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Synthetic detergents, which are also known as syndets, were developed to overcome the difficulties faced while using soap as a cleaning agent. Soaps when used in hard water precipitate the calcium and magnesium salts, due to which it's effectiveness as a cleaning agent deteriorates.

In addition, edible oil & fats, which could be put to other uses, are used as raw materials for the manufacture of soaps. These problems are circumvented in synthetic detergents that are highly stable in hard water and do not consume valuable and expensive oil for their manufacture.

 
Detergent Slurry Formulation
Detergent powder falls into four major groups :
Heavy duty detergents (high and low foaming)
Light duty detergents
Soap powders
Soda products.
 
Detergent formulations essentially consists of :
Active ingredients
STPP
Filler (e.g. Sodium sulphate)
Silicate
 
 
Normally active ingredients used for detergents are linear alkyl benzyl sulphonates.
 
Detergent Spray Drying
 

Free flowing, non dusty, non caking detergent products in bead form are produced by Spray Drying mostly in counter current flow using pressure nozzle atomization.
Inlet temperatures vary according to product and upto 400°C inlet temperatures are used for some detergents. Hot air from direct fired air heaters is used for Spray Drying. Exhaust high efficiency cyclones / bag houses are used to control emissions and maximize product recovery are part of the spray drying plant. RAJ offers stand alone spray drying plants on turnkey basis.

Pneumatic Conveying, Perfuming & Packing

 

The dried detergent powder is pneumatically conveyed from the Spray Dryer to the product silos after sieving. Here filtered atmospheric air is used as the cooling & conveying media. Dense phase conveying systems are normally preferred.
The detergent product from the silo is then blended along with the perfume in a continuous mixer after which it is packed.

 
 
Applications
 
Washing Powders
 

(Detergents, Soaps, Surface Active Agents)
The free-flowing, non-dusty, non-caking products in bead form are produced in counter-current flow dryers with nozzle atomization is the preferred layout for high-bulk-density detergents. Feeds are homogenized and fine-filtered prior to passing to nozzles operating at high pressure. Hot air from direct-fired air heaters enters at the base of the cylindrical part of the tower with slight rotary motion. The exhaust air is drawn from the top of the tower. Inlet temperatures vary according to product. Up to 400°C (750°F) is used for some detergents, but lower temperatures are used for fine washing agents. Product recovery from the drying tower is high (99%). The fines fraction is usually returned to feed preparation. Open - cycle dryers are normally used, Co-current dryers are used for low - bulk - density detergents.

Soda Products

 

Detergent formulations consist basically of (a) an active ingredient (b) sodium tripolyphosphate, (c) silicates, (d) sodium sulphate. Normally the active ingredients are fatty alcohol sulphates, primary and secondary alkyl sulphonates and alkyl aryl sulphonates. Synthetic detergents are currently based upon linear alkyl benzene sulphonates. Formulations are with variations as decided by each company.

Heavy - Duty Detergents

 

Synthetic detergents are widely used in cleaning of all types and operate successfully with hard water. The coarse powder granules in bead form are free-flowing, non-dusty and readily dissolve in water. Shelf-life is excellent, with no tendency to instability or lumping. The feed can be formulated batchwise or continuously. RAJ slurry preparation systems ensures the right preparation technique which improves the quality of the final dried detergent powder. Precise weighing / metering, mixing, homogenizing and de-aeration take place before spray drying. As high a solid content as possible is used (50 - 65%) to give the optimum powder bulk density and best economic use of the spray dryer.
The product is dried in a counter-current-flow drying tower at inlet temperature 350 - 400°C (660 - 750°F). The dried powder leaves the base of the drying tower and is transported via a conveyor belt to an air lift. During passage on the belt, product dosing is carried out. Dosing materials can be products that would be damaged during spray drying, e.g. lauryl alcohol, enzymes. Bleach alongwith enzymes is also added at this stage. Perfume is added after the following air lift.

Light Duty Detergents

 

Light - duty detergents are used less than heavy duty. They find wide application only in dish washing and light household cleaning (janitoring). Light -duty detergents are produced in nozzle towers with either co-current or counter-current flow. Choice depends upon required bulk density. Inlet drying temperatures are also lower, 250 - 275°C (480 - 530°F).

Detergent Allied Products

 

RAJ also provides state of art powder technology for detergent allied products like Sodium Lauryl Sulphate (SLS), Alfa Olefin Sulphonate (AOS), Optical Brightening Agents (OBA), Linear Alkyl Benzyl Sulphonate (LABSA), Sodium Silicate, Sodium Tri-polyphosphate (STPP).

 
 
        
Detergent Plant Spray Drying Manufacturers, Dryes & Pigments Spray Drying Manufacturers
Raj Process Equipments And Systems Pvt. Ltd. is one of the most specialized manufacturers of Detergent Plant Spray Drying and Dryes & Pigments Spray Drying in India.
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