⚗️ Atomized Powder Detergent Manufacturing – Production, Formulation and Properties
Overview:
Atomized Powder Detergent Manufacturing represents the advanced stage of powder detergent production, combining spray drying with post-addition technology to achieve maximum performance and ingredient stability.
In this process, detergent slurry is atomized into a spray-drying tower to form light, porous granules, followed by post-blending of heat-sensitive additives such as enzymes, fragrances, colorants, and optical brighteners.
The result is a high-performance, premium-quality detergent powder with excellent solubility, cleaning power, and shelf stability.
Atomized Powder Detergents are widely used in household, institutional, and industrial laundry applications, where superior washing results and product uniformity are essential.
This production route enables manufacturers to achieve a balance between process efficiency, aesthetics, and advanced formulation flexibility, ensuring consistent results across various washing conditions.
Production and Formulation:
The Atomized Powder Detergent Manufacturing Process begins with the creation of a liquid detergent slurry, similar to spray-dried methods, but includes additional post-processing and enhancement stages.
Typical formulation components:
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Surfactants: Linear alkylbenzene sulfonate (LAS), alpha olefin sulfonate (AOS), nonionics (ethoxylated alcohols).
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Builders: Sodium tripolyphosphate (STPP), zeolite, sodium carbonate – provide alkalinity and water softening.
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Fillers: Sodium sulfate, sodium bicarbonate – regulate density and powder consistency.
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Silicates: Provide corrosion protection and alkalinity control.
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Anti-Redeposition Agents: Carboxymethyl cellulose (CMC) – prevent dirt reattachment to fabric.
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Bleaching Agents: Sodium percarbonate, TAED – for oxygen-based stain removal.
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Additives (Post-Added): Enzymes, brighteners, perfumes, colorants – added after drying to prevent degradation.
Process steps:
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Slurry Preparation: All ingredients are mixed and heated to form a homogeneous liquid phase (solid content: 35–45%).
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Spray Drying: The slurry is atomized through high-pressure nozzles into the drying tower.
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Drying Stage: Hot air (250–400°C inlet) evaporates moisture rapidly, forming dry granules.
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Cooling & Sieving: Powder is cooled, screened, and classified for particle size uniformity.
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Post-Addition Blending: Heat-sensitive additives (enzymes, perfumes, dyes) are mixed in a separate low-speed blender.
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Final Mixing & Packaging: The finished Atomized Powder Detergent is cooled, homogenized, and packaged in sealed, moisture-proof materials.
This hybrid method provides greater formulation flexibility, allowing fine control of active matter concentration, density, and visual appearance.
Properties:
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Production Method: Spray drying followed by post-addition blending.
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Bulk Density: 400–700 g/L depending on formula and additive load.
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Moisture Content: 4–8%.
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Foam Level: Adjustable (from low-foam machine types to rich-foam hand-wash types).
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Solubility: Excellent in cold and warm water.
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Additive Retention: High enzyme and perfume stability due to post-addition technique.
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pH (1% solution): 9–11.
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Appearance: Fine, free-flowing powder with bright, uniform texture.
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Shelf Life: 18–24 months when stored in airtight packaging.
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Eco-Performance: Supports phosphate-free and biodegradable formulations.
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Application Range: Household, hotel, hospital, and industrial laundry use.
Advantages of Atomized Powder Detergent Manufacturing:
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Superior washing efficiency and stain removal due to active ingredient preservation.
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Ability to incorporate multiple enzymes and brighteners without thermal degradation.
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Produces light, uniform, and visually appealing powders with consistent density.
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Facilitates formulation customization for both automatic and manual detergents.
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Compatible with eco-friendly, phosphate-free production trends.
Summary:
Atomized Powder Detergent Manufacturing combines the precision of spray drying with the innovation of post-addition blending to create next-generation detergent powders.
By separating thermal and sensitive ingredient stages, this process ensures maximum cleaning power, fragrance stability, and aesthetic quality.
It provides a versatile, high-performance solution for modern detergent manufacturers seeking premium, sustainable, and market-competitive products.
