Abstract: A continuous process for preparing granular detergent composition including a first step of dry neutralizing an acid precursor of an anionic surfactant with a particulate water-soluble alkaline material in a high speed mixer for a mean residence time of about 0.2 to about 50 seconds, thereby partly or totally neutralizing the acid precursor and producing a dry neutralized material containing the anionic surfactant, in the form of a free-flowing powder; and a second stop of agglomerating the free-flowing powder into a detergent agglomerate using an agglomeration binder. The agglomeration binder is preferably a viscous surfactant paste binder. The resulting agglomerates are dry, free-flowing, and have a substantially more narrow particle size distribution, compared to the free-flowing powder, with reduced fine particles and over-sized particles that generally are recycled.

Abstract: A process is provided for producing high-active detergent agglomerates through multi-stage surfactant paste injection. According to the process, starting detergent materials are mixed with an initial amount of surfactant paste and then allowed to age for a specified period of time. Following the initial paste injection and aging period, additional amounts of surfactant paste are injected incrementally to make a final detergent agglomerate having at least about 45% by weight of surfactant.

Abstract: A process is provided for producing high-active detergent agglomerates through multi-stage surfactant paste injection. According to the process, starting detergent materials are mixed with an initial amount of surfactant paste and then allowed to age for a specified period of time. Following the initial paste injection and aging period, additional amounts of surfactant paste are injected incrementally to make a final detergent agglomerate having at least about 45% by weight of surfactant.

Abstract: A process for preparing low density detergent agglomerates is provided. The process involves the step of: (a) agglomerating a detergent surfactant paste or precursor thereof and dry starting detergent material having a median particle size in a range from about 5 microns to about 70 microns in a first high speed mixer to obtain detergent agglomerates having a median particle size of from about 100 microns to about 250 microns; (b) mixing the detergent agglomerates with a binder in a second high speed mixer to obtain built-up agglomerates having a median particle size in a range of from 140 microns to about 350 microns; and (c) feeding the built-up agglomerates into a fluid bed dryer in which the built-up agglomerates are agglomerated with another binder and dried to form detergent agglomerates having a median particle size in a range from about 300 microns to about 700 microns and a density in a range from about 300 g/l to about 550 g/l.