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Modern Fabric Softener Production: High Concentrate Formulation and Efficient Processing

Rise of High-Concentrate Liquid Fabric Softeners

Packing sizes have decreased to 1–1.5 liters with the advent of 4x concentrates (approx. 20% active matter), enabled by cationics like esterquat.

Challenges of Traditional Batch Production

High viscosity during mixing limits capacity and increases production time, especially when molten esterquat meets warm water.

Continuous Processing with BRAN+LUEBBE Master Batch System

This modern approach streamlines production and enhances stability through frequency-controlled mixing with PENTAX equipment.

Controlled Mixing and Electrolyte Addition

Electrolyte solutions are key to final viscosity and shelf stability; mixed precisely with softened water and esterquat in the pre-mix chamber.

Perfume and Color Integration After Cooling

Once cooled to 25°C, final additives like fragrances and colorants are introduced via static or dynamic mixing.

Flexible Finishing Options for Perfume-Color Variants

• Energy-efficient process flow
• Parallel B+L finishing lines for multiple combinations

Energy Optimization Strategies

Option 1: Heat Recovery from Dispersion

Uses process water as a coolant; recovers 70–80% of thermal energy before final cooling via cold-water heat exchanger.

Option 2: Hot and Cold Water Split

Premix with hot water and electrolyte in the PENTAX, followed by cold-water dilution and final cooling in a heat exchanger.

Customization Based on Site-Specific Parameters

Production strategy depends on raw materials, local infrastructure, and desired product quality.