Process for making a high density detergent composition in a single mixer/densifier with selected recycle streams for improved agglomerate properties

A process for continuously preparing high density detergent composition comprising the steps of:

• (a) continuously charging a detergent surfactant paste and dry starting detergent material into a high speed mixer/densifier and a moderate speed mixer/densifier for densification and build-up such that agglomerates are formed which have a median particle size from about 300 microns to about 900 microns, wherein the mean residence time of said agglomerates in said high speed mixer/densifier is from about 2 seconds to about 45 seconds and the mean residence time of said agglomerates in said moderate speed mixer/densifier is from about 0.5 minutes to about 15 minutes;
• (b) screening said agglomerates so as to form a first agglomerate mixture substantially having a particle size of at least about 6 mm and a second agglomerate mixture substantially having a particle size of less than 6 mm;
• (c) feeding said first agglomerate mixture to a grinding apparatus and said second agglomerate mixture to a conditioning apparatus for improving the flow properties of said second agglomerate mixture and for separating said second agglomerate mixture into a third agglomerate mixture and a fourth agglomerate mixture, wherein said third agglomerate mixture substantially has a particle size of less than about 150 microns and said fourth agglomerate mixture substantially has a particle size of at least about 150 microns;
• (d) recycling said third agglomerate mixture into said high speed mixer/densifier for further agglomeration;
• (e) separating said fourth agglomerate mixture into a fifth agglomerate mixture and a sixth agglomerate mixture, wherein said fifth agglomerate mixture has a particle size of at least about 900 microns and said sixth agglomerate mixture has a median particle size of from about 50 microns to about 1400 microns;
• (f) inputting said fifth agglomerate mixture into said grinding apparatus for grinding with said first agglomerate mixture to form a ground agglomerate mixture which is recycled into said conditioning apparatus;
• and
• (g) admixing adjunct detergent ingredients to said sixth agglomerate mixture so as to form said high density detergent composition.