Granulates – Risk Free Handling
Unique combination of high – shear granulation and various coating technologies. This results in an effective encapsulation of the enzymes, which isolates it from the environment until the moment the detergent product is dissolved into the washing solution. In addition to ensuring optimal stability of the enzymes while being Stored within the detergent, the granulate form also prevents undesired exposures.
The mixing of the different components in order to encapsulate the enzyme is very important to control. The typical procedure is first to add all solid materials to the granulator, and add the binder solution hereafter. The type of granulator used for this granulation process is usually a high-shear mixer; but also a fluid bed coating granulator can be used. Herein layers of enzyme and protective coating are sprayed onto a core. The addition order and application method of the ingredients varies depending on the type of the produced granulate.
In A granules , enzymes are homogeneously mixed with stabilizing agents, like sugars and salts, to create a core. Then, this core is coated with a protective layer consisting of polymers like polyethylene glycol, salts, anti-dust agents like kaolin or calcium carbonate and colors (Fig. 2.9-a).
The enzyme-containing core is manufactured by mixing the stabilizer and enzymes. Generally, one the following methods are employed:
a) a solution containing an enzyme and a stabilizer is dried, followed by granulation;
b) a solution containing enzyme and a stabilizer is subjected to a wet granulation process; and
c) powders of enzyme and stabilizer are blended uniformly, followed by granulation. The first method is more utilized.
The particle size of granulates ranges between 300-1200µm. It is important to have particle size similar to that of the rest of the detergent components in order to prevent segregation during transportation. The average In the enzymes are mixed with binders and adsorbed to an inert core. Then, the raw granule is coated with several protective layers containing salts and polymers (B). The A has greater stabilizing effect on the enzymes, since the numerous coating layers comparatively prevent the diffusion of moisture and oxidizing agents. Although, visually A and B- type granulates are similar in appearance, but the later have a higher bulk density. They also have better dissolution rates, since enzymes are adsorbed on a single layer
Enzymes have effectively assisted the development and improvement of modern household and industrial detergents. The major classes of detergent enzymes-protease, lipase, amylase, cellulase, mannanase & pectinase – each provide specific benefits for application in laundry and automatic dishwashing. In addition to raising the level of cleaning, they have also provided environmental benefits for by reducing energy consumption through shorter washing time, lower washing temperatures, and reduced water consumptions. Today multi-enzymes formulations and granulations improving detergents efficacy especially for household laundering at lower temperatures and, in industrial cleaning operations, at lower pH levels. Cellulase contributes to overall fabric care by rejuvenating or maintains the new appearance of washed garments.
Enzymes act like small selective scissors to break down stains into pieces. Typically, enzymes are carefully optimized molecules for their respective process- such as the removal of a specific protein, starch or fat stain. Thus, each enzyme has specific for one type of reaction, which results in specific enzymes being targeted to specific types of stains. By being broken down into smaller pieces, stains on laundry are more easily removed.
In many commercial market enzyme are available in liquid formulations with included stabilization system for liquid detergent applications and also as encapsulated granulates for powder detergents and soap bars.
Protease: protease accelerates the breakdowns of proteins into peptides and soluble amino acids. Proteases are basic ingredient in laundry detergents and are used worldwide because of their effectiveness on common stains components, such as food, grass and blood.
Lipase: Lipase accelerates the breakdown of tri-glycerides (Lipids) into fatty acids and glycerol and is applied in laundry detergents to improve the removal of body stains on collars and cuffs and non-mineral oil and fat, such as lipsticks, butter, vegetable oil and others, from fabric surface.
Amylase: Amylase are specifically supplemented to the laundry and automatic dishwashing detergent to liquefaction of starch and digest starchy stains from pasta, potatoes sauces, spaghetti, custards, gravies, padding and chocolate.
Cellulase: Cellulase can effectively remove microfiber on fabric for wear. It also can keep cotton fiber fabric with bright color and good smoothness. Therefore, after the washing with cellulase, white clothes will be whiter and color clothes will be brighter and softer.
Mannanase: Mannanase degrade stains containing mannans. These stains are commonly caused by things like barbecue sauce, chocolate, ice cream and toothpaste.
Pectinase: Pectinase act on pectin-based stains from fruits and vegetable, jam and other food containing thickeners.
Environmental regulations and consumer concerns are putting pressure on the entire detergent value chain to offer more environmentally friendly detergents to the market. The environmental impact of doing laundry in the world primarily affected by the raw materials used to manufacture detergents and, more importantly, the temperature used in washing machines. The development of new enzyme solutions allows detergent manufacturers to reduce the environmental impact of their detergents by replacing traditional chemicals such as surfactants with a multienzyme solution. This can be done without compromising performance or cost, while at the same time allowing for good cleaning performance at low wash temperatures.
The positive environmental effects of replacing surfactants with enzymes and of reducing wash temperature for a broad range of impact categories for the detergent with 70% surfactant and a multi-enzyme solution. The impact is nearly the same for the detergent with 90% surfactant with a multi-enzyme solution. The results show that the environmental impact caused by enzyme production is generally quite small compared to the environmental impact savings obtained by the wash temperature reduction and the reduced use of surfactants. The overall reduced environmental impact reflects the use of a small amount of enzyme having a relatively small impact on the environment as opposed to a much larger amount of surfactants and a relatively large amount of electricity. For global warming, the saved environmental impacts are primarily caused by reduced production of surfactants and propylene glycol and the reduction of the wash temperature.