Process of Forming a Dissolvable Fiber

A process of forming a dissolvable fiber comprising:

• a. adding one or more water soluble polymers and one or more plasticizers to a twin screw extruder to form a premix;
• b. heating the premix to from about 150° C. to about 400° C.;
• c. cooling the premix to below 135° C.;
• d. mixing one or more anionic surfactants water with the premix to form a mixture;
• e. extruding the mixture from the twin screw extruder to produce an extrudate, wherein the extrudate has a moisture content of from about 20% to about 60%, and wherein the extrudate is from about 70° C. to about 130° C.;
• f. metering the extrudate through a spinneret assembly to produce one or more fiber strands;
• and
• g. spin-drawing and drying the one or more fiber strands to form one or more dissolvable fibers, the dissolvable fiber comprising;
• i. from about 10% to about 60% of one or more anionic surfactants, by weight of the dissolvable fiber, wherein the one or more anionic surfactants have a Krafft point of less than about 30° C.;
• ii. from about 10% to about 50% of one or more water soluble polymers, by weight of the dissolvable fiber;
• iii. from about 1% to about 30% of one or more plasticizers, by weight of the dissolvable fiber;
• and
• iv. from about 0.01% to about 30% water, by weight of the dissolvable fiber;
• wherein the one or more dissolvable fibers has an average diameter of from about 20 microns to about 1,000 microns.