New alcohol ether sulfates with extremely low 1,4-Dioxane and no possibility for drift when formulated

Over the past five years, global regulations for 1,4-dioxane levels in cleaning and personal care products have become increasingly stringent, with laws in regions such as New York, heightened oversight from the U.S. EPA, and regulations from the European Union. The primary challenge stems from the sulfation process, where alcohol ethoxylates are converted into alcohol ether sulfates, inadvertently generating 1,4-dioxane as a byproduct. As a highly water-soluble compound, its removal is both costly and time-consuming. Additionally, alcohol ether sulfates can continue to generate 1,4-dioxane during storage over time through a process known as drift, further complicating compliance efforts.

While there are alternative low or no 1,4-dioxane options, many of these alternatives avoid ether sulfates which requires entirely different chemistries. As a result, formulators often need to return to the bench to reformulate, which can necessitate re-registering their products. This process can be time-consuming, costly, and disruptive for manufacturers.

In response to these challenges, the process for creating alcohol ether sulfates was reimagined and optimized, ensuring the improved product does not generate 1,4-dioxane during the standard sulfation process with SO3 or through drift over time.  The resulting new product remains a “drop-in” replacement to traditional alcohol ether sulfates with the same effectiveness in home and personal care applications. This innovative alcohol ether sulfate contains 1,4-dioxane at concentrations below the detectable limit of 60 ppb and shows no increase in 1,4-dioxane levels even under acidic conditions or elevated storage temperatures (54°C). By eliminating 1,4-dioxane formation both during production and storage, the new product offers a safer, more compliant solution to formulators, enabling them to meet strict regulatory requirements without the need for costly reformulation or re-registration. This breakthrough provides a “drop-in” replacement and an efficient path forward for cleaning and personal care formulations in the face of increasing regulatory pressure.