Bioactive Particle Formation Without Activity Loss
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Solution Overview
Problem
Existing methods for producing fine particles with bioactive substances result in significant reduction of biological activity due to heating, shaking, or stirring, leading to potential inactivation of the bioactive substance and incomplete encapsulation.
Innovation Solution
A method involving the discharge of a bioactive-substance-containing liquid as droplets without applying heat or external stress, followed by solvent removal to form particles, minimizing changes in biological activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If heating, shaking, or stirring is applied during particle production, then the particle formation process is accelerated and mixing is improved, but the biological activity of the bioactive substance is significantly reduced
Solution Approach 1:
The patent replaces mechanical mixing methods (stirring, shaking) with a spray drying system that uses atomization and rapid evaporation. The liquid containing the bioactive substance is sprayed into fine droplets and quickly dried, forming particles without requiring mechanical agitation that would damage the bioactive substance.
Solution Approach 2:
The patent utilizes the phase transition of the solvent from liquid to vapor through rapid evaporation during spray drying. This phase change occurs so quickly that it forms particles before the bioactive substance can be damaged, achieving both efficient particle formation and preservation of biological activity.
2Manufacturing precision
If conventional spray drying or emulsion solvent diffusion is used, then fine particles can be produced, but the bioactive substance becomes inactivated or incompletely encapsulated
Solution Approach 1:
The patent performs preliminary action by preparing the liquid formulation with appropriate surfactants and viscosity modifiers before spray drying. This pre-treatment ensures that when the liquid is sprayed, it forms uniform droplets that encapsulate the bioactive substance completely during the rapid drying process, preventing inactivation.
Solution Approach 2:
The patent uses rapid spray drying that skips the intermediate stages where damage could occur. The liquid is quickly atomized and dried in a short residence time, rushing through the process before the bioactive substance can be inactivated or before incomplete encapsulation can occur.
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 method effectively maintains a biological activity level of 80% or greater during particle production, ensuring the bioactive substance remains active and encapsulated within the particles.
Implementation Method 1
discharging the bioactive-substance-containing liquid as droplets
Implementation Method 2
removing the solvent from the droplets to form particles
Data Source
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AI summary
A method for producing particles is provided. The method includes: preparing a bioactive-substance-containing liquid that includes a bioactive substance and a solvent; discharging the bioactive-substance-containing liquid as droplets; and removing the solvent from the droplets to form particles, wherein a biological activity ratio represented by {(biological activity level B/biological activity level A) × 100} is 80% or greater, where the biological activity level A is a biological activity level of the bioactive substance before the preparing the bioactive-substance-containing liquid, and the biological activity level B is a biological activity level of the bioactive substance after the preparing of the bioactive-substance-containing liquid.