Laundry Powder Detergents

Hand-wash powders serve manual laundering where copious foam signals cleaning and per-wash cost must be minimal. Builder systems emphasize soda ash precipitation; filler content is maximized for price control.

FC-5.1-E: Hand-Wash Powder — Economical Tier

Raw Materials

Active matter: 8.2% ± 0.5%. Addition Order (Dry-Mix): Pre-blend sodium sulfate + soda ash (10%) in ribbon blender (3 min, 25 rpm). Pre-neutralize LABSA with remaining soda ash in vented vessel (5 min, 45–55 °C). Add to blender; mix 5 min. Add CMC, silicate, brightener (3 min). Spray perfume (2 min). Screen 12-mesh; pack at < 60% RH.

Safety Notes: LABSA is corrosive (pH 1.5–2.5); neutralization generates CO₂ — vented vessel required.

Expected Problems & Solutions: Caking: reduce moisture to < 3.5%. Low foam: add 2% AOS for CaCO₃ > 200 ppm.

QC Tests: Active matter (ASTM D3049, 7.7–8.7%); bulk density (ISO 697, 550–750 g/L); pH 1% (10.0–11.0); moisture (≤ 4.0%).

Cost Notes: ~USD 0.28–0.35/kg (2024, FOB Asia).

FC-5.1-M: Hand-Wash Powder — Medium Tier

Raw Materials

Active matter: 15.8% ± 0.6%.

Addition Order (Spray-Dry): Dissolve LAS + SLES in warm water (50 °C, 15% batch weight); add soda ash, zeolite, CMC, silicate; 60% solids slurry. Spray dry: 50–70 bar, inlet 280 °C, outlet 90 °C; 450–550 g/L. Cool to < 40 °C. Post-add enzymes, brightener, perfume (5 min at 12 rpm). Pack in laminate (WVTR < 2 g/m²/day).

Safety Notes: Cool base before enzyme addition.

Expected Problems & Solutions: Enzyme loss: reduce moisture to < 3%; add 0.5% calcium acetate. Greying: increase CMC to 1.5%.

QC Tests: Active matter (15.2–16.4%); enzyme retention (≥ 80% at 12 weeks/30 °C); bulk density (450–580 g/L).

Cost Notes: ~USD 0.55–0.70/kg.

FC-5.1-P: Hand-Wash Powder — Premium Tier

Raw Materials

Active matter: 22.4% ± 0.8%.

Addition Order: Slurry: LAS (50 °C); add AE-7EO, soda ash, zeolite, polycarboxylate, CMC, silicate; 55–60% solids. Spray dry: 60–75 bar, inlet 290 °C; 480–550 g/L. Cool to < 35 °C. Post-add: percarbonate + TAED (3 min), enzymes (2 min), brightener (1 min), perfume (2 min at 8 rpm).

Safety Notes: TAED + percarbonate can exotherm — DSC screening before scale-up.Expected Problems & Solutions: Percarbonate decomposition: use coated percarbonate; add 0.2% MGDA. Low foam at 15 °C: increase AOS to 5%.

QC Tests: Active matter (21.6–23.2%); AvO (≥ 0.55%); percarbonate stability (≥ 85% at 8 weeks/32 °C, 80% RH).

Cost Notes: ~USD 1.10–1.40/kg.

Front-loading machines require low-foam detergents; excess foam reduces agitation and may trigger safety shutoffs.Low foam is achieved via low-foaming co-surfactants (MES, FAEO), silicone antifoam at 0.2–0.35%, and reduced surfactant loading.

FC-5.2-E: Automatic Machine-Wash Powder — Economical Tier

Raw Materials

Active matter: 10.0% ± 0.5%.

Addition Order: Dissolve LAS (45 °C); add soda ash, silicate, CMC; 58–62% solids. Spray dry: 270 °C inlet, 85 °C outlet, 45–55 bar. Cool to < 40 °C. Dilute antifoam 1:5; spray onto tumbling base (2 min). Add perfume + brightener (3 min). Screen; pack.

Safety Notes: Dilute silicone antifoam before spraying — undiluted emulsion causes spotting.

Expected Problems & Solutions: Excess foam: increase antifoam to 0.5%; verify LAS 2-phenyl < 20%. Caking: add 1% fumed silica.

QC Tests: Active matter (9.5–10.5%); Ross-Miles foam (0.1%, 40 °C, ≤ 80 mm); bulk density (400–520 g/L); pH 1% (10.5–11.3).

Cost Notes: ~USD 0.32–0.40/kg.

FC-5.2-M: Automatic Machine-Wash Powder — Medium Tier

Raw Materials

Active matter: 16.5% ± 0.6%.

Addition Order: Slurry: LAS (50 °C); add AE-7EO, soda ash, zeolite, CMC, silicate, MGDA; 60% solids. Spray dry: 280 °C inlet, 88 °C outlet, 50–60 bar; 450–550 g/L. Cool to < 35 °C. Post-add enzymes, diluted antifoam, brightener, perfume (5 min at 12 rpm).

Safety Notes: AE-7EO clouds above 58 °C — keep slurry < 50 °C.

Expected Problems & Solutions: White residue on darks: increase zeolite fineness (d₅₀ < 5 µm). Enzyme loss: verify MGDA ≤ 0.5%.

QC Tests: Active matter (15.9–17.1%); foam (≤ 60 mm); enzyme retention (≥ 80% at 12 weeks/30 °C).

Cost Notes: ~USD 0.65–0.85/kg.

FC-5.2-P: Automatic Machine-Wash Powder — Premium Tier

Raw Materials

Active matter: 25.2% ± 0.9%. TAED:percarbonate = 3:8 (0.375), within optimum 0.25–0.67.Addition Order: Slurry: LAS (50 °C); add MES (pre-dispersed at 35 °C), AE-9EO, soda ash, zeolite, polycarboxylate, CMC, silicate, MGDA; 58% solids. Spray dry: 55–65 bar, inlet 290 °C; 480–560 g/L. Cool to < 30 °C. Post-add: percarbonate + TAED (3 min), enzymes (2 min), brightener (1 min), antifoam (2 min), perfume (2 min at 8 rpm). High-barrier pack with desiccant.

Safety Notes: Coated percarbonate mandatory — uncoated loses > 30% AvO in 2 weeks with zeolite.Expected Problems & Solutions: Percarbonate-zeolite incompatibility: use Mg-silicate-coated percarbonate; add 0.3% sodium borate. MES dissolution: pre-disperse at 35–40 °C.

QC Tests: Active matter (24.3–26.1%); AvO (≥ 0.90%); percarbonate stability (≥ 85% at 6 weeks/32 °C, 80% RH); foam (≤ 50 mm).

Cost Notes: ~USD 1.30–1.65/kg.

FC-5.3-M/P: Concentrated Powder

Raw Materials

Active matter: 28.0% ± 1.0%. Process (Dry Agglomeration): Load zeolite, SKS-6, soda ash, CMC, polycarboxylate, silicate into high-shear mixer. Spray surfactant blend (LAS + AE-7EO at 40 °C) onto tumbling powder at 15–20% liquid. Agglomerate 5–8 min; fluid bed dry (80 °C); cool to < 35 °C. Post-add enzymes, antifoam, brightener, perfume. Bulk density: 750–850 g/L.

Safety Notes: Dust generation — ATEX 2014/34/EU compliance mandatory. SKS-6 is irritant.

Expected Problems & Solutions: Caking: SKS-6 is hygroscopic — pack in WVTR < 1 g/m²/day film. Slow dissolution: mill to d₅₀ 400–600 µm.

QC Tests: Active matter (27.0–29.0%); bulk density (750–850 g/L); dissolution (1% in 20 °C water, < 45 s).

Cost Notes: ~USD 1.20–1.50/kg.

FC-5.4-M/P: Enzyme-Enhanced Powder

Raw Materials

Active matter: 20.4% ± 0.7%. Total enzyme loading: 3.25% (highest in chapter). Addition Order: Spray-dry slurry (60% solids, 280 °C); cool to < 30 °C. Post-add sequentially: protease first, then amylase, lipase, cellulase — 2 min between each. Add calcium acetate with first enzyme.

Safety Notes: Handle enzyme granules with dust control.

Expected Problems & Solutions: Protease autolysis: PVA-barrier granules; add protease last. Cellulase damage: alkaline cellulase only; loading ≤ 0.5%.QC Tests: Active matter (19.7–21.1%); each enzyme ≥ 80% at 12 weeks/30 °C.

Cost Notes: ~USD 0.90–1.15/kg.

FC-5.5-P: Oxygen Bleach Powder

Raw Materials

Active matter: 14.6% ± 0.6%. AvO: 1.84% ± 0.15%. TAED:percarbonate = 1:3 (optimum 1:2 to 1:4).No zeolite — soda ash + MGDA avoids percarbonate-zeolite decomposition.Addition Order: Spray-dry base (LAS, AE-9EO, soda ash, sulfate, CMC, silicate); cool to < 30 °C. Post-add percarbonate + TAED (pre-blended), MGDA, brightener + perfume.

Safety Notes: Percarbonate-organic mixtures can exotherm — DSC screening before scale-up.Expected Problems & Solutions: Bleach odor: use marine/floral fragrances; avoid citrus.

QC Tests: AvO (1.70–1.98%); percarbonate stability (≥ 80% at 8 weeks/32 °C, 80% RH); TAED (HPLC, 4.5–5.5%).

Cost Notes: ~USD 1.15–1.40/kg.

FC-5.6-M/P: Color Care Powder

Raw Materials

Active matter: 17.6% ± 0.6%. pH 1%: 8.5–9.2 (critical). Addition Order: Spray-dry base (LAS, AE-7EO, zeolite, bicarbonate, CMC, silicate); cool to < 35 °C. Post-add PVP, cellulase, protease, antifoam, perfume.

Safety Notes: PVP is hygroscopic — add as fine powder.

Expected Problems & Solutions: High pH on wool/silk: reduce soda ash to 3%; increase bicarbonate to 15%.

QC Tests: pH 1% (8.3–9.2, critical); dye transfer (ASTM D5548, gray scale ≥ 4).

Cost Notes: ~USD 0.80–1.05/kg.

FC-5.7-M/P: White/Brightening Powder

Raw Materials

Active matter: 18.7% ± 0.6%. Total OBA: 0.50% (2–3× standard). Addition Order: Spray-dry base; cool to < 35 °C. Post-add percarbonate + TAED, enzymes, brighteners (pre-blended), ultramarine (dispersed in 0.5% AE-7EO to < 1 µm), antifoam, perfume.

Safety Notes: Ultramarine must be < 1 µm to prevent visible spotting.

Expected Problems & Solutions: OBA spotting on darks: label for whites only. Ultramarine speckling: mill with 2× AE-7EO.

QC Tests: OBA fluorescence (≥ 120% vs. 0.1% CBS-X); active matter (18.1–19.3%); AvO (≥ 0.55%).

Cost Notes: ~USD 0.85–1.10/kg.

FC-5.8-P: Industrial Laundry Powder

Raw Materials

Active matter: 25.4% ± 0.8%. pH 1%: 12.0–12.8. Process (Dry Mix): Blend all solids in ribbon blender (8 min at 20 rpm). Spray perfume last. Pack in 25 kg sacks with PE liner.

Safety Notes: pH > 12.0 causes serious eye damage and skin burns (CLP Category 1). PPE: chemical goggles, nitrile gloves, apron. Verify STPP permitted locally.Expected Problems & Solutions: Fabric damage at 90 °C: add 0.5% sodium borate or limit to 60 °C. Aluminium corrosion: metasilicate attacks Al — verify machine metallurgy.

QC Tests: Active matter (24.6–26.2%); pH 1% (12.0–12.8); alkalinity as Na₂O (≥ 18%); bulk density (650–850 g/L); foam (≤ 40 mm).

Cost Notes: ~USD 0.85–1.10/kg. STPP at 15% = ~20% of cost; where banned, substitute zeolite (18%) + polycarboxylate (2%) + MGDA (1%) at ~15% premium.

Table 5.1 — Manufacturing Process Parameters by Powder Type

Table 5.2 — Quality Control Test Reference

Table 5.3 — Powder Detergent Comparison Matrix

Active matter spans 3.4-fold (8.2% to 28.0%) with a ~4.3× cost ratio. Automatic formulations target Ross-Miles foam ≤ 80 mm while hand-wash powders omit antifoam. The pH range spans 4.5 units — 8.3 (color care) to 12.8 (industrial). Zeolite dominates phosphate-free builders; STPP is retained industrially where permitted. The concentrated powder uniquely employs SKS-6 for rapid dissolution at high bulk density.Oxygen bleach appears in four premiums at percarbonate + TAED loadings of 5% + 2% to 15% + 5%, the latter the practical maximum.Post-addition of thermally sensitive components is universal across spray-dried formulations.

Table 5.4 — Surfactant and Builder Loading Reference by Tier

Economical tiers allocate 35–50% to sodium sulfate, driving cost below USD 0.40/kg but limiting active matter to 8–12%. Medium tiers substitute zeolite and enzymes, reaching 15–18%. Premium tiers maximize surfactants and add percarbonate + TAED for cold-water whitening. Polycarboxylate at 0.5–2.5% appears in all automatic formulations to prevent carbonate incrustation. Formulators should adjust for local water hardness, raw material availability, and phosphate/bleach activator regulations.

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