The structure of spray-dried detergent powders

The complex multi-scale structure of spray-dried detergent granules has been characterized using a range of techniques including microscopy, wide-angle and small-angle X-ray scattering and X-ray microtomography. Four simple model formulations based on linear alkyl benzene sulphonate (NaLAS) and sodium sulphate were used to probe the influence of initial slurry water content and sodium silicate on the structure. The structure can be viewed as a porous matrix consisting of liquid crystalline NaLAS, sodium sulphate and binder in which large crystals of sodium sulphate are embedded. These large crystals were initially undissolved in the slurry and are consequently reduced in number in the product made from higher water content slurry. The both slurry water content and sodium silicate changed the polymorphs, and the d-spacing of the lamellae. The surface micro-structure and particle morphology can also be significantly affected with the high initial water content; particles having a distinct agglomerated and blistered structure.