Process for making a high density detergent composition by controlling agglomeration within a dispersion index

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

• (a) agglomerating a detergent surfactant paste and dry starting detergent material in a high speed mixer/densifier to obtain agglomerates, wherein said dry detergent material comprises a builder selected from the group consisting of aluminosilicates, crystalline layered silicates, sodium carbonate, Na.sub.2 C.sub.3 (CO.sub.3).sub.2, K.sub.2 Ca(CO.sub.3).sub.2, Na.sub.2 Ca.sub.2 (CO.sub.3).sub.3, NaKCa(CO.sub.3).sub.2, NaKCa.sub.2 (CO.sub.3).sub.3, K.sub.2 Ca.sub.2 (CO.sub.3).sub.3, and mixtures thereof;
• (b) controlling the flow rate and temperature of said surfactant paste and said dry starting material and the residence time, speed, and mixing tool and shovel configuration of said high speed mixer/densifier such that said agglomerates have a Dispersion Index in a range of from about 1 to about 6, wherein
• Dispersion Index=A/B
• A is the surfactant level in said agglomerates having a particle size of at least 1100 microns, and B is the surfactant level in said agglomerates having a particle size less than about 150 microns;
• (c) mixing said agglomerates in a moderate speed mixer/densifier to further densify, build-up and agglomerate said agglomerates;
• (d) feeding said agglomerates into a conditioning apparatus for improving the flow properties of said agglomerates and for separating said agglomerates into a first agglomerate mixture and a second agglomerate mixture, wherein said first agglomerate mixture substantially has a particle size of less than about 150 microns and said second agglomerate mixture substantially has a particle size of at least about 150 microns;
• and
• (e) recycling said first agglomerate mixture into said high speed mixer/densifier for further agglomeration so as to form said high density detergent composition having a density of at least 650 g/l.