Active-Ingredient Flakes Using Conductance Window Drying
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Solution Overview
Problem
Existing methods for encapsulating, entrapping, and drying active ingredients such as flavors, plant extracts, and nutraceuticals face challenges in preserving their integrity, as freeze-drying is costly and non-continuous, while spray drying leads to significant loss and requires excess active ingredient to compensate for volatilization and oxidation, and there is a need for controlled release in aqueous environments.
Innovation Solution
A process involving combining active ingredients with carriers and optional stabilizers, using conductance window drying to create flakes with low moisture and controlled water activity, resulting in a stable dried product with embedded active ingredients.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If freeze-drying is used to preserve active ingredient integrity, then active ingredient retention is improved, but manufacturing cost increases and productivity decreases
Solution Approach 1:
The invention changes the drying parameters by using conductance window drying at controlled temperatures (60-92°C) with specific belt speeds and moisture contents, transitioning from the gentle but slow freeze-drying process to a more efficient thermal drying process that maintains active ingredient integrity while improving productivity
Solution Approach 2:
The invention replaces the mechanical freeze-drying system with a conductance window drying system that uses thermal conduction through a heated belt, substituting the phase-change-based freeze-drying mechanism with a direct thermal drying mechanism that is more industrially scalable
2Productivity
If spray drying is used to improve productivity, then manufacturing efficiency increases, but active ingredient loss increases due to volatilization and oxidation
Solution Approach 1:
The invention changes the drying parameters by controlling belt temperature (60-92°C), moisture content (0.5-5%), and belt speed to optimize the balance between drying efficiency and active ingredient retention, reducing volatilization and oxidation losses while maintaining high productivity
Solution Approach 2:
The invention introduces a carrier material as an intermediary that encapsulates and protects the active ingredient during the drying process, reducing direct exposure to oxidative environments and volatilization while enabling efficient conductance window drying
3Reliability
If excess active ingredient (10-20%) is added to compensate for spray drying losses, then product stability is improved, but manufacturing cost increases
Solution Approach 1:
The invention converts the potential harm of thermal drying (which could cause loss) into a benefit by using controlled conductance window drying conditions that protect the active ingredient, eliminating the need for excess active ingredient addition while maintaining product stability
4Ease of manufacture
If conventional drying methods are used, then manufacturing simplicity is maintained, but controlled release properties in aqueous environments are insufficient
Solution Approach 1:
The invention applies local quality by creating flakes with specific internal structures and compositions that provide controlled release properties in specific environments (aqueous solutions), while maintaining overall process simplicity through conductance window drying
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process achieves high active ingredient retention, stable release, and cost-effectiveness compared to freeze-drying, with improved stability and controlled release properties.
Implementation Method 1
spreading the wet mixture on a belt of a conductance window dryer with a belt temperature in the range of 60° C.-92° C., and drying the mixture
Implementation Method 2
drying the mixture to produce a flake with less than 7% moisture and a water activity of between 0.15 and 0.7
Data Source
AI summary
A process for producing a dried product, optionally in the form of a flake, the process comprising (a) combining an active ingredient with a carrier, and an optional stabilizer, to create a wet mixture, wherein the active ingredient and carrier are in a ratio of about 1:1 to about 1:250 in the wet mixture; (b) spreading the wet mixture on a belt of a thin film belt dryer with a belt temperature in the range of about 60° C.-92° C.; and (c) drying the mixture to produce a dried product with less than about 7% moisture, optionally about 2-5% moisture, and a water activity of about 0.15 and about 0.65; as well as a dried product that can be produced by the method, and related methods and compositions.