Formulation Card
FC-5.2-E
Automatic Machine-Wash Powder — Economical Tier
economicalSource: Chapter 5 §5.2
Ingredients
| Material | % w/w | Function |
|---|---|---|
| LAS spray-dried beads (80%) | 12.5 | Primary surfactant |
| Soda ash (light) | 39.2 | Builder, alkalinity |
| Sodium sulfate | 38.0 | Filler |
| Sodium silicate (ratio 2.4) | 6.0 | Corrosion inhibitor |
| CMC | 0.8 | Anti-redeposition |
| Silicone antifoam emulsion (20%) | 0.3 | Foam suppression |
| CBS-X | 0.05 | Whiteness |
| Perfume (neat) | 0.15 | Fragrance |
| Moisture | 3.0 | Residual |
| Total | 100.0 |
Addition Order & Process
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.
Formulation Notes
[Attributes table]
Raw Materials
Active matter: 10.0% ± 0.5%.
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.