

2 conventional powder and liquid forms of detergents in a number of industrial and institutional markets.

The detergents are typically used by dispensing the detergent with a water spray-on dispenser. In the dispenser, the detergent is combined with a major proportion of water producing a detergent concentrate solution that is added to wash water in a washing machine to form a wash solution. The wash solution, when contacted with a soiled article, successfully removes the soil from the article. Such detergency (soil removal) is most commonly obtained from a source of alkalinity used in manufacturing the detergent.
Sources of alkalinity can include alkali metal hydroxides, alkali metal silicates, alkali metal carbonates and other typically inorganic based materials. Additional detergency can be obtained from the use of surfactant materials. Typically, anionic or nonionic surfactants are formulated into such detergents with other ingredients to obtain compositions that can be used to form cleaning solutions having substantial soil removal while controlling foam action. A number of optional detergent ingredients can enhance soil removal, but primarily soil removal is obtained from the alkalinity source and the anionic or nonionic surfactant.

One typical ingredient used in manufacturing cast solid detergents includes a hardness ion sequestering composition. Such compositions are used to soften water by sequestering typically divalent and trivalent metal ions that are commonly found in varying type and compositions of water drawn from local water utilities.

3 Depending on geographical location, service water can contain substantial quantities of ferrous, ferric, manganese, magnesium, calciuni and other divalent or trivalent inorganic species that can be present in hard water. Most locales have differing types and concentration of such inorganic species in the water.
Typically greater than about 150 ppm of hardness ions determined as calcium is considered hard water in most locales. Most hardness sequestering agents act to complex such hardness ions using multivalent anionic inorganic and organic species. The most common inor_aq nic sequestering agent, in these applications, comprises a condensed phosphate hardness sequestering agent such as tripolyphosphate, hexametaphosphate, pyrophosphate and other such phosphate materials.
Similarly, more expensive orafanic sequestering agents are also known but are not preferred. Organic sequestering agents such as r.Litrilotriacetic acid, ethylene diamine tetraacetic acid, nitrilotriphosphonic acid, 1-(hydroxyethylidene)-1.,1-diphosphonic acid and others have been known for many years to be effective sequestrants for detergents used in aqueous systems.
One commonly available inorganic sequestrant, sodium tripolyphosphate is known to have protein peptizing capacity that tends to aid ir.i the suspension of protein in washing solutions used in warewashing. However, to date sequestering agents have: not been known to provide cleaning properties to deterclent compositions.

Jacobsen, U.S. Patent No. 4,105,573 discloses the use of a combination of an alkyl phosphonate, wherein the alkyl group contains 10-24 carbon atoms, with a

4 particular class of alcohol ethoxylates to exhibit soil releasing effect. The preferred material is an octadecane phosphonate. Leikhim et al., U.S. Patent No.
4,284,532 disclose an isotropic liquid using a phosphate ester or a "hydrophilic surfactant" such as sodium xylene sulfonate to couple with a builder and a surfactant in a cleaning composition. The cleaning composition can contain as a builder, DEQUEST-2010, 1-hydroxy-1,1-ethylidene diphosphonate or a similar phosphonate compound.

Baeck et al., U.S. Patent No. 5,019,292 teach a fabric softening clay in a laundry detergent. Ethylene diamine tetramethylene phosphonic acid is used as a builder in certain examples without other sequestrant compositions.

Krummel et al, U.S. Patent No. 3,985,669, Campbell et al., U.S. Patent No. 4,216,125; O'Brien et al., U.S.
Patent No. 4,268,406; Corkill et al., U.S. Patent No.
4,274,975; Ward et al., U.S. Patent No. 4,359,413;

Corkill et al., U.S. Patent No. 4,605,509; Lewis, U.S.
Patent No. 4,698,181; and Bruegge et al., U.S. Patent No. 5,061,392 teach that organic phosphonates can be successful co-builders that function by chelation of additional calcium and magnesium ions. Note that Lewis, U.S. Patent No. 4,698,181 teaches that the overall detergent composition is successful at removing organic soil stains such as food and beverage stains. Glogowski et al., U.S. Patent No. 4,983,315 teach a technology similar to that disclosed above and specifically teach that chelation agents can bind transition metals in soils to enhance cleaning performances.

G, Lastly, Bartolotia et al., U.S. Patent No.

4,000,080; Rose, U.S. Patent No. 4,072,621; Schwuger et al., U.S. Patent No. 4,148,6C)3; and Ferry, U.S. Patent No. 4,276,205 teach that certain combinations of builders (not a combination of a condensed phosphate and an organophosphonate) provide good results in a particular application. The prior art shown here does not suggest that improved soil release capacity can be obtained by combining a condensed phosphate sequestrant with an organophosphonate sequestrant.

In any highly competitive market, a substantial need exists in improving the properties of detergent systems. In improving such systems, the cleaning properties of the systems are examined for the purpose of obtaining sufficient cleariing of all types of soils including inorganic soils, food soils such as fats, carbohydrates and proteins arid organic soils obtained from the environment such as hydrocarbon oils, pigments, lipstick, etc. Such improved detergents can obtain adequate cleaning of a variety of soils at reduced concentrations.

BRIEF DISCUSSION OF THE INVENTION

We have discovered that, in the alkaline detergent compositions of the invention, a blend of an organic and an inorganic sequestering agent can substantially soften water and can substantially _Lmprove organic soil removal properties. More particularly, we have found that the combination of a source of alkalinity with a blend of a condensed phosphate sequestrant and an organic phosphonate sequestrant, wherein there is less than about 14.0%, preferably less than 8.7o total phosphorus (measured as P) in the composition and wherein there is at least about one part by weight of organic phosphonate sequestrant per each 100 parts by weight of the condensed phosphate sequestrant. Within these product ranges surprising and substantial organic soil removal is obtained with expected water softening.

We have found that the blend of the condensed phosphate sequestrant and the organic phosphonate sequestrant provides excellent water softening or water treatment of service water used in making the detergent concentrates of the invention, but also provide a substantially improved soil removal property for organic soils to the detergent. We have found that the source of alkalinity, a surfactant material and the mixed sequestrants cooperate to provide substantially improved soil removal when compared to similar detergents comprising a source of alkalinity, a surfactant and a single component sequestrant such as either sodium tripolyphosphate, an organophosphonate, or a polyacrylic material. Further, we have found that the detergents of this invention containing a blend of condensed phosphate and an organic phosphonate is superior to other sequestrant blends. The detergents of this invention including the condensed phosphate and the organic phosphonate is superior to a blend of, for example, sodium tripolyphosphate and a polyacrylic acid material.
We have found that there is some aspect of the blend of a condensed phosphate and an organic phosphonate particularly in hard water to remove soils such as lipstick, coffee stains, etc. that substantially improved soil removal is obtained. We believe that there is some interaction between calcium, magnesium ion or other di- or trivalent metal species with substantially organic food stains dried from soil, lipstick and other soil sources. The interaction between the organic soil and the inorganic divalent or trivalent ions tend to form a difficult to remove soil.
We believe that the combination of sequestrants improve the removability of the organic soil polyvalent metal blend.

We have found that the combination of a condensed phosphate sequestrant and an organophosphorus sequestrant provides the highest quality soil removal.
For the purpose of this invention, "condensed phosphate"

relates to an inorganic phosphate composition containing two or more phosphate species in a linear or cyclic polyphosphate form. The preferred condensed phosphate comprises sodium tripolyphosphate but can also include condensed phosphate such as pyrophosphate, hexametaphosphate, cyclic condensed phosphates and other similar species well known to the artisan in detergent chemistry.

The term "organic phosph.onate" includes a phosphonic acid, diphosphonic acid, triphosphonic acid, etc. compound or its alkali rrietal salts thereof. Such phosphonic acids are typically formulated having an organic compound or backbone having one or more pendent phosphonate groups.

Typically, phosphonate groups are pendent off of nitrogen or carbon atoms in the core compound or polymer backbone. Such a phosphonate group typically has the formula:

- P - OH
I
OH
Such a group is characteristic of organophosphonic acid (phosphonate) compositions. Such organophosphonates include compounds such as aminotris(methylene phosphonic acid), 1-hydroxy-(ethylidene)-l,l-diphosphonic acid, 2-phosphonobutane-1,2,4-tricarboxylic acid, ethylene diamine tetra(methylene phosphonic acid), diethylene triamine penta(methylene phosphonic acid), ethanehydroxy-1,1,2-triphosphonates which can be hydroxy substituted where desired, oligomeric ester chain condensates of ethane-l-hydroxy-l,l-diphosphonates and other well known organic phosphonate species and their alkali metal salts thereof.

BRIEF DISCUSSION OF THE DRAWING

The figure is an isometric drawing of the preferred wrapped solid detergent.

DETAILED DISCUSSION OF THE INVENTION

Active Ingredients An alkaline detergent composition can include a source of alkalinity and minor but effective amounts of other ingredients such as a chelating agent/sequestrant blend, a bleaching agent such. as sodium hypochlorite or hydrogen peroxide, an enzyme such as a protease or an amylase, and the like.

Alkaline Sources The cleaning composition. produced according to the invention may include minor but effective amounts of one or more alkaline sources to enhance cleaning of a substrate and improve soil removal performance of the composition. The alkaline matrix has a tenancy to solidify due to a change in state relating to work done by the manufacturing equipment or due to the activity of an alkaline source in fixing the free water present in a composition as water of hydration. Premature hardening of the composition may interfere with mixing of the active ingredients to form a homogeneous mixture, and/or with casting or extrusion of the processed composition.
Accordingly, an alkali metal hydroxide or an alkali metal carbonate or other alkaline source is preferably included as a primary alkaline source in the cleaning composition in an amount effective to provide the desired level of cleaning action yet avoid premature solidification of the composition by the reaction of the caustic material with the other ingredients. However, it can be appreciated that an. alkali metal hydroxide or other hydratable alkaline source can assist to a limited extent, in solidification of the composition. It is preferred that the composition comprises about 0.1-70 wt-%, preferably about 10-60 wt-% of an alkaline source, most preferably about 20-55 wt-%. The cleaning capacity can be augmented with a second source of alkalinity. These percentages and others in the ' ERCHANT&GOULU NA u y 0o'TU7 M

specification and claime are based on the actual active ma:.erials used. These composi':ion materials are added as aqueous or other materials with an active content of ~ (e.g.) 10% to 100~; of the material.
For the purpose of this a-pplicatior., th e alkalinity source can comprise a carbonate base eource of alitalinity. Such an alkalinity eource can comprise an alkali metal carbonate augmented by other caustic or i0 basic materials. Typi.cal. carbonatee include sodi::m carbcnate (NazCO3) , potassium carbonate (K2CO 3; or other typycal carbonate sources. Such carbonates can contain as an impurity some prcportion of bicarbonate (HC03').
Such a carbonate source of alkalinity can be augmented using a variety of other inorganic sources of alkalinity or inorganic bases.
St:~.:abl.e alkali metal hydroxides include, for example, sodium or potassium hydroxide. An alkali metal hydroxide may be added to the composition ::n the form cf 2C eolid beads, dissolved in an aqueous sclutior., cr a co-mbination thereof. Alkali metal hydroxides are ccmmercially available as a sclid in the form of pri:.ied beads having a mix of particye, or as an aqueous solution, as for example, as a 50 wt-% and a 73 wt-%-25 eclution. The cleaning compoE3ition may comprise an alkal-ine source other than an alkali mptal hydroxide.
Examples of ueeful alkaline sources include a metal silicate such as a sodium or a potassium silicate (with aM,ZO : SiOz ratio of 1: 3. 5 to 5: 1, M representing ar.
3C alkali metal) or metasilicate, a metal borate such as scdwum or potassium borate, a..:d the like; ethar,oiamines a:.d amines ; and AMENDED SHEET
IPE.A,/ EP

1:1 other like alkaline sources. Secondary alkalinity agents are commonly available in either aqueous or powdered form, either of which is useful in formulating the present cleaning compositions. The composition may include a secondary alkaline source in an amount of about 0.1 to 4 wt-%. Greater amounts can interfere with successful casting and can reduce product dimensional stability.

Cleanincl Agents The composition can comprises at least one cleaning agent which is preferably a surfactant or surfactant system. A variety of surfactants can be used in a cleaning composition, including anionic, cationic, nonionic and zwitterionic sui-factants, which are commercially available from a number of sources. For a discussion of surfactants, see Kirk-Othmer, Encyclopedia of Chemical Technology, Third Edition, volume 8, pages 900-912. Preferably, the cleaning composition comprises an anionic or a nonionic cleaning agent in an amount effective to provide a desired level of cleaning, preferably about 0-20 wt-%, more preferably about 1.5-15 wt-o.

Anionic surfactants useful in the present cleaning compositions, include, for example, carboxylates such as alkylcarboxylates and polyalkoxycarboxylates, alcohol ethoxylate carboxylates, nonylphenol ethoxylate carboxylates, and the like; sulfonates such as alkylsulfonates, alkylbenzenesulfonates, alkylarylsulfonates, sulfonated fatty acid esters, and the like; sulfates such as sulfated alcohols, sulfated "'v ihT&v ' ' CA 02277139 1999~07-07"

~
awcohol ethoxylates, sulfated alkylpheno:.s, a':.kvlsulfates, sulfosuccinates, ai.kyle~her sulfates, and t.-e like; and phosphate esters such as alkylphosphate ~ esters, and the like. Preferred ar.io nics are sodium, a1ky:~aryl9ulfonate, aipha-olefinsulfonate, and fatty alcc:.cl sulfates.
No nionic surfacta.~.ts useful in c::ear.in a ccmpositions, include those having a polyalkylene oxide 1C nolymer as a portion of the surfactant molecule. Such :.crion :.c surfactants include, for exa:r,ple, chlorine-, be::zyl-, methyl-, ethyl-, propyl-, butyl- and ot::er like alky:.-capped polyethylene glycol et::ers of fatty alcohols; polyalkylene oxide free r.onionics suc: as :.5 alkyl polyglycoeides; sorbitan and sucrose esters and their ethoxylates; alkoxylated ethy'-ene diamine; alcohol alicoxylatee euch as alcohol ethoxylate propoxylates, alcohol propoxylates, alcohol propoxylate ethoxylate propoxylates, alcohol ethoxylate butoxylates, and the 20 like; nor.ylphenol ethoxylate, polyoxyethylene glycol ethers and the like; carboxylic: acid esters such as glycerol esters, polyoxyethyiene esters, ethoxylated and glycol esters of fatty acids, and the like; carboxylic amides such as diethanclamine condensates, 25 monoalkanolamine condensates, polyoxyethylene fatty acid amidee, and the like; and polyalkylene oxide block ccpolymers including an ethylene cxide/propylene oxide block copolymer such as those commercially available under the trademark PLURONICTA (nASr-Wyandot:.e) , and t: e 30 like; and other like nonionic compounds. Silicone surfactants compri.sing a hydroQhciaic silicone group and a hydrophilic group such a6 ABIL'rM B8852 ca n also be used.

AMENDED SHEET
iP EA.lEP

1:3 Cationic surfactants useful for inclusion in a cleaning composition for sanitizing or fabric softening, include amines such as primary, secondary and tertiary monoamines with C18 alkyl or alkenyl chains, ethoxylated alkylamines, alkoxylates of ethylenediamine, imidazoles such as a l-(2-hydroxyethyl)--2-imidazoline, a 2-alkyl-l-(2-hydroxyethyl)-2-imidazolirie, and the like; and quaternary ammonium salts, as for example, alkylquaternary ammonium chloride surfactants such as n-alkyl (C12-C1a) dimethylbenzyl ammonium chloride, n-tetradecyldimethylbenzylamnnonium chloride monohydrate, a naphthylene-substituted quaternary ammonium chloride such as dimethyl-l-naphthylmethylammonium chloride, and the like; and other like cationic surfactants.

Detergent compositions raade according to the invention may further include conventional additives such as a water softening agent, apart from the claimed sequestrant blend, a bleaching agent, alkaline source, secondary hardening agent or solubility modifier, detergent filler, defoamer, anti-redeposition agent, a threshold agent or system, aesthetic enhancing agent (i.e., dye, perfume), and the like. Adjuvants and other additive ingredients will vary according to the type of composition being manufactured. The composition may include a chelating/sequestering agent such as an aminocarboxylic acid, a condensed phosphate, a phosphonate, a polyacrylate, and the like. In general, a chelating agent is a molecule capable of coordinating (i.e., binding) the metal ions commonly found in natural water to prevent the metal ions from interfering with the action of the other detersive ingredients of a cleaning composition. The chelating/sequestering agent may also function as a threshold agent when included in an effective amount. Preferably, a cleaning composition includes about 0.1-70 wt-%, preferably from about

5-60 wt-%, of a chelating/sequestering agent.

Useful aminocarboxylic acids include, for example, n-hydroxyethyliminodiacetic acid, nitrilotriacetic acid (NTA), ethylenediaminetetraacetic acid (EDTA), N-hydroxyethyl-ethylenediaminetriacetic acid (HEDTA), diethylenetriaminepentaacetic acid (DTPA), and the like.
Examples of condensed phosphates useful in the present composition include sodium and potassium orthophosphate, sodium and potassium pyrophosphate, sodium tripolyphosphate, sodium hexametaphosphate, and the like.
A condensed phosphate may also assist, to a limited extent, in solidification of the composition by fixing the free water present in the composition as water of hydration.

The composition may include a phosphonate such as i-hydroxyethane-l,1-diphosphonic acid CH3C(OH)[PO(OH)2]2;
aminotri (methylenephosphonic acid) N[CHzPO (OH) 2] 3;

aminotri(methylenephosphonate), sodium salt, ONa I
POCH2N [CH2PO (ONa) 2] 2;

OH
2-hydroxyethyliminobis(methylenephosphonic acid) HOCH2CH2N [CH2PO (OH) 2] 2;

diethylenetriaminepenta(methylenephosphonic acid) (HO) 2 POCH2N [CH2CHzN [CH2P0 (OH) 2] 2] 2;
diethylenetriaminepenta(methylenephosphonate), sodium salt C9H(28_X)N3NaXO15P5 (x=7) ;
hexamethylenediamine(tetramethylenephosphonate), T~o~ZSSlu~ sa!-- Cloh(29-x)N'2KxC12Pq (x=6;

b,5 (~:examethylene) tria~line (Uenta:T;At;"lyle::eDti':oSp ):C nic ac'_d) (HC2) POCHzN'l (CH2) EN (CH_PC (OH) 2; 2] z; and phosphcr::s 5 acld H3P03.
A preferred phosphonate corb:nation is ATMP and D;PMP. A
neutralized or alkaline phosphonate, or a combination of the phosphonate with an alkali source prior to being added ir.to the ma.xture such that there is little or no : Qat cr 10 gas generated by a neutralizatior,, reaction wr.en the phosphor.ate is adc3ed is preferred.

Polycarboxylates suitable for use as cleaning agents include, for example, polyacrylic acid, maleic/olefin copolymer, acrylic/maleic copolymer, 15 pc'-ymethacrylic acid, acrylic acid-methacry:ic acid copolymere, hydrolyzed polyacryla-:ide, hydrolyzed polymethacrylamide, hydrolyzed polyamide-methacrylamide copolymers, hydrolyzed polyacrylonitr:le, hydrolyzed polymethacrylonitrile, hydrolyzed acrylonitrile-methacrylonitrile copolymers, and the like. For a fsrther discussion of chelating agente/seqt:estrants, see Kyrk-Othmer, FT1C'}~rl onPdi a nf Chp _4r.a7 "' .hr?n': yaT, Th ird -.-ditior., volume 5, pages 339-366 and vol::me 23, pagee 319-320.
Bleaching agents for use in a cleaning compositions for lightening or whitening a substrate, incl::de bleaching compounds capable of liberating an active : alogen species, such as C121 Br,, -CCl and/or -OBr', under conditions typically er.countered during the cleansing process. Suitable bleaching agents for use in the present cleaning compositions include, for example, chlorine-containing compounds such as a chlorine, a AMENDED SHEEZ' r.. ~ ,.... ..
'~ .._.

__..- ...._......_~......._.....

.".ypcchlor: te, chlora;r;:.ne. ?referred ha:cge::-reieas' ng ccrntcunds i:iclude the a:ka'.i metai dichl.oroisocyanurates, c:lorir.ated trisodium phosphate, the alkali metal hypoc: +orites, mor.och lora:nine and dich:.oraTine, and the like. Encapsulated c::lorine so-arces may a- se be used to en :a::ce the stability o: t: e c: lori::e source ir. th e ccmpositio.~. (see, for exar;.ple, .S. Patent Nos. 4,618,914, and 4,53C,773. A bleac::=ng agent -~ay aiso be a percxyge n or active oxygen so::rce such as :ywrogen peroxide, perborates, sodium. carbonate peroxyhydrate, phosphate peroxyhydrates, potassi.um permo :osulfate, and sodium perbora:e mono and tetrahydrate, with and without activators such as tetraacetylethylene diamine, and the like. A cieani:g compos:.tion may '_nclude a minor but effective amount of a bieaching agent, preFerably about C.::-10 wt-v, pref ew ably about 1-6 wt -k.

In one embodiment, the invention provides a solid block alkaline detergent composition, having improved organic soil removal capacity, the detergent comprising:

a. a source of alkalinity comprising about 0.1 to about 70 wt%, based on the composition, of sodium carbonate b. an effective cleaning, soil removing and hardness treating amount of a sequestrant comprising:
i. an organic phosphonate composition comprising amino trimethylene phosphonic acid, 2-phosphonobutane-1, 2, 4-tricarboxylic acid, 1-(hydroxy ethylidene)-1, 1-diphosphonic acid or mixtures thereof; and ii. an inorganic condensed phosphate comprising about 0.1 to 35 wt%, based on the composition, of sodium pyrophosphate, sodium tripolyphophate or mixtures thereof; and 16a) c. a soil removing surfactant;
wherein there is at least one part by weight of organic phosphonate per each 100 parts by weight of inorganic condensed phosphate and there is less than 14 wt% of total phosphorus in the detergent; and wherein the composition forms a solid block with a mass of at least 500 grams.
Preferably the composition comprises greater than 10 wt% of the condensed phosphate and about 0.1 to 15 wt% of the organic phosphonate.

Most preferably, the composition comprises about 15 to 35 wt% of the condensed phosphate and about 0.1 to 10 wt% of the organic phosphonate.

Still most preferably, the composition comprises about 10 to 35 wt% of the sodium tripolyphophate and about 0.1 to 5 wt% of the phosphonate composition comprises amino trimethylene phosphonic acid, 3-phophonobutane-1, 2, 4-tricarboxylic acid, 1-(hydroxy ethylidene) -1, 1-diphosphonic acid or mixtures thereof.

In a further embodiment, there is provided a solid block alkaline detergent composition having improved organic soil removal capacity, said detergent comprising:
a. about 0.1 to 60 wt% of an alkali metal carbonate detergent;
b. about 0.1 to 20 wt% of a soil removing surfactant; and c. a sequestrant comprising at least an effective cleaning, soil removing and hardness treating amount comprising less than 15 wt% of an organic phophonate and about 5 to 35 wt% of sodium tripolyphosphate, the sequestrant comprising at least about 1 part by weight of 16b) organic phophonate composition per each one hundred parts by weight of the tripolyphosphate, wherein there is less than 9 wt % total phosphorus in the composition;
wherein the organic phosphonate comprises amino trimethylene phosphonic acid, 2-phosphonobutane-1, 2, 4,-tricarboxylic acid, 1-(hydroxy ethylidene)-l, 1-disphosphonic acid, or mixtures thereof; and wherein the solid block has a mass of at least 500 grams.

More preferably, this composition comprises about 10-35 wt%
of sodium tripolyphosphate and about 0.1 to 5 wt% of amino trimethylene phosphonic acid, 2-phosphonobutane-1, 2, 4-tricarboxylic acid, 1-(hydroxy ethylidene)-1, 1-diphosphonic acid or mixtures thereof.

In a further embodiment, there is provided a solid block alkaline detergent composition having improved organic soil removal capacity, said detergent comprising the solid block having a mass greater than 500 grams, said detergent comprising:
a. about 25 to 65 wt% of sodium carbonate;
b. about 0.1 to about 10 wt% of a nonionic surfactant;
c. an effective cleaning, soil removing and hardness treating amount of a sequestrant comprising:
i. about 10 to about 40 wt% of sodium tripolyphosphate, based on the total composition;
and ii. about 5 to 15 wt% of an organic phosphonate, based on total composition, wherein the organic phosphonate comprises aminotrimethylene phophonic acid or sodium salts thereof, 2-phophonobutane-1, 3, 4-tricarboxylic acid or salts thereof, 1-(hydroxy ethylidene)-1, 1-diphosphonic acid or 16c) (hydroxy ethylidene)-l, 1-diphosphonic acid or salts thereof, or mixtures thereof; and d. about 0.01 to about 1.3 moles of water per each mole of sodium carbonate;
wherein there is less than 9 wt% of total phosphorus in the detergent composition.

More preferably, this composition provides the effective cleaning, soil removing and hardness treating amount of the sequestrant comprises about 25 to about 35 wt%, based on the total composition, of sodium tripolyphosphate and about 1 to 5 wt% of an organic phosphonate, based on the total composition.

v~c--dazy HaYdan= rg N'~di 1PYs -The preseno co:r.positicne may include a minor but effective amount cf a secondary hardening agen t, as for example, an amide such stearic ,;.cr.cethanolamide or lauric diethancyamide, or an alkylamide, and the like; a solid polyethylene glyccl or a propylene g:ycol, and the like; starches t: a: have beer. made water-soluble through an acid or alkaline treatment process; various ir.orga nics that y~:part solidifying properties tc a heated composition upon cooling, and the ' ike . Such corpour.ds may alec vary the solubility of the cor.pcsj.tion in an aqueous medium during use such rhat

6 PCTIUS98/00451 the cleaning agent and/or other active ingredients may be dispensed from the solid composition over an extended period of time. The composition may include a secondary hardening agent in an amount of about 5-20 wt-%, preferably about 10-15 wt-%.

Detergent Builders or Fillers.

A cleaning composition may include a minor but effective amount of one or more of. a detergent filler which does not perform as a cleaning agent per se, but cooperates with the cleaning agent to enhance the overall cleaning capacity of the composition. Examples of fillers suitable for use in the present cleaning compositions include sodium sulfate, sodium chloride, starch, sugars, C1-C10 alkylene glycols such as propylene glycol, and the like. Preferably, a detergent filler is included in an amount of about 1-20 wt-%, preferably about 3-15 wt-%.

Defoaminq Agents A minor but effective am.ount of a defoaming agent for reducing the stability of foam may also be included in the present cleaning compositions. Preferably, the cleaning composition includes about 0.0001-5 wt-% of a defoaming agent, preferably about 0.01-3 wt-%.

Examples of defoaming agents suitable for use in the present compositions include silicone compounds such as silica dispersed in polydimethylsiloxane, fatty amides, hydrocarbon waxes, fatty acids, fatty esters, fatty alcohols, fatty acid soaps, ethoxylates, mineral oils, polyethylene glycol esters, polyoxyethylene-? 99(TUEj MERCHANT'&GOULD PA ~~~. n~' CA 02277139 1999-07 07' polyoxypropylene block copolymers, alkyl phosphate esters such as monostearyl phosphate, and the ~ike. A
discussion of defoaming aaents may be found, for example, ir. U. S. Patent No. 3, 05,8, 548 to Martir. et al., U.S. Patent No. 3,334,147 to Brunelle et al., and U.S.
Patent No. 3,442,242 to Rue et al.

An!-~ -rPcien~s; r~ ~n A~~P~~s A cleaning composition may aiec i::clude an anti-redeposition agent capable of facilitating sustained suspension of soils in a cleaning solution and preventing the removed soils from being redeposited onto the substrate being cleaned. Examples of suitable anti-redeposition agents include fatt-y acid amides, fluorocarbon surfactants, complex phosphate esters, styrene maleic anhydride copolymers, and celluloeic derivatives such as hydroxyethy:l cellulose, hydroxypropyl cellulose, and the like. A cleaning composition may include about 0.5-1-0 wt-%, preferably about 1-5 wt-t, of ar. anti-redeposition agent.

nyPgf Odor;3ntB
Various dyes, odorants including perfumes, and other aesthetic enhancing agents may also be included in the composition. Dyes may be included to alter the appearance of the composition, as for example, Direct B1ue 86 (Miles), Fastusol Blue (Mobay Chemical Corp.), Acid orar.ge 7 (American Cyanamid), Basic Violet 10 (Sandoz), Acid Yellow 23 (GAF), Acid Yellow 17 (Sigma Che-nical), Sap Green (Keyston Analine and Chemical), A lY1 ~Tl~-= ~(..:1~' V!' _.1'~
~ ,_ ' ., Eh a~T~iu ~! r, . ~ - . , .. .
- CA 02277139 1999~07-07 Meta :- l Yellow Keystone Analine and Chemical) , Acid Blue'N 9(Hilton Davis) , Sar.dclar. Blue/Acid al-ue 182 (Sandoz), Hisol Fast Red (Capitol Color and Chemical), Fluoresceir. (Capitol Color and Chemicay), Acid Green 25 (Ciba-Geigy) , a:.d the 1-ike.
Fragrances or perfumee that may be included in the cc~~position s include, for example, terpenoids s::c : as citronellol, aldehydes such as amy; cinnamaldehyde, a i0 -asmi::e euch as CIS-jasrr,:ne or jasmal, vaaillin, ar.d the liite AQl.ieoue Mad;um :he ingredients may optionally be prccesaed in a minor but effective amount of an aquecus medium such as i5 water to substantially blend and so:ubilize the ingredients and achieve a homogenous mixture, to aid in the hydration reaction if needed, to provide an effective level of viscosity for processing the mixture, and to provide the processed compositicn with the 20 desired amount of firmness and cohesion during discharge and upon hardening. The mixture during processing preferably comprises about 2-20 wt-a of an aqueous medium, preferably about 5-15 wt-k, The extruded e;nbodiment. can contain less than about 1.3 moles of 25 water per mole of alkalinity source, preferably less than y.25 moles per mole of sodium carbonate.
T)F.TATT,FT) T)F.SrRTPTTON OF T-4F n$AWTNGS
'"he figure is a drawing of a preferred e;nbodiment 30 cf the packaged solid block detergent of the invention.
The detergent has a uniaue pinch waist elliptical profile. Th'= proFile ensures that this block with its AMENDED SHEET
IPEF,/EP

particular profile can fit only spray on dispensers that have a correspondingly shaped location for the solid block detergent. We are unaware of any solid block detergent having this shape in the market place. The 5 shape of the solid block ensu:res that no unsuitable substitute for this material can easily be placed into the dispenser for use in a wa:rewashing machine. In Figure 1 the overall product 10 is shown having a cast solid block 11 (revealed by the removal of packaging 12) 10 with a mass of at least 500 gms, preferably 1 to 10 kg.
The packaging includes a label 13. The film wrapping can easily be removed using a tear line or fracture line 15 or 15a incorporated in the wrapping.

15 Processing of the Composition The detergent compositions of the invention can comprise powdered, agglomerated, liquid, pellet and solid block detergents. The powdered, agglomerated, liquid and pellet compositions can be made 20 conventionally.

The invention provides a method of processing a solid block cleaning composition. According to the invention, a cleaning agent and optional other ingredients are mixed in an aqueous medium. A minimal amount of heat may be applied from an external source to facilitate processing of the mixture.

The alkaline cast solid materials of the invention can be manufactured in batch processing. In such processing, one or more of the ingredients used in making the cast solid materials can be charged to a mixing vessel that can be equipped with a heating source i ~~v saci-: as hot water, steam, electrical heaters, etc. The ccntainer and its charge can be heated to an effective mixing temperature and the balance of ir.gredie nts can be added. Once mixed and fully uniform, the agitated centents can then be removed from the batch mixer 4-nto moide or containers for solidification. Alternati.vely, the mixing of the ingredients can be accompl4- shed in a series of two or more batch mixing vessels, each eqaipped with its own agitator and heat source.
Ingredients can be added singly to any specific mdxing apparatus or can be combined to make a premix which can be charged to a mixing apparattis prior to the addition of other ingredients or can be added to one or more ingrediente in mixing apparatus.
Optional mixing system provides for contynuous mlxing of the ir.gredients at high shear to forrr, a s::bstantiaily homogeneous liquid or semi-sol:.d mixture in which the ingredients are di.etributed throughout its mass. Preferably, the mixing system includes extrusior.
means for mixing the ingredients to provide shear effective for maintaining the mixture at a flowable consistency, with a viscosity during processing of about 1,000-1,000,000 cP, preferably about 50,000-200,000 cP.
The mixing system is preferably a continuous flow mixer (extruder), as for example, a Teledyne continuous prccessor or a Breadsley Piper continuous mixer, more preferably a single or twin screw extruder apparatus, with a tw::n-screw extruder being highly preferred, as for example, a multiple section Buhler Miag twin screw ext:ruder.

AMENDED SHEET
IPEA/EP ~~,.

It is preferred that the mixture is processed at a temperature to maintain stability of the ingredients, preferably at ambient temperatures of about 20-80 C, more preferably about 30-50 C. Although limited external heat may be applied to the mixture, it can be appreciated that the temperature achieved by the mixture may become elevated during processing due to variances in ambient conditions, and/or by an exothermic reaction between ingredients. Optionally, the temperature of the mixture may be increased, for example, at the inlets or outlets of the mixing system, by applying heat from an external source to achieve a temperature of about 50-150 C, preferably about 55-70 C, to facilitate processing of the mixture.

Optionally, the mixing system can include means for milling the ingredients to a desired particle size. The components may be milled separately prior to being added to the mixture, or with another ingredient. An ingredient may be in the form. of a liquid or a solid such as a dry particulate, and may be added to the mixture separately or as part of a premix with another ingredient, as for example, the cleaning agent, the aqueous medium, and additional ingredients such as a second cleaning agent, a detergent adjuvant or other additive, a secondary hardening agent, and the like.
One or more premixes may be added to the mixture.

An aqueous medium may be included in the mixture in a minor but effective amount to solubilize the soluble ingredients, to maintain the mixture at a desired viscosity during processing, and to provide the processed composition and firial product with a desired amount of firmness and cohesion. The aqueous medium may be included in the mixture as a separate ingredient, or as part of a liquid ingredient or premix.

The ingredients are mixed to form a substantially homogeneous consistency wherein the ingredients are distributed substantially evenly throughout the mass.
The mixture is then discharged from the mixing system by casting into a mold or other container, by extruding the mixture, and the like. Preferably, the mixture is cast or extruded into a mold or other packaging system which can optionally, but preferably, be used as a dispenser for the composition. It is preferred that the temperature of the mixture when discharged from the mixing system is sufficiently low to enable the mixture to be cast or extruded directly into a packaging system without first cooling the mixture. Preferably, the mixture at the point of discharge is at about ambient temperature, about 20-50 C, preferably about 30-45 C.
The composition is then allowed to harden to a solid form that may range from a low density, sponge-like, malleable, caulky consistency to a high density, fused solid, concrete-like block.

Optionally, heating and cooling devices may be mounted adjacent to mixing apparatus to apply or remove heat in order to obtain a desired temperature profile in the mixer. For example, an external source of heat may be applied to one or more barrel sections of the mixer, such as the ingredient inlet section, the final outlet section, and the like, to increase fluidity of the mixture during processing. Preferably, the temperature of the mixture during processing, including at the discharge port, is maintained at or below the melting temperature of the ingredients, preferably at about 20-50 C.

When processing of the ingredients is completed, the mixture may be discharged from the mixer through a discharge port. The cast composition eventually hardens due, at least in part, to cooling and/or the chemical reaction of the ingredients. The solidification process may last from a minute to about 2-3 hours, depending, for example, on the size of the cast or extruded composition, the ingredients of the composition, the temperature of the composition, and other like factors.
Preferably, the cast or extruded composition "sets up"
or begins to harden to a solid form within about 1 minute to about 3 hours, preferably about 1 minute to about 2 hours, preferably about 1 minute to about 20 minutes.

Packaging System Powdered, agglomerated, liquid and pellet detergents can be packaged in conventional envelopes, canisters, tubs, bottles, drums, etc.

The processed block compositions of the invention may be cast into temporary molds from which the solidified compositions may be removed and transferred for packaging. The compositions may also be cast directly into a packaging receptacle. Extruded material may also be cut to a desired size and packaged, or stored and packaged at a later time.

The packaging receptacle or container may be rigid or flexible, and composed of any material suitable for R ~"KtiNTK GJ~' : , .. CA 02277139 1999-07-07 - 25 containing t::e compcsiticr.s produced according tc the inve:.t:.on, as for example, glaeis, steei, plastic, card.board, carciboard composites, paper, and t:ne like.
Advantageously, since the composition is processed at or near am,bient tereperatureEi, the tetr.perature of the -irocessed mixture is low enough so t:at the mixture may be cast or extruded directly i:ito the cont.ainer or other packaging receptacle without st:ructurally damaging t:e 1G weceptacle material. As a resul:., a wider variety of materials may be -,:sed to manufacture the container :.:.an t:ose used for compositione that processed and dispensed under molten conditions.
Preferred packaging used to ccntain the '5 co;npoeitions is -manufactured from a materwal which is biodegradable and/cr water-soluble during use. Such packaging is useful for providing controlled release and dispensing of the contained cleaning composition.
Sicdegradable materials useful for packaging the 20 corr.positions of the invention include, for example, water-soluble polymeric films comprising po'~yvi nyl a".'~cohol, as disclosed for example in U.S. Patent Vo.
4,474,976 to Yang; U.S. Patent Nc. 4,692,494 to Sonenstein; U.S. Patent No. 4,608,187 to Chang; U.S.
25 Patent No. 4,416,793 to Haq; U.,S. Patent No. 4,348,293 to Clarice; U.S. Patent No. 4,289,815 to Lee; and U.S.
Pater.t No. 3,695,989 to Albert, w:.ere the composition comprises a highly caustic ;~aterial, safety measures shou:ld be taken during 3C manufacture, storage, dispeneing and packaging of the processed composition. ln narr_icu'Lar, steps should be ! NI D E

;? G9 ( iUE1 1 ~?9 MERCHANT&GOULD PA CA 02277139 1999 '1o~-o~:' ''' 3 1~ ";
'): '.-1 taken to reduce the risk of direct contact bezween the operator and the solid cast composition, and the washing solution that comprises the composition.
The variety of cleaning composit'on made according to the present invention is dispensed from a spray-type dispenser such ae that disclosed in U.S. Pat, Nos.
4,826,661, 4,690,305, 4,667,121, 4,426,362, Re Nos.
32,762 and 32,818. Briefly, a spray-type dispenser functions by impinging a water spray upon an exposed surface of the solid composition to dissolve a portion of the composition, and then immediately direct--ng the concentrate solution comprisin(~ the composition out of the dispenser to a storage reservoir or directly to a point of use. The spray is created by a spray head that can shape the spray pattern to match rhe sclid detergent shape.
The above specification provwde9 a baeis for understanding the broad meets and bounds of t:~e :.nvention. The following examples and test data provide an understanding of the specific embodiments of the invention and contain a best mode. All sodium. carbonate based examples were made by extrusion as disclosed herein. All caustic based products were made by the Fernholz molten process disclosed above.
Preparatory Example The experiment was run to determine the level of water needed to extrude a sodium carbonate product. The 3C -.roduct of this example is a presoak but appi-ies eqsally -o a warewash detergent product. A liquid premix was made using water, nonyl phenol ethoxylate with 9.5 moles EO
(NPE 9 . 5 ), AMENDED SHEET
IPEA/EP

7' R'o'NA NTKU~ .. cA 02277139 1999-07-07::
-._ ,. , .. .. __ ~27 IA_~irect Blue) 86 dye, a fragrar.Lce and a Silicone Anti_oaml 544. T?:ese were mixed in a jacketed mix vessei equipped with a marine prop agit.ator. The temperature of this premix was held between 85-90 F (29-32 C) to prevent gelling. The rest of the ingreciients for this experiment were eodiurn tripclyphosphate, sodium carbonate, and LAS
90t flake which were all fed by separate powder feeders.
T:.ese materials were all fed int:o a Teiedyne 2" ( 6. 3 cm) ~0 paste processor. Production rates for this experimer.t varied between 20 and 18 lbs /miriute (B to 9 hg/rr.inste ) The experiment was divided into five different sections, each section had a different liquid premix feed rate, w:ich reduced the amount of water ir. the formula. Product discharged the Teledyne through an elbow and a 1-1/2"
(3.8 cm) diameter san+tary pipe. Higher levels of water to ash molar ratios (about l. e-:~.5) produced eevere cracking and swelling. Only when levels of water approached 1.3 or less did we see no cracking or swelling of the blocks. Best results were seer. at a 1.25 water to aer, molar ratio. This shows an example that an extruded ash based product can be made bl.it the water level has to be maintained at lower levels in order to prevent severe cracking or swelling.
Fxxmple Carbonate compositions were prepared in extrusion processes similar to t: cse ir. the Preparatory Exarr.ple. A
sodium carbonate based deterge:nt (formula 1) was tested vs. a NaOH based detergent (formula 2). The compos_'tio.~.s of these two formulas are listed in :able .~
'D ',HEF-T
qM=ND
1r=Pk/F:P

h~ERCHANT&uOULD PACA 02277139 1999 07"'0' =

+y4ii~~
ssm==1 a 1 F, mi +1 a (Alkalinity source) NaOH ---- 45.6 NaZCO3 50.5 6.1 (Chelating/water STPP* 30.0 30.0 condition agent) Sodium Aminotri-methylene Phosphonat:e 6 , 7 - - - -Polyacryli.c Acid ---- _.6 (Nonionic Defoamer) EO/PO Bloc:k 1.5 1.4 Polymer Defoamer (Detergency enhancing surfactant) Nonionic .. . S - - - -(Other) Ash - 11ik water inerts Inerts 2C S. P. [water] to i00 to 100 * Sodium Tripolyphosphate (IY) Tpsr- Prcce,air,-q A 10-cycle spot, film, protein, and l:pstick removal test was used to compare formulas 1 and 2 under different test conditions. In this test proced;:re, t::ree clean and five milk-coate.d Libbey glasses were washed in an institutional dieh, machine (a Hobart C-44) together with a lab soil and the test detergent formula.
One clear glass was directly marked with a lipstick streak from top to bottom. The concentrations of each detergent were maintained constant throughout the 10-cycle tegt.
The lab soil used ie a 50/50 combi::ation of beef stew and hot point soil, The hot point soil is a greasy, hydrophobic soil made cf 4 parte Blue Bonnet all -AMENDED SHF-'ET
IPEA/EP '~

I~E RHA N7111r'CA 02277139 1999 07 07 " ti vege--able margarine and 1 part Carna;,i.on Instant Non-Fat milk powder.
In the test, the mi-k-coated a;.asses are used to test the scil removal ability c:): th e deterge::;. formula, while the initially ciear. glasses are used to test the anti-redeposition abiiity of the detergent formula.
Milk coatings were made by dipping clean g:aeses into whole milk and condit'cn_ng the coated glass at 100 F
_C (38 C) and E5~ RH. At the end of t:e test, t:e glasses are rated for spots, filn;, and protein cn t he milk cooled glasses, and lipstick removal on the clean glasses. The rating scale is :=rorr, 1 to 5 wl'th 1 being the best and S being the woret results.
'5 (711) TASt ReH11 1_t9 In example 1, fcrmula 1 was compared witY~. formula 2 in the 10-cycle spot, film, protein, and lipstick removal test u:zder 100C ppm detergent, 50C ppm food 20 soil, and 5.5 grains city water cor.diticns (moderate hardness). The tept results are listed in Table 2.
TahL2 ~a -rm Dr ~ t-: Tl ' pw-i r' k Formula 1(Ash) 3.06 1.81 3.25 Not Done Formula 2 (Caustic) 4.30 1.75 3.25 Not Done 3C These results show that under low water hardness and ~.orr.~ta;, soil conditions, the ash-based formula 1 performs as we:.l as the caustic-based formu'..a 2.

"AMENDED SHEE=T
IP' =,w'r P

Examp]_e 2 In example 2, formula 1 was compared with formula 2 in the 10-cycle spot, film, protein, and lipstick 5 removal test under 1500 ppm detergent, 2000 ppm food soil, and 5.5 grains city water conditions. The test results are listed in Table 3,.

Table 3 Spots Film Protein Lipstick Formula 1 3.55 1.75 3.25 1.00 Formula 2 3.20 2.50 3.00 5.00 These test results show that under low water hardness and heavy soil conditions, higher detergent concentrations can be used to get good spot, film, and protein results that are comparable to those obtained in Example 1. Surprisingly, forrnula 1 outperformed formula 2 in lipstick removal.

Example 3 In example 3, formula 1 was compared with formula 2 in the 10-cycle spot, film, protein, and lipstick removal test under 1500 ppm detergent, 2000 ppm food soil, and 18 grains hard wate:r conditions. The test results are listed in Table 4.

Table 4 Spots Film Protein Lipstick Formula 1 3.00 3.00 4.00 1.50 Formula 2 5.00 3.00 5.00 >5.00 31.
These test results show that under high water hardness and heavy soil conditions, cleaning results generally suffer, even with higher detergent concentrations. However, formula 1 outperformed formula 2, especially in lipstick removal.
Example 4 In order to evaluate the relative importance of the detergency enhancing nonionic surfactant (a benzyl ether of a C10_19 linear alcohol (12.4 moles) ethoxylate, and the strong chelating agent (sodium aminotrimethylene phosphonate), in the ash-based detergent, four variations of formula 1 were compared vs. each other under 1000 ppm detergent, 500 ppm food soil, and 5.5 grain city water conditions. The test results are listed in Table S.

Table 5 Spots Film Protein Lipstick Formula 1 3.25 1.75 3.25 1.00 Formula 1A 2.50 1.50 3.25 1.00 Formula 1B 3.00 1.50 3.25 2.00 Formula 1C 3.00 1.50 3.50 2.00 -- Formula 1A is formula 1 without nonionic -- Formula 1B is formula 1 without nonionic and sodium aminotrimethylene phosphonate -- Formula 1C is formula 1 without sodium aminotrimethylene phosphonate These test results show that the chelating agents cooperate with the alkalinity sources to remove soil such as in lipstick removal.

Example 5 Two caustic based detergents were evaluated, one with sodium aminotrimethylene phosphonate and the other without this raw material. The compositions of these two formulas are listed in Table 6.
Table 6 Formula 3 Formula 4 (Alkalinity source) NaOH 47.50 47.5 Na2CO3 14.11 7.41 (Chelating/water STPP 28.50 28.50 condition agent) Sodium Aminotri-methylene Phosphonate 1.34 (Nonionic Defoamer) EO/PO Block 1.34 1.4 Polymer Defoamer (Other) Inerts Inerts to 100 to 100 Test Results:

In Exampl'e 5, formula 3 was compared to formula 4 in the 10 cycle spot, film protein, and lipstick removal test with 1000 ppm detergent, 2000 ppm food soil, and five grains city water conditions. The test results are listed in Table 7.

Tab -e- 7_ Spots Film Protein Lipstick Formula 3 4.50 1.50 3.50 5.00 Formula 4 3.00 1.75 2.50 3.0 These test results show that under low water hardness and heavy sol conditions, that the addition of sodium aminotrimethylene phosphonate to a caustic based detergent contributes to lipstick soil removal.

Exam&1e 6 In Example 6, formula 3 was compared to formula 4 in the 10 cycle spot, film, protein and lipstick removal test with 1500 ppm detergent, 2000 ppm food soil, and five grains city water conditions. The test results are listed in Table 8.

Ta12e 8 Spots Film Protein Lipstick Formula 3 2.75 1.50 2.50 5.00 Formula 4 3.50 1.75 2.50 2.50 These test results show again at a higher detergent concentration that the addition of sodium aminotrimethylene phosphonate to the caustic detergent contributes to lipstick soil removal. Note that Formula 3 at 1500 ppm does not remove lipstick as well as Formula 4 at 1000 ppm. This combination of Example 5 uG !~UE! ~ ~ 0 MERCHANT&GOULU rH V"
._ CA 02277139 1999-07-07 and Example 6 ciemonstrates well the perLcrr-Lance be.~.efit of the invention.
The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without depa--ting from the scope of the invention, the inventior. resides in the claims hereinafter appended.

Claims (14)

WE CLAIM:

1. A solid block alkaline detergent composition, having improved organic soil removal capacity, the detergent comprising:
a. a source of alkalinity comprising 0.1 to 70 wt%, based on the composition, of sodium carbonate b. an effective cleaning, soil removing and hardness treating amount of a sequestrant comprising:
i. an organic phosphonate composition comprising amino trimethylene phosphonic acid, 2-phosphonobutane-1,2,4-tricarboxylic acid or mixtures thereof; and ii. an inorganic condensed phosphate comprising 0.1 to 35 wt%, based on the composition, of sodium pyrophosphate, sodium tripolyphophate or mixtures thereof; and c. a soil removing surfactant;
wherein there is at least one part by weight of organic phosphonate per each 100 parts by weight of inorganic condensed phosphate and there is less than 14 wt% of total phosphorus in the detergent; and wherein the composition forms said solid block with a mass of at least 500 grams.

2. The composition of claim 1 wherein the composition comprises 10 to 35 wt% of the condensed phosphate and 0.1 to 15 wt% of the organic phosphonate.

3. The composition of claim 1 wherein the composition comprises 15 to 35 wt% of the condensed phosphate and 0.1 to 10 wt% of the organic phosphonate.

4. The composition of claim 1 wherein the inorganic condensed phosphate composition comprises sodium tripolyphosphate.

5. The composition of claim 1 comprising 0.1 to 5 wt% of amino trimethylene phosphonic acid, 2-phosphonobutane-1,2,4-tricarboxylic acid or mixtures thereof.

6. The composition of claim 1 comprising 0.1 to 20 wt% of a nonionic surfactant.

7. The composition of claim 1 wherein the source of alkalinity comprises 0.1 to 70 wt% of sodium carbonate, based on the composition, and the condensed phosphate comprises 0.1 to 35 wt% of sodium tripolyphosphate, based on the composition.

8. The composition of claim 1 wherein the sequestrant comprises 10 to 35 wt% of the sodium tripolyphophate and 0.1 to 5 wt% of the phosphonate composition, which comprises amino trimethylene phosphonic acid, 3-phophonobutane-1,2,4-tricarboxylic acid or mixtures thereof.

9. The composition of claim 1 wherein the mass of the composition is 2 to 10 kilograms.

10. A solid block alkaline detergent composition having improved organic soil removal capacity, said detergent comprising:
a. 0.1 to 60 wt% of an alkali metal carbonate detergent;

b. 0.1 to 20 wt% of a soil removing surfactant; and c. a sequestrant comprising at least an effective cleaning, soil removing and hardness treating amount comprising less than 15 wt% of an organic phophonate and 5 to 35 wt% of sodium tripolyphosphate, the sequestrant comprising at least 1 part by weight of organic phophonate composition per each one hundred parts by weight of the tripolyphosphate, wherein there is less than 9 wt % total phosphorus in the composition;
wherein the organic phosphonate comprises amino trimethylene phosphonic acid, 2-phosphonobutane-1,2,4,-tricarboxylic acid or mixtures thereof; and wherein the solid block has a mass of at least 500 grams.

11. The composition of claim 10 wherein the surfactant comprises a nonionic surfactant.

12. The composition of claim 10 wherein there is 10-35 wt%
of sodium tripolyphosphate and 0.1 to 5 wt% of amino trimethylene phosphonic acid, 2-phosphonobutane-1,2,4-tricarboxylic acid or mixtures thereof.

13. A solid block alkaline detergent composition having improved organic soil removal capacity, said detergent comprising the solid block having a mass greater than 500 grams, said detergent comprising:

a. 25 to 65 wt% of sodium carbonate;
b. 0.1 to 10 wt% of a nonionic surfactant;
c. an effective cleaning, soil removing and hardness treating amount of a sequestrant comprising:
i. 10 to 40 wt% of sodium tripolyphosphate, based on the total composition; and ii. 1 to 15 wt% of an organic phosphonate, based on total composition, wherein the organic phosphonate comprises aminotrimethylene phophonic acid or sodium salts thereof, 2-phophonobutane-1,3,4-tricarboxylic acid or salts thereof or mixtures thereof; and d. 0.01 to 1.3 moles of water per each mole of sodium carbonate;

wherein there is less than 9 wt% of total phosphorus in the detergent composition.

14. The composition of claim 13 wherein the effective cleaning, soil removing and hardness treating amount of the sequestrant comprises 25 to 35 wt%, based on the total composition, of sodium tripolyphosphate and 1 to 5 wt% of organic phosphonate, based on the total composition.