The present invention relates to a aqueous liquid automatic dishwashing composition disposed in a water soluble package that can be added directly into an automatic dishwasher.

The present invention relates to an automatic dishwashing composition disposed in a water soluble package that can be added directly into an automatic dishwasher.
U.S. Pat. Nos. 6,191,088; 5,998,346; 5,693,602; 5,750,483; 5,468,411; 5,279,756; 5,240,632 and 5,205,954 relate to an aqueous gel automatic dishwashing composition. The use of these compositions are burdensome and difficult to obtain precise dosing.
The present invention relates to an automatic dishwashing cleaning system comprising:
(a) a water soluble container; and
(b) an aqueous liquid automatic dishwashing composition disposed in said water soluble container.
An object of the present invention is to provide an aqueous automatic dishwashing composition disposed in a water soluble container, wherein the system containing the aqueous automatic dishwashing composition and container can be placed directly into an automatic dishwasher.
The present invention relates to an automatic dishwashing cleaning package which is a system comprising:
(a) a water soluble container; and
(b) an aqueous automatic dishwashing composition disposed in said water soluble container, wherein said aqueous liquid automatic dishwashing composition comprises approximately by weight:
(i) 15% to 25%, more preferably 17% to 23% of pentasodium triphosphate;
(ii) 15% to 25%, more preferably 17% to 23% of sodium citrate;
(iii) 5% to 15%, more preferably 7% to 13% of potassium citrate;
(iv) 0.5% to 15%, more preferably 7% to 13% of potassium sulfate;
(v) 0 to 10%, most preferably 0.1% to 8%, more preferably 0.5% to 8% of a mixture of a protease enzyme and an amylase enzyme in a weight ratio of protease enzyme to amylase enzyme of 10:1 to 1:10, more preferably 2:1 to 1:2;
(vi) 0 to 6%, more preferably 0.25% to 5% of a sodium salt of a polyacrylic acid homopolymer and/or a sodium salt of a copolymer of polyacrylic acid and sulfonic acid;
(vii) 0.1% to 4% of an ethoxylated nonionic surfactant; and
(viii) the balance being water.
Excluded from the instant compositions are anionic surfactants, fatty acid or alkali metal salts of fatty acid, alkali metal silicates, chlorine bleach compounds, and crosslinked polyacrylate polymers.
The nonionic surfactants that can be used in the present automatic dishwasher detergent compositions are generally described as ethoxylated/propoxylated fatty alcohols which are low-foaming surfactants and may be possibly capped, characterized by the presence of an organic hydrophobic group and an organic hydrophilic group and are typically produced by the condensation of an organic aliphatic or alkyl aromatic hydrophobic compound with ethylene oxide and/or propylene oxide (hydrophilic in nature). Practically any hydrophobic compound having a carboxy, hydroxy, amide or amino group with a free hydrogen attached to the oxygen or the nitrogen can be condensed with ethylene oxide or propylene oxide or with the polyhydration product thereof, polyethylene glycol, to form a nonionic detergent. The length of the hydrophilic or polyoxyethylene chain can be readily adjusted to achieve the desired balance between the hydrophobic and hydrophilic groups. Typical suitable nonionic surfactants are those disclosed in U.S. Pat. Nos. 4,316,812 and 3,630,929.
Preferably, the nonionic surfactants that are used are the low-foaming polyalkoxylated lipophiles wherein the desired hydrophile-lipophile balance is obtained from addition of hydrophilic poly-lower alkoxy group to a lipophilic moiety. A preferred class of the nonionic detergent employed is the poly-lower alkyoxylated higher alkanol wherein the alkanol is of 9 to 18 carbon atoms and wherein the number of moles of lower alkylene oxide (of 2 or 3 carbon atoms) is from 3 to 15. Of such materials, it is preferred to employ those wherein the higher alkanol is a high fatty alcohol of 9 to 11 or 12 to 15 carbon atoms and which contain from 5 to 15 or 6 to 16 lower alkoxy groups per mole. Preferably, the lower alkoxy is ethoxy but in some instances, it may be desirably mixed with propoxy, the latter, if present, usually being major (more than 50%) portion. Exemplary of such compounds are those wherein the alkanol is of 12 to 15 carbon atom and which contain about 7 ethylene oxide groups per mold.
Useful nonionics are represented by the low foam Plurafac series from BASF Chemical Company which are the reaction product of a higher linear alcohol and a mixture of ethylene and a propylene oxides, containing a mixed chain of ethylene oxide and propylene oxide, terminated by a hydroxyl group. Examples include Product A (a C12-C15 fatty alcohol condensed with 6 moles ethylene oxide and 3 moles propylene oxide). Product B (a C12-C15 fatty alcohol condensed with 7 mole propylene oxide and 4 mole ethylene oxide), and Product C (a C12-C15 fatty alcohol condensed with 5 moles propylene oxide and 10 moles ethylene oxide). Another group of liquid nonionics are available from Shell Chemical Company, Inc. under the Dobanol trademark: Dobanol 91-5 is a low foam ethoxylated Cg-C11 fatty alcohol with an average of 5 moles ethylene oxide and Dobanol 25-7 is an ethoxylated C12-C15 fatty alcohol with an average of 7 moles ethylene oxide. Another liquid nonionic surfactant that can be used is sold under the tradename Lutensol SC 9713.
Plurafac nonionic surfactants from BASF are biodegradable, low-foaming surfactant which are specially preferred for the instant automatic dishwashing compositions. Plurafac(trademark) SLF18 which is water dispensible and has a low surface tension and low cloud and is low foaming is especially preferred for use in the instant automatic dishwashing compositions.
Other useful surfactants are Neodol 25-7 and Neodol 23-6.5, which products are made by Shell Chemical Company, Inc. The former is a condensation product of a mixture of higher fatty alcohols averaging about 12 to 13 carbon atoms and the number of ethylene oxide groups present averages about 6.5. The higher alcohols are primary alkanols. Other examples of such detergents include Tergitol 15-S-7 and Tergitol 15-S-9 (registered trademarks), both of which are linear secondary alcohol ethoxylates made by Union Carbide Corp. The former is mixed ethoxylation product of 11 to 15 carbon atoms linear secondary alkanol with seven moles of ethylene oxide and the latter is a similar product but with nine moles of ethylene oxide being reacted.
The sodium salt of the polyacrylic acid homopolymer has a molecular weight of about 2,000 to about 8,000, more preferably about 3,000 to about 6,000. A preferred sodium salt of the polyacrylic acid homopolymer is Acusol 445ND(trademark) having a molecular weight of about 4,500 which is manufactured by Rohm and Haas. The sodium salt of the copolymer of polyacrylic acid/sulfonic acid has a molecular weight of about 8,000 to about 16,000 and is Acusol(trademark) 587 manufactured by Rohm and Haas.
The detergent formulation also can optionally contain a mixture of a protease enzyme and an amylase enzyme and, optionally, a lipase enzyme that serve to attack and remove organic residues on glasses, plates, pots, pans and eating utensils. Lipolytic enzymes can also be used in the automatic dishwashing composition. Proteolytic enzymes attack protein residues, lipolytic enzymes fat residues and amylolytic enzymes starches. Proteolytic enzymes include the protease enzymes subtilisn, bromelin, papain, trypsin and pepsin. Amylolytic enzymes include amylase enzymes. Lipolytic enzymes include the lipase enzymes. The preferred amylase enzyme is Duramyl(trademark) 300L, Type DX having an activity of 300 KNU/g. It is an alpha amylase prepared by submerged fermentation of a selected strain of Bacillius.
A preferred protease enzyme is Everlase(trademark) 16.OL Type, Ex sold by Novozyme. It has an actively of 16 EPU/g and is prepared by submerged fermentation of an genetically modified strain of Bacillus. Another useful protease enzyme is Durazym(trademark) 16.0 L Type Ex which is sold by Novozyme and has an activity of 16 DPU/g. It is a protein-engineered variant of Savinase.
Other conventional ingredients may be included in the instant compositions in small amounts, generally less than about 3 weight percent, such as perfume, hydrotropic agents such as the sodium benzene, toluene, xylene and cumene sulphonates, preservatives, dyestuffs and pigments and the like. The preferred colorant is a yellow dye or pigment. Preferred yellow colorants are Nylosan Yellow N-LGL (Cl Acid Yellow 218), Graphtol Yellow 4534-2 Paste (Cl Pigment Yellow 14, Cl21095), DandC Yellow No. 10 and FDandC Yellow No. 6 and mixtures thereof. A titanium dioxide pigment dispersion such as Hostatint White(trademark) R30 manufactured by Clariant which contains 70 wt. % of titanium oxide can be mixed with the yellow colorant in a weight ratio of 1:20 to 20:1. The instant compositions have a pH of at least about 9., more preferably at least about 8.5.
The water soluble container which can be in the form of a sachet, a blow molded capsule or other blow molded shapes, an injected molded ampoule or other injection molded shapes, or rotationally molded spheres or capsules are formed from a water soluble thermoplastic resin. Water soluble plastics which may be considered for forming the container include low molecular weight and/or chemically modified polylactides; such polymers have been produced by Chronopol, Inc. and sold under the Heplon trademark. Also included in the water soluble polymer family are melt processable poly(vinyl) alcohol resins (PVA); such resins are produced by Texas Polymer Services, Inc., tradenamed Vinex, and are produced under license from Air Products and Chemicals, Inc. and Monosol film produced by Monosol. Other suitable resins include poly (ethylene oxide) and cellulose derived water soluble carbohydrates. The former are produced by Union Carbide, Inc. and sold under the tradename Polyox; the latter are produced by Dow Chemical, Inc. and sold under the Methocel trademark. Typically, the cellulose derived water soluble polymers are not readily melt processable. The preferred water soluble thermoplastic resin for this application is Monosol Film. Any number or combination of PVA resins can be used. The preferred grade, considering resin processability, container durability, water solubility characteristics, and commercial viability is Monosol film having a weight average molecular weight range of about 55,000 to 65,000 and a number average molecular weight range of about 27,000 to 33,000.
The sachet may be formed from poly(vinyl) alcohol film. The pelletized, pre-dried, melt processable polyvinyl alcohol (PVA) resin, is feed to a film extruder. The feed material may also contain pre-dried color concentrate which uses a PVA carrier resin. Other additives, similarly prepared, such as antioxidants, UV stabilizers, anti-blocking additives, etc. may also be added to the extruder. The resin and concentrate are melt blended in the extruder. The extruder die may consist of a circular die for producing blown film or a coat hanger die for producing cast film. Circular dies may have rotating die lips and/or mandrels to modify visual appearance and/or properties.
Typical film properties are:
1. Tensile strength (125 mil, break, 50% RH)=4,700 to 5,700 psi
2. Tensile modulus (125 mil, 50% RH)=47,000 to 243,000 psi; preferred range is 140,000 to 150,000 psi
3. Tear resistance (mean) (ASTM-D-199 gm/ml)=900-1500
4. Impact strength (mean) (ASTM-D-1709, gm)=600-1,000
5. 100% Elongation (mean) (ASTM-D-882, psi)=300-600
6. Oygen transmission (1.5 mil, 0% RH, 1 atm)=0.0350 to 0.450 cc/100 sq. in./24 h
7. Oxygen transmission (1.5 mil, 50% RH, 1 atm)=1.20 to 1.50 cc/100 sq. in./24 h
8. 100% modulus (mean) (ASTM-D-882, psi)=1000-3000
9. Solubility (sec) (MSTM-205,75xc2x0 F.) disintegration=1-15; dissolution=10-30
Typical resin properties are:
1. Glass Transition Temperature (xc2x0C.)=28 to 38; preferred is 28 to 33,
2. Weight Average Molecular Weight (Mw)=15,000 to 95,000; preferred is 55,000-65,000
3. Number Average Molecular Weight (Mn)=7,500 to 60,000; preferred is 27,000 to 33,000. Preferred poly(vinyl) alcohol film is formed from Monsol 9500 or Monosol 8630
The extruded film is slit to the appropriate width and wound on cores. Each core holds one reel of film. The reels of slit film are fed to either a vertical form, fill, seal machine (VFFS) or a horizontal form, fill, seal machine (HFFS). The Form, Fill, Seal machine (FFS) makes the appropriate sachet shape (cylinder, square, pillow, oval, etc.) from the film and seals the edges longitudinally (machine direction seal). The FFS machine also makes an end seal (transverse direction seal) and fills the appropriate volume of aqueous suspended liquid above the initial transverse seal. The FFS machine then applies another end seal. The liquid is contained in the volume between the two end seals.
Blow molded capsules are formed from the poly(vinyl) alcohol resin having a molecular weight of about 50,000 to about 70,000 and a glass transition temperature of about 28 to 33xc2x0 C. Pelletized resin and concentrate(s) are feed into an extruder. The extruder into which they are fed has a circular, oval, square or rectangular die and an appropriate mandrel. The molten polymer mass exits the die and assumes the shape of the die/mandrel combination. Air is blown into the interior volume of the extrudate (parison) while the extrudate contacts a pair of split molds. The molds control the final shape of the package. While in the mold, the package is filled with the appropriate volume of liquid. The mold quenches the plastic. The liquid is contained within the interior volume of the blow molded package.
An injection molded ampoule or capsule is formed from the poly(vinyl) alcohol resin having a molecular weight of about 50,000 to about 70,000 and a glass transition temperature of about 28 to 38xc2x0 C. Pelletized resin and concentrate(s) are fed to the throat of an reciprocating screw, injection molding machine. The rotation of the screw pushes the pelletized mass forward while the increasing diameter of the screw compresses the pellets and forces them to contact the machine""s heated barrel. The combination of heat, conducted to the pellets by the barrel and frictional heat, generated by the contact of the pellets with the rotating screw, melts the pellets as they are pushed forward. The molten polymer mass collects in front of the screw as the screw rotates and begins to retract to the rear of the machine. At the appropriate time, the screw moves forward forcing the melt through the nozzle at the tip of the machine and into a mold or hot runner system which feeds several molds. The molds control the shape of the finished package. The package may be filled with liquid either while in the mold or after ejection from the mold. The filling port of the package is heat sealed after filling is completed. This process may be conducted either in-line or off-line.
A rotationally molded sphere or capsule is formed from the poly(vinyl) alcohol resin having a molecular weight of about 50,000 to about 70,000 and a glass transition temperature of about 28 to 38xc2x0 C. Pelletized resin and concentrate are pulverized to an appropriate mesh size, typically 35 mesh. A specific weight of the pulverized resin is fed to a cold mold having the desired shape and volume. The mold is sealed and heated while simultaneously rotating in three directions. The powder melts and coats the entire inside surface of the mold. While continuously rotating, the mold is cooled so that the resin solidifies into a shape which replicates the size and texture of the mold. After rejection of the finished package, the liquid is injected into the hollow package using a heated needle or probe after filling, the injection port of the package is heat sealed.
The invention may be put into practice in various ways and a number of specific embodiments will be described to illustrate the invention with reference to the accompanying examples.
All amounts and proportions referred to herein are by weight of the composition unless otherwise indicated.


A source encoder schedules its access to a network IP stack. During that scheduled period, the source encoder blocks the transport of non-real-time TCP and UDP packets. After at least one real-time packet has been transported through the stack, the source encoder allows the non-real-time packets to access the physical layer until the beginning of the next scheduled period. Consequently, the packet transport delay is reduced significantly, which results in a substantial increase in throughput.

1. Technical Field of the Invention
The present invention relates in general to the telecommunications field and, in particular, to an Internet Protocol (IP) stack which is suitable for use with real-time telecommunications applications.
2. Description of Related Art
There is a significant need to improve the perceived quality of real-time communications for end users. For example, the perceived quality of such real-time applications as audio or video communications connected with packet-based networks that allow mixed services (e.g., voice, video, data, file sharing, etc.) needs to be improved. A good example of such a packet-based network that allows mixed services is the IP network typically used in the Internet and many companies"" intranets.
Today""s implementation of telephony over IP-based networks has developed into a multi-million dollar industry, wherein data communication companies such as Microsoft, Intel and 3Com are competing with traditional telecommunication companies such as Ericsson, Nokia and Lucent to market their respective products to the network operators. The network operators are not only the traditional companies such as Telia and Telstra, but they also include new companies entering this field, such as Delta Three and Telecom Finland which offer end users low-cost telephony services over IP-based networks. The lower cost for IP-telephony service results from the fact that IP-based communications equipment is less costly than traditional circuit-switched communications equipment. The reduction in costs for the IP-based equipment is due to the large mass market for IP products offered by different vendors, and the less complex components required for the IP-based equipment to complete their assigned tasks.
The typical end user has a great deal of confidence in the traditional telephony services that utilize circuit-switched networks. Users of these services seldom experience dropped calls or blocked calls due to a network overload. Also, the perceived quality of these traditional telephony services is relatively stable. Consequently, in order for IP-based network telephony services to become strongly competitive with the traditional telephony services, the end users will have to receive IP-based services which are similar in both reliability and quality to the traditional services being provided. However, an end user might discount such attractive features if other benefits are made available, such as, for example, lower costs or higher mobility. In fact, the advantages of higher mobility are the primary reasons why the cellular telephony field has grown enormously during the past few years.
From an end user""s point of view, the perceived quality of the telephony services being provided depends on the end-to-end delay and packet losses experienced between the source encoder and decoder. Notably, a packet is assumed to be lost if it is delayed in reaching the decoder for more than a specified period. As such, it is desirable to keep the end-to-end delay as short as possible in all interactive applications (e.g., especially for telephony). A shorter delay improves the conversation possibilities when two persons are talking to each other. A shorter delay also reduces the complexity of the echo cancellers being used, because an echo associated with a shorter delay is less annoying to an end user. Consequently, less cancellation of the echo is needed (i.e., less complex cancellation algorithm). For example, echoes can occur whenever a mismatch exists somewhere in the analog part of the network. Also, echoes can be caused by acoustical coupling between an audio output stage (loudspeaker) and input stage (microphone) of a cellular phone.
As such, the end-to-end delay from an audio input stage to an audio output stage is illustrated by the following delay budget: (1) source encoder delay (including encoder look-ahead); (2) source encoder processing delay; (3) source encoder analysis data packetizing delay; (4) network access delay; (5) network transportation delay; (6) decoder unpacking delay; and (7) decoder synthesis delay. Each of these seven delay segments can introduce an addition to the end-to-end delay, and all of these segments except the source encoder delay (1) can introduce variations to the delay. At the decoder side, a terminal should be able to compensate for the end-to-end delay and the delay variations, or the transmitted packets from the encoder side will be lost.
Terminals used in IP-based networks typically have IP stacks implemented as shown in FIG. 1. As illustrated by FIG. 1, there are various network bearers of IP packets (physical layer), including the Ethernet (most commonly used transport media for IP packets), Asynchronous Transfer Mode (ATM) networks, and wireless network bearers such as the data channels of the Global System for Mobile Communications (GSM) or the packet-based General Packet Radio Service (GPRS). Above the physical layer, the IP (network layer) performs two functions: addressing and fragmentation.
Above the physical layer is the transport layer. In that layer, the Telecommunications Control Protocol (TCP) is connection-oriented between two end-points, and thereby supports the re-transmission of packets which are lost in the chain between the two end-points. The User Datagram Protocol (UDP) is connection-less and used, for example, in real-time applications where re-transmissions would be useless because of the real-time requirements imposed.
IP-telephony applications can be executed in the application layer. An IP-telephony application performs a call setup procedure over the transport layer using the TCP, because it is important that the call be correctly connected. As soon as the connection is established, the application switches over to use the UDP for transmitting speech packets in real-time. As such, the IP stack is a unique resource at an end-point, and several applications can share the IP stack through addressing using the transport layer protocol.
A significant problem that exists for terminals with an IP stack implementation is that the stack functions in accordance with a first-in-first-out (FIFO) scheme, which can lead to undesirable results. For example, several different applications can share the same IP stack. Consequently, TCP packets, which have different real-time requirements than the UDP which is carrying interactive voice packets, can delay the transport of real-time packets through the network stack. Notably, this problem is exacerbated when the physical layer has limited bandwidth.
To illustrate such a problem, assume that a terminal is being used in a GPRS system with a maximum bit rate of 115 kbits/s. Also, assume that the terminal is providing a GSM (or similar system) speech service using a 13 kbits/s coder/decoder (codec). Every 20 ms, the codec packetizes the speech data into 260 bit packets for transmission over the radio channel. Simultaneously, the terminal""s user initiates the transmission of a data file over the radio link. If the maximum packet size needed to obtain a reasonable payload is 132 bytes long (4 bytes and 128 bytes for compressed header and application data, respectively), it takes about 10 ms to transmit the packet containing the data file. If this data packet reaches the IP stack before the speech packet does (with its real-time requirements), the transport of the speech packet will be unnecessarily delayed. This additional transport delay of the speech packet becomes more severe for channels with lower bandwidths, or systems that utilize larger packets. In fact, an additional delay of 10 ms is relatively large compared to a delay requirement of less than 2 ms per router hop or 5-6 xcexcs/km for transmissions between routers. As described in detail below, the present invention successfully resolves these delay problems and other related problems.
In accordance with a preferred embodiment of the present invention, a source encoder schedules its access to a network stack. During that scheduled period, the source encoder blocks the transport of non-real-time TCP and UDP packets. After at least one real-time packet has been transported through the stack, the source encoder allows the non-real-time packets to access the physical layer until the beginning of the next scheduled period.
An important technical advantage of the present invention is that the end-to-end delay is reduced significantly.
Another important technical advantage of the present invention is that packet losses are minimized.
Yet another important technical advantage of the present invention is that there is a substantial increase in throughput.

Internet protocol stack for real time applications


A corrugated box machine having improved delivery means is disclosed. A conveyor belt assembly works in combination with tensioning apparatus, a support bracket assembly and an idler guide assembly.

Corrugated boxes are typically produced in large machines which have several sections, each of which performs one or more steps in the mass production of the boxes. These sections often include an inking section, a gluing section, a folding section, a delivery section and a stacking section.
In operation, corrugated board is fed into the inking section of the corrugated box machine. Here the board is cut, printed and scored for folding. From the inking section the board travels into the gluing section where a bead of glue is applied along one edge of the board. The board then travels into the folding section where long rotating belts convey the board and cause the outer edges of the board to be folded inwardly along the scorelines. As the edges fold over, the glued edge is folded onto the unglued edge to form a seal. Once the board is glued, folded and sealed, it then passes into the delivery section which facilitates the transfer of the finished corrugated box from the folding section into the separate stacking section.
A common problem involved with the folding process is that the leading and trailing edges of the corrugated board become skewed. It is therefore an object of this invenion to provide a corrugated board conveying system which will produce a properly aligned corrugated box.
Another problem with present corrugated box machines involves the belts used for conveying the board material through the gluing and folding sections of the machine. As the belts become worn, they begin to stretch and slip on the rollers and drive pulleys. This is particularly true with the lower main drive belts. It is therefore an object of this invention to provide a corrugated board conveying system which will lessen the slippage of the belts about their respective rollers and drive pulleys.
Once the corrugated box emerges from the folding section, it passes into the delivery section. The delivery section of prior art machines consist of a pair of upper and lower kidney belt assemblies which are used to keep smaller boxes in alignment as they cross the void between the folding and stacking sections of the machine.
The reason for the void between the two sections is that the entrance to the stacking section contains two vertical spiral gears which contact the outer edges of the finished corrugated box and gradually lift the box up and out of the way of the next box exiting the folding section. If the spiral gear is too close to the folding section, longer boxes become bent because the leading edge of the box reaches the top of the spiral before the trailing edge is freed from the folding section. Consequently, upper and lower kidney belt assemblies are used to increase the distance between the two sections.
The upper kidney belt in the prior art machinery is pivotally mounted. Thus when small corrugated boxes are being run, the upper kidney belt can be positioned atop the lower kidney belt to guide the smaller boxes as they pass from the folding section into the stacking section. When larger boxes are being run, the upper kidney belt assembly is pivoted up and out of the way to prevent bending of the larger boxes.
The kidney belts are driven by long drive shafts. As a result, when an old or damaged belt has to be replaced, the entire drive shaft has to be pulled through the machine to replace the belt. This results in costly losses in money and operation time while repairs are being made. It is therefore an object of this invention to provide an improved box conveying system which alleviates the need for such kidney belt assemblies.
Finally, when very wide boxes are being run, they tend to sag under their own weight. This can cause jamming and also loosen the glue seal between the two folded edges of the box. It is therefore an object of this invention to provide a box conveying system with an improved and simplified box support means.
Other objects and advantages of the invention will become apparent as the invention is described hereinafter in detail and with reference to the accompanying drawings.


An animal litter that includes seed meal. The animal litter comprises discrete plural particles of a seed meal, which particles tend to agglomerate into clumps when wetted. The litter of the invention absorbs liquids such as animal excretions, and substantially reduces the odor thereof. Preferably, the litter further includes a grain germ, such as corn germ.

The present invention relates to a grain-based animal litter, and more particularly relates to an animal litter comprising discrete plural particles which tend to agglomerate upon wetting. The invention further relates to a process for preparing the animal litter, and to related products and processes.
Clumping animal litters are those litters which a re initially provided in the form of discrete plural particles, which particles tend to agglomerate into solid masses or clumps when wetted by a liquid such as animal urine. A number of such Clumping litters have been provided in the prior art. One advantage of such clumping litters is that the solid clumps formed upon wetting of the litter can be separately removed as discrete entities from the remaining litter and can be discarded by the animal owner, leaving behind a quantity of relatively uncontaminated litter. Animal owners, and in particular owners of animals such as house cats, often find the clumping property of such litters to be convenient for periodic cleaning of the animal litterbox. Some known animal litters have good ammonia-masking properties. Because ammonia is a breakdown product of the urea found in animal urine, the ability of an animal litter to mask the odor of ammonia is a desired property.
Many clumping animal litters are made from clays and other mineral substrates. Such litters typically include particles of a mineral substrate, which substrate functions as an absorbent and/or odor reducer. The particles may be coated with a liquid-activated adhesive material, such as gelatinized starch, on the surfaces of the particles. When wetted, the adhesive material is activated and causes the discrete litter particles to agglomerate into clumps.
Although clay-based litters may be functional as clumping animal litters, such litters suffer from certain drawbacks. For example, one disadvantage of clay litters is the high density of the clay component of the litter. Because of this high density, a heavy mass of litter must be used for a given volume of urine. The resulting clumps of spent litter are somewhat heavy, and thus can fracture in the absence of strong interparticle adhesion. Another disadvantage of clay litters is that, because the clay is not biodegradable, the litter cannot be flushed into some sewerage systems after use. This may be inconvenient for certain animal owners.
In recognition of these drawbacks, the prior art also has provided animal litters made from biodegradable materials, such as seed hulls or other grain-based materials. Such litters are often suitable for disposal by flushing into sewerage systems. In recognition of the advantages inherent in clumping animal litters, the prior art has provided biodegradable litters that exhibit a clumping property. Like typical clumping clay litters, such litters often comprise discrete particles of a liquid-absorbent substrate having a liquid-activated adhesive coated thereon.
Conventional grain-based litters also suffer from a number of drawbacks. For example, spent clumps of such grain-based litters typically are less durable than clumps of clay-based litters. Moreover, conventional grain-based litters also often have a strong odor, which some people find objectionable, and which further may entice animals such as dogs to eat the litter. Moreover, while grain-based clumping litters may initially form cohesive clumps, the long-term cohesiveness of the formed clumps may be poor. Thus, while a solid clump may be formed and remain solid for a short period of time, the clump may tend to disintegrate with time or on handling, making it difficult to separate the spent clumped litter from the litterbox.
Another problem with both clay-based and grain-based clumping litters relates to clumping efficiency, or the amount of litter required to form a clump. Large amounts of conventional litters are required to form a clump, and thus conventional clumping litters are used up quickly. The animal owner thus is forced to replenish the supply of litter frequently.
In light of the drawbacks inherent in known clay-based and grain-based animal litters, there exists a need in the art for a more satisfactory biodegradable clumpable cat litter. Ideally, the litter should be made from a renewable, biodegradable resource, such as a grain-based substrate. The litter should not be edibly attractive to animals, should have a low odor, and should have excellent ammonia masking properties. The litter also should possess acceptable clumping properties, both with respect to initial and long-term cohesiveness of the clumps. It is a general object of the present invention to provide an animal litter that overcomes the drawbacks inherent in known clumping animal litters.
It has now been found that seed meal, alone or in combination with ground germ or another grain-based substrate, is particularly suitable for use as a clumping animal litter. The present invention is premised on this surprising discovery.
In accordance with one embodiment of the invention, an animal litter is provided. The animal litter comprises discrete plural particles of grain germ and ground seed meal in admixture, the particles tending to agglomerate when wetted. In a preferred embodiment, the litter includes a cohesiveness agent in an amount sufficient to enhance the cohesiveness of the granules. In another embodiment, the invention includes seed meal and a cohesiveness agent. In yet another embodiment, a seed meal is used as animal litter, alone or in combination with other ingredients. Most preferably, the animal litter comprises discrete plural granules of washed grain germ that is spent of oil, seed meal, and a cohesiveness agent in an amount sufficient to enhance the cohesiveness of the granules. The invention further encompasses methods for preparing an animal litter and methods for removing animal waste.
When a litter is made in accordance with the invention, the litter will exhibit an excellent clumping function, such that the granules of litter will agglomerate upon wetting. The clump or clumps formed upon agglomeration of the animal litter will be cohesive, and will remain cohesive for many hours to allow for later removal. Moreover, the litter will be substantially odorless, and will not be edibly attractive to animals such as dogs. The litter will have excellent ammonia-masking properties, and will have a high clumping efficiency.
Other features and embodiments of the invention are disclosed in the following description of the invention and appended claims.
The invention provides a clumping animal litter which agglomerates when wetted by a liquid, such as, for example, liquid animal excretions or liquid that is present in solid or semisolid animal excretions. In accordance with the invention, the litter is provided in the form of discrete plural particles of litter, at least a portion of which particles will agglomerate into at least one clump when wetted. By xe2x80x9cagglomeratexe2x80x9d is meant formation of a relatively cohesive interparticle consolidation of at least two particles. By xe2x80x9cclumpxe2x80x9d is meant a relatively cohesive consolidated mass, or agglomeration, of two or more particles. It is contemplated that the clumps of animal litter formed in accordance with the invention will comprise an agglomeration of at least two particles, preferably at least about 200 particles, and more preferably at least about 2,000 particles, depending upon the volume of liquid applied.
Generally, the litter of the invention includes a seed meal. Examples of such meals include linseed meal, soy bean meal, sunflower meal, cotton seed meal, rapeseed meal, peanut meal, safflower seed meal, and combinations thereof. By xe2x80x9cseedxe2x80x9d is meant to include that part of a plant which is capable of forming a new plant upon germination, e.g., whole grains of wheat, including the fruit or fruit-like structure housing the seed. The seed meal comprises spent ground seed, which is seed residue from which oil has been expelled, such as by solvent extraction or expeller extraction. The extracted residue then is ground, by which is contemplated the reduction of the residue to smaller particles, preferably to a semi-course to fine powder. It is contemplated that some seeds will include a hull that may (but need not) be removed prior to expelling oil and grinding. Thus, the meal may comprise a dehulled meal.
The seed meal alone may be used as an animal litter in accordance with the invention. Preferably, however, the litter further includes a grain germ or another grain-based substrate, which substrate may comprise or be derived from any suitable grain. While grains such as wheat, corn, soy, sorghum, alfalfa, and barley, suitable for use in conjunction with the invention, the grain-based substrate preferably is a corn-based substrate. Most preferably, the grain-based substrate is a grain germ, and even more preferably the substrate is corn germ that is obtained in a wet or dry milling process. The grain germ preferably comprises spent germ, which is grain germ from which oil has been expelled, such as by pressing or hexane or other solvent extraction. Most preferably, the grain germ is expeller extracted, that is, the oil has been removed by pressing. Most preferably, the spent germ is substantially free of odor components.
Surprisingly, it has been found that washing of the germ and seed meal, and the germ or other grain-based substrate prior to the incorporation of these ingredients in an animal litter will substantially remove odor components from the substrate. More surprisingly, it has been found that by so removing the odor components, washing will render the litter more acceptable to cat owners and substantially edibly unattractive to animals such as dogs. It is further believed that washing will reduce the level of flavor components in the grain-based substrate.
The litter of the invention is in the form of discrete plural particles. Preferably, the litter includes discrete plural particles of grain germ and seed meal in admixture, generally an intimate blend of the germ or other substrate and the seed meal and any other ingredients. In accordance with a preferred embodiment of the invention, the particles are in the form of compressed or compacted particles, i.e., in the form of granules. By xe2x80x9cgranulesxe2x80x9d is meant particles that are compressed or compacted, such as by a pelletizing, extrusion, or similar compacting step. Such compression or compacting of the particles is preferred, inasmuch as the intraparticle cohesion of the particles will be enhanced by such compacting or compressing step. In the preferred embodiment of the invention, the granules are prepared by pelletizing the grain-based substrate in a pellet mill. The pellets prepared thereby are ground or crumbled to a granule size suitable for use as an animal litter. Preferably, the animal litter is in the form of granules having a granule size ranging from about 4 to about 400 mesh (USS); more preferably, about 8 to about 80 mesh; and most preferably about 14 to about 20 mesh. If the seed meal and grain based substrate are spent via solvent extraction, use of a lubricity agent such as corn oil may be necessary in the pelletizer, but such a lubricity agent ordinarily is not necessary if the ingredients are expeller extracted. In other embodiments of the invention, the litter is prepared by other compacting or compressing processes such as, for example, by extrusion of the grain-based substrate through a die and grinding of the extrudate to a suitable granule size.
The granules of grain-based substrate may be sufficiently cohesive for use as an animal litter. referably, however, the granules include a cohesiveness agent to enhance the cohesiveness of the animal litter granules. In accordance with the invention, the cohesiveness agent is believed to provide additional hydroxyl groups, which enhance the bonding between grain proteins within the litter granule. It is further believed that the additional hydroxyl groups so function by enhancing the hydrogen bonding of proteins to starch and to other proteins. The cohesiveness agent may be present in any amount suitable to enhance the cohesiveness of the granules of animal litter.
In accordance with the invention, the cohesiveness agent preferably is a polysaccharide. Any suitable polysaccharide may be used in conjunction with the invention and thus, for example, the cohesiveness agent may comprise one or more polysaccharides such as dextrins, maltodextrins, starches, flours, cellulosics, hemicellulosics, and the like. Preferably, the cohesiveness agent comprises a starch, and most preferably, the cohesiveness agent comprises a corn starch.
Prior art litters employ modified, pre-gelatinized starches to effect adhesion between particles of litter, i.e., interparticle adhesion. The starch used in conjunction with the present invention is not used specifically for this purpose, but rather is employed to effect intraparticle cohesion. The clumping interparticle agglomeration of the animal litter of the invention is believed to result primarily as a result of the interaction of proteins or other components present by virtue of the seed meal and/or the grain-based substrate, and is not believed to result from adhesion forces generated through the use of starch. surprisingly, it has been found that non-gelatinized, unmodified starches are especially suitable for use as cohesiveness agents in conjunction with the invention. When unmodified starches are employed, it is believed that such starches may contribute to a small extent to interparticle adhesion in the clumped litter.
The cohesiveness agent of the invention preferably further includes a supplemental cohesiveness agent. In accordance with the invention, the supplemental cohesiveness agent is an ionic species that is believed to enhance protein-protein and/or protein-starch interactions. Any suitable ionic salt may be used in conjunction with the invention. For example, in accordance with preferred embodiments of the invention, the supplemental cohesiveness agent is selected from among the alkali and alkaline-earth salts of common anions, such as the halide, nitrate, nitrite, carbonate, phosphate, sulfate, and bicarbonate salts, and the like. More preferably, the supplemental cohesiveness agent is selected from the group consisting of sodium chloride, calcium chloride, sodium carbonate, calcium carbonate, sodium bicarbonate and mixtures thereof. Even more preferably, the supplemental cohesiveness agent is selected from among sodium chloride, calcium carbonate, and mixtures thereof. Most preferably, the supplemental cohesiveness agent is sodium chloride. The supplemental cohesiveness agent may be present in any amount sufficient to assist the cohesiveness agent in enhancing the cohesion of the animal litter granules.
The animal litter of the invention may comprise the ground seed alone, or in conjunction with other ingredients. The seed meal is preferably present in am amount of at least about 30% by weight, and more preferably at least about 40% by weight, with a highly preferred range being from about 40% to about 50% by weight when the litter includes a grain-based substrate such as corn germ. In these embodiments the grain germ or other grain-based substrate is present in an amount of at least about 25% by weight (dry basis), more preferably at least about 30% by weight, with a preferred range being from about 40% to about 50%, with the proviso that the total amount of germ or other substrate and seed meal preferably is in the range of about 75% to about 95% of the total weight. When the litter includes primarily seed meal and cohesiveness agent, the ground seed preferably is present in an amount of at least about 55% by weight, more preferably at least about 70% by weight, with a highly preferred range being from about 75% to about 95% by weight.
The remaining dry components of the animal litter preferably include the cohesiveness agent, and, when used, a supplemental cohesiveness agent. The cohesiveness agent may be present in a dry basis amount ranging up to about 45% by weight of the animal litter; preferably, an amount ranging from about 3% to about 35% by weight; more preferably, an amount ranging from about 5% to about 25% by weight and most preferably, inclusive of the supplemental cohesiveness agent. The supplemental cohesiveness agent, when used, is preferably present in an amount of at least about 0.05% be weight, exclusive of the polysaccharide cohesiveness agent. More preferably, the supplemental cohesiveness agent is present in an amount ranging from about 0.05% to about 10% by weight; more preferably, about 0.1% to about 8% by weight; and most preferably, about 1.5% to about 4% by weight. In a preferred embodiment, the supplemental cohesiveness agent is present in an amount of about 2% by weight of litter.
The animal litter preferably consists essentially of seed meal, and, in some embodiments, of seed meal, a grain-based substrate such as a grain germ, and a cohesiveness agent with a supplemental cohesiveness agent. Because such animal litters are made from biodegradable materials, the litter is subject to spoilage, such as by molding. To prevent or inhibit such molding, the litter may include a mold inhibitor, which may be present in any amount sufficient to inhibit the molding of the animal litter. Any suitable mold inhibitor may be employed in conjunction with the invention. The mold inhibitor preferably is selected from among the propionate salts, and most preferably is selected from the group consisting of sodium propionate and calcium propionate. When a mold inhibitor is employed, it preferably is present in an amount ranging from about 0.02% to about 3.5% by weight.
To maintain the cohesiveness and sorption capacity of the animal litter, the litter preferably has a moisture content sufficiently high to prevent the granules of animal litter from becoming friable and sufficiently low to allow additional moisture to be absorbed. Preferably, the moisture content is less than about 30%. More preferably, the moisture content ranges from about 5% to about 25%; even more preferably, the moisture content ranges from about 10% to about 20%; even more preferably, the moisture content ranges from about 12% to about 16%, and most preferably the moisture content is about 14.5%. It is contemplated that some of the moisture in the animal litter will be present originally in the grain-based substrate and/or cohesiveness agent.
In accordance with the invention, the animal litter will be effective in suppressing odors of animal waste. Animal urine contains urea, a compound which breaks down in animal litterboxes to form ammonia. The ammonia odor of animal litterboxes is often considered to be objectionable. Animal litters made in accordance with the preferred embodiments of the invention will be effective in masking ammonia odors, and a litterbox containing such litter will remain free from ammonia odors even after up to about 30 hours after an animal has excreted waste into the litter.
The litter of the invention preferably has a density sufficient to allow interparticle binding, yet that will minimize the weight of litter in a litterbox. In accordance with the invention, the litter preferably has a density ranging from about 15 to about 45 lbs./cu.ft.
More preferably, the density of the cat litter of the invention ranges from about 25 to about 40 lbs./cu.ft.; and even more preferably, the density is in the range of from about 30 to about 35 lbs./cu.ft. Density preferably is evaluated after loosely filling a container and measuring the weight of a specific volume of the litter.
Because the animal litter of the invention is to be used to absorb animal waste, the litter should have a sorption capacity sufficient to allow the animal litter to so function. The sorption capacity of the preferred litters of the invention typically is at least about 0.04 ml water per gram of litter, and more typically ranges from about 0.04 to about 2.4 ml/g; more typically, the sorption capacity is from about 1.0 to about 1.4 ml/g. The sorption capacity is determined per gram of animal litter, and is based on the sorption of deionized water, as described in more detail in U.S. Pat. No. 6,098,569.
Preferred sorption capacity ranges are believed to approximate that of animal urine.
Other properties may be desired of an animal litter. For example, to minimize inconvenience and mess associated with packaging, transporting, and using the litter, the litter preferably generates a minimal amount of dust. The preferred litters of the present invention do not generate substantial dust. Another preferred property is clumping efficiency. Clumping efficiency is the amount of litter required to form a clump with a given volume of liquid, with lower amounts of requited litter corresponding to higher clumping efficiencies. Preferably, to absorb 150 ml animal urine, less than about 120 g of litter is required; more preferably, less than about 110 g is required.
Other desired properties include biodegradability and tendency to remain clumped. Biodegradability is particularly desired when the animal owner wishes to dispose of clumps of litter by flushing them into the toilet. The litter of the invention is believed to be at least as biodegradable as hull-based materials, and thus the litter of the invention may be disposed of by flushing, even into a septic system. Tendency to remain clumped refers to the stability of the clump of clumped cat litter. A clumping litter should remain clumped for at least 48 hours after the clump has formed. The litters of the invention have an excellent tendency to remain clumped.
The invention is also directed towards a process for preparing an animal litter. In accordance with the invention, the process comprises the step of providing discrete plural particles of a seed meal in a particle size suitable for use as an animal litter, as previously described. Preferably, the process includes a step of compacting or compressing the particles of animal litter into granules, which most preferably is accomplished in a pelletizing step. The mold inhibitor and cohesiveness agent, when used, can be added at any suitable time, and preferably are mixed with the seed meal in the desired proportions prior to pelletizing. Moisture content in the pellet mill feed preferably is in the ranges set forth above with respect to the moisture content in the finished product, and preferably is about 14-14.5%. Preferably, moisture is added to the feedstock in the form of liquid water to bring the feedstock to this moisture content. The temperature in the pellet mill preferably is brought to about 82xc2x0 C. with steam. The pellet mill may be operated under any conditions that impart sufficient work to the feedstock to provide pellets. In one preferred embodiment, the pellet mill is operated with a xe2x85x9 in.xc3x972 in. die at 100 lb./min. pressure at 82xc2x0 C. to provide pellets, which then are crumbled in a pellet mill crumbler to provide discrete plural particles having a particle size capable of passing through an 8 mesh screen but being retained on a 20 mesh screen.
The process of the invention preferably further includes a step of washing the seed meal and, when used, the germ or other grain-based substrate to substantially remove odor components therefrom. Any suitable washing step can be employed in conjunction with the invention. For example, in accordance with preferred embodiments of the invention, the washing is countercurrent washing. Any suitable washing solvent, such as an aqueous solvent, may be employed in conjunction with the invention. Preferably, the washing solvent is selected from among methanol, ethanol, hydrogen peroxide, water, and mixtures thereof; most preferably, the washing solvent is water.
Also encompassed by the invention is a method for the removal of animal waste. In accordance with the invention, the method comprises the steps of providing a container including the animal litter, allowing the animal to excrete waste into the container, whereby the litter agglomerates into at least one clump, and removing the clump and any solid waste leaving behind substantially unspoiled litter. By xe2x80x9ccontainerxe2x80x9d is meant any enclosed or partially enclosed area, such as a litterbox, a cage, a stall, a pen (such as a poultry cage), or the like. The method is contemplated to be useful for any animals, such as cats, dogs, mice, birds (especially poultry birds such as turkeys and chickens), gerbils, and other animals, and finds particular applicability in connection with removal of waste from house cats and of poultry waste.

Animal litter, process for preparing animal litter, and method for removal of animal waste


A method of creating a comminuted feedstock of wood pulp for use in a processing plant which includes the steps of mounting a plurality of rolls of wood pulp sheet material of a first range of properties in a first roll stand, drawing sheet material off each roll in the first roll stand and laying the sheet materials one on the other to create a first pluri-layer web, withdrawing the first pluri-layer web from the first roll stand and leading it to a cutting area of a shredding mill, acting on the first pluri-layer web in the cutting area with rotating hooked disc cutters to tear platelets from the first pluri-layer web and to pass the torn platelets to an outlet of the shredding mill, pneumatically conveying the torn platelets away from the outlet using a fan with a bladed member rotating in a fan casing, and beating the torn platelets with the bladed member as they are conveyed through the fan casing to separate the torn platelets into pieces torn from the individual layers making up the first pluri-layer web.

1. Field of the invention
This invention relates to a method of creating a comminuted feedstock for use in a processing plant and has particular, but not exclusive, reference to cellulose-based feedstock materials which may be used, inter alia, in the production of cellulosic fibres.
It is known to use wood fibres as a feedstock for a variety of different industrial processing plants. The wood fibres can be supplied to users in the form of rolls of wood pulp sheet material which may have to be broken down into small pieces as an initial stage in the process. This invention is concerned with the method of carrying out a breaking down of wood fibre sheet material to produce small pieces for subsequent processing.
Wood pulp is commonly supplied to end users in roll form, each roll being categorised with reference to at least one particular property of the sheet material, the end user selecting which roll to use for the creation of a feedstock on the basis of an assessment of the value of the particular properties assigned to the rolls that are currently available for use as feedstock. The invention has particular, but not exclusive, application to the situation where an eventual feedstock required for subsequent processing is created by mixing together small pieces removed from the sheet material drawn from a number of different rolls.