Selling an Idea or a Product

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Littleford Day Inc. Where Processing Ideas become
Reality.
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Processing Detergents with Littleford
Equipment
Littleford Day Inc. Where Processing Ideas
Become Reality.
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Littleford Equipment for the Detergent Industry
Presentation Index
Page
Contents 4 Our
Engineering for Detergents Neutralizing,
Mixing, Drying, Densifying. 5
Preparation of Dry Powder Detergents using Dry
Neutralization. 6 Wet and Dry
Neutralization. -Comparative Table- 7
The Fluidized-Bed Operation for Detergent
manufacturing. 8 Chopper action on
Acids dispersion. 9 Manufacturing
options for the FM/FKM Equipment. 10
How do we build them. 11 Our Regular
Sizes. 12 Densification of Dry Powder
Detergents in our CB Units. 13 The
Littleford CB High Speed Processor. 14
Advanced drying process in the Littleford
equipment. 15 Advantages of the
Choppers operation in drying. 16
Granulation in the Littleford equipment.
17 Rental Program. 18 Service and Spare
Parts. 19 Technical Center Our Lab.
Facilities. Testing/Optimizing your products.
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Cutting Edge Engineering for
Dry Neutralization. Mixing of additional
components. Drying. Densification.
The specially designed tools in the
Littleford FM/FKM equipment create a
mechanically fluidized bed of material providing
exceptionally fast and accurate contacting
of the acid and powder. Supplementary high
speed impact choppers supply localized high
shear fields required for the thorough
dispersion of the acid. The choppers also aid
in deagglomeration and densification of the
product. After an excellent neutralization has
been accomplished, blending of the dry
neutralized surfactant with the remai- ning
components of the detergent is done in the
same vessel. This can be done in a batch or
continuous basis. Extremely accurate drying so
as densification is also done, if required, in
our FM/FKM machines. Our CB High-Speed
Processors, in combination with the KM mixers
provide continuous densification of
detergents, to fully suit demanding market
requirements.
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Preparation of Dry Powder Detergents using Dry
Neutralization.
Dry Powder Detergent Formulations are usually
composed of a combination of Ionic and/or
Non-Ionic surfactants, builders (such as
carbonates, phosphates, silicates, brightening
agents, etc.) and inerts. These components are
processed to form a dry powder product
possessing desirable flow properties and
appearance. There are two generally
accepted methods by which to arrive at the final
product. One is
a Wet Process and the other is a Dry
Process. In the wet formulation, the product of
the sulfonation (a heavy liquid acid) is added
to a caustic solu- tion. The resulting
surfactant is in slurry form. This slurry is
homogenized with the other components of the mix
in a vertical stirred tank. The resulting
material is a heavy past, which is pumped to a
spray drying tower where the moisture is removed.
The dry, low density, hollow granules are
collected at the bottom and may be packaged as
it is or may be processed further. Since
the trend in todays market is towards
densified detergent, this low density product
is often densified in additional
equipment. In the Dry Process the surfactant is
prepared by spraying the liquid acid onto Sodium
Carbonate. This is known as Dry
Neutralization. The resulting surfactant is a
dry granular powder. The dry surfactant may
then be blended with the other components of the
mix. Since the resulting mix is dry, the
costly spray drying operation is eliminated.
A Non-Ionic surfactant is sometimes sprayed onto
the product to enhance flowability and reduce
dusting. The manner in which the liquid acid is
added to the sodium carbonate is critical.
The acid must be added at a controlled rate
and dispersed uniformly to avoid overwetting,
which would produce large we t agglomerates
containing unreacted material not suitable
for use in the final blending operation. When
processed properly, the product of the dry
neutralization will be homogenous in
composition and particle size. The
specially designed mixing tools in the Littleford
FM/FKM Series Mixer, create a mechanically
fluidized bed of material, providing
exceptionally fast and accurate contacting of the
acid and powder. High speed impact
choppers supply localized high shear fields
required for the thorough dispersion of the
acid, and aid in deagglomeration and
densification of the product. Blending of the
dry neutralized surfactant with the remaining
components of the detergent formulation is then
done. Using the same vessel for both the
dry neutralization and final blending is yet
another advantage of using Littleford Day
Technology.
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Wet and Dry Neutralization
A Comparison between two Processes
The Wet-Type Process. In the wet
formulation, the product of the sulfonation (a
heavy liquid acid) is added to a caustic
solution. The resulting surfac- tant is in a
slurry form. This slurry is then homogenized
with the other components of the mix in a
vertical stirred tank. The resulting material
is a heavy paste, which is pumped to a spray
drying tower where the moisture is removed. The
dry, low den- sity, hollow granules are formed.
Since the trend in todays market is towards
densi- fied detergents, this low density
product is often densified in additional
equipment.
The Dry-Type Process. The surfactant is
prepared by spraying the liquid acid onto
sodium carbonate. This is known as Dry
Neutralization. The resulting surfactant is a
dry granu- lar powder. The dry surfactant may
then be blended with the other dry
compo- nents of the mix. Since the
resulting mix is dry, the costly spray drying
ope- ration is eliminated. A Non-Ionic
sur- factant is sometimes sprayed onto
the product to enhance flowability
and reduce dusting.
No need for costly spray drying. Simpler, less
expensive system.
Single Vessel for Neutralization and Mixing of
final detergent components.
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The Fluidized Bed Operation for Mixing Drying
The unique mixing action of the FKM series
mixers is accomplished by a ho- rizontal shaft
which revol- ves at a high rate of speed rapidly
projecting and hur- ling the mix materials
away from the vessel wall into free space,
filling the entire vessel. The mixing action
causes the materials to crisscross in the
direc- tion of the vessel walls and inversely
back again, pro- viding a high volume rate of
material transfer. The mechanically fluidized
bed of particles is the basis of its mixing
efficiency and accuracy, including
combi- nations with diverse speci- fic gravities
as well as other problems such as
liquid incorporation and heat transfer.
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Chopper Action, sending fluidized particles
upward, against sprayed liquids flowing
in the opposite direction.
Superb Liquids Dispersion into Powders, through
high speed Choppers
(Showing Top Injection Type. Bottom Liquids
Injection also available)
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Manufacturing Options
Vacuum System Stack (s) Pulse Back Filter
(s) Condenser, Receivers. Vacuum Pumps.
Material C.Steel, 304 S.S., 316 SS., Special.
Interior Std. 120 Grit or
higher.
Liquid Injection Tower, Manifold. Top and / or
Bottom Mountings.
Electric's H.P., TEFC,Expl.Proof.
Vessel Construction Atmospheric Std., Vacuum
Rated, Pressure Rated, Sanitary Construction.
FDA Ratings.
Feeding Ports
Drive Type. Sanitary or Welded Design RPMs 1 or
2 Speeds, Variable Speed. Hydraulic Coupling.
Seals Std. Packing, Positive
Pressure Mechanical.
Plows Std.,Heat Transfer, Becker
Jacket. Std. 75 PSI Other PSI Ratings Heating
Cooling
Special Bases, Load Cells.
Choppers H.P., TEFC, Expl.Proof
Blade Types
Discharge Valve Manual,Pneumatic. Ball type,
Butterfly, Sphericals Slide Options.
Control Panels Manual, Automatic. RPM Control
Batch Times,
Amp,Power,Reports
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How do we build them
Standard or Sanitary Construction. TEFC
or Explosion Proof Electric's. Full Vacuum or
rated for several Internal Pressure Ratings.
Single or Variable Speeds.
Pulse Back Filters.
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Our regular FM/ FKM sizes
Working capacity depends on the process, and
is normally between 50 and 70 of total capacity.
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Densification of Dry Powdered Detergents
Until recently, the manufacture of most dry
detergent products relied on the Spray Drying
Process to produce a light density powder product
(18-22 Lb/Ft3, Aprox). The Spray dried
powder consisted of homogeneous, hollow,
spherical particles. Reducing the overall
cost of producing dry detergents provided the
driving force behind the development of more
densified products. Densification of
the detergent results in reduced packaging
costs and waste, reducing shipping costs and
smaller shelf space requirements at the point
sale. When leaders in the detergent industry
began searching for a process to densify
detergents, they quickly arrived at the concept
of using a high speed continuous mixer to
achieve their goals. A mixer densifies the
product by adding work energy to the product via
mechanical shear. The continuous mixer/mixing
systems best satisfying industrys needs are the
Littleford CB Series High Speed Processor (as
a stand-alone unit), and the CB used in
combination with a l arger KM Series
Littleford Continuous Ploghshare Mixer. The
desired level of densification determines
which equipment configuration is used. The CB
Processor features a jacketed, horizontal, clam
shell-type mixing chamber, with a horizontal
shaft with a significant quantity of specially
designed feeding and mixing tools arranged in a
spiral-like pattern, to supply high shear mixing
rates and material transport. Liquid may be added
via a manifold system located at the lower half
of the shell. The typical retention time of
detergent product in the CB Processor is 15 to 20
Seconds. During that time the product is
subjected to intense mechanical shear causing
the fragile spray dried granules to break up and
densify. Increases in product density of up
to 50 are common (or an increase to 25 to 30
Lb/Ft3). If further densification is required,
product is then transferred to a Littleford KM
Mixer, which provides additional mechanical
shear via the rolling/agglomerating action of
the curve-sided mixing tools. Liquids can
also be added in this unit, and high speed impact
choppers are used to aid in both liquid
dispersion and lumps breaking. Common
retention times in the KM Mixers are 5-10
Min. Final product densities of 45 Lb/Ft3, or
greater are achieved, increasing original
density up to 100.
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Littleford CB High Speed Processor
Densification of Detergents through addition of
high shear input rates.
Ideal for the
densification of detergent powders. Typical
retention time of detergent productis 15 to 20
seconds. During that time the product is
subjected to intense mechanical shear, causing
the fragile spray dried granules to break up
and densify. Increases in product density
of up to 50 If further densification is
required, product is then transferred to a
KM series continuous mixer, delivering
up to 100 density increase.
High Shear Densification Zone
Mixing Predensification Zone
Charge Chute
Heating/Cooling Jacket (Top Bottom Shell)
Charging Zone
Double Row Spherical Bearings
Dinamically Balanced High Speed Shaft.
Pneumatic Control of Discharge Gate
Tangential Liquid Lances on Bottom- Top, Optional
Littleford Day Inc.
To an optional KM Continuous Mixer, for up to
100 Densification
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Advanced Drying Technology
1.-High efficiency drying of Suspensions, pastes,
and bulk materials. 2.-Fast drying cycles and
discharge. 3.-Allows efficient drying of
sensitive materials at low Temperatures. 4.-Comple
te dispersion of agglomerates, lumps and fiber
bundles. 5.-Homogeneous mixing of dissimilar
ingredients. 6.-Drying operations from liquid
state to free-flowing powder in one
vessel. 7.-Allows liquid addition during
processing. 8.-Adapts itself to effective
recovery of costly solvents. 9.-Eliminates need
for additional processing equipment.
The Key to this State-of-the Art drying
technology is the unique,
mechanically fluidized ploughshare action
which agi- tates and individualize the
solid parti- cles to be dried. The
ploughshare action forces the product into a
3-dimensions motion that individualizes each
particle, continuosly exposing tremendous
surface area for drying. The particles
constantly contact one another, and the heated
inte- rior walls of the jacketed vessel
furthering the drying process. Our dryers
are also equipped with independently
operated, high shear choppers, to reduce the
particle size of the lumps or agglomerates, to
expo- se undried materials and ensure
thoroughly dried particle interior.
Deagglomeration further shortens drying time.
Heated Pulse Back Filter with Stack.
Wet Product
Condenser
Littleford Dryer.
Recovery Tank.
Vacuum Pump.
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Advance Drying

Advanced Drying The Chopper Advantages.
The action of the turbulent plows and the high
shear choppers reduce the forming lumps to
smaller granules, thus exposing large amounts of
new surface area for drying.
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Granulation
Littleford mixers/granulators, equipped with
plow-like mixing tools, develop an intermediate
intensity mix action, which is gentle, yet
thorough. This action is supplemented by
high shear choppers, which quickly disperse
minor liquid, or powder ingredients. In a
typical run, the excipient and the powdered
active ingredient are charged to the static
granulator and mixed, with choppers, for several
minutes, until the power curve levels off,
indicating that dispersion is complete. Then
the agglo- merating liquids are sprayed into
the active chopper field, where t hey are
quickly dispersed into the batch. The degree of
granulation, and thus the amount of power
utilized, is dependent upon the amount of liquid
added to the batch, so as of the wet mix batch
time. The action of the plows causes
snow- balling the choppers generates
small, granules.
For a Given Liquid Level More Wet-Mix Time
Material more wet out,
Higher Power
used
More uniform particles.
Wet-Mix Time Higher Liquid Level Material
more wet out,
Higher Power used

larger granule size.
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Rental Programs
In addition to our Process Development Testing
Programs, our Rental Program offers a unique
opportunity to test our processing equipment in
your own Plant.
A portion of the rental cost, under this program,
will be applied to the purchase of any related
Littleford Day Equipment.
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Service Spare Parts

• Exclusive Dept. for customer assistance.
• Laboratory for formulations optimization.
• Specialized Field Service Engineers.

• Stock of common required parts.
• Top American Mfrd. Parts SKF, Falk, Chesterton,
  etc.,etc.
• Assistance in Spanish, if required.

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Process Development Testing
Main Office Florence, Ky. Ph.- [phone].
Fax [phone] Latin America Mexico Cy.Ph.-
(52-5)550-9459. Fax [phone]

Minutes away from Greater Cincinnati Airport,
Our Lab. Center is fully equipped with all the
required machinery for product development
Mixers, Dryers, Reactors, Granulators,
Intensive Mixers-Coolers and support equipment
such as filtering and vacuum drying systems.
Cosmetics Detergents Soaps Foundry
Additives Pharmaceutical Ceramics Fertilizers/Seed
s Rubber Mortar Mixes Brake Linings Powdered
Metals Herbicides Flame Retardant
Chemicals Pigments Color Flushing BMC SMC
Plastics. Color Concentrates PVC
Compounding Coatings Plastisols Adhesives
Caulks Inks Varnish ChemicalReactions
Drying Cellulose Reactions Spices Chocolate
processing Gelatin Powdered drinks Bakery
Mixes Instantanization
Technical Center Main Equipment FM-130
Mixer/Processor Ploughshare DVT-130 Polyphase
Reactor KM-150 Continuous Mixer/Processor M-5
Lab. Mixer Dryer W-180/K-300 PVC
Compounder W-10 High Intensity Mixer Daymax 10
Pastes Disperser Daymax 100 Pastes
Disperser Mixtruder Sigma Double-Arm Mixer Mogul
Tangential Sigma Mixer Cincinnatus Overlapping
Sigma Mixer FA-10 Nauta Processor


Bring Us Your Toughest Mixing, Drying
Reacting Problems.