Nano-dispersed Carotenoid Microcapsule Preparation via Rotating Packed Bed
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Solution Overview
Problem
Existing methods for preparing water-dispersible carotenoid powders face challenges such as low grinding efficiency, high power consumption, difficulty in achieving particle sizes less than 1 μm, and low content of all-trans-isomers, along with complex and costly processes that are hard to control, leading to inefficient production and bioavailability issues.
Innovation Solution
A method involving milling crystallized carotenoids with dichloromethane to achieve a 10-20% suspension, followed by dissolution in a high gravity rotating packed bed, rapid desolventization, and spray drying with antioxidants and protective colloids to produce nano-dispersed high-all-trans-carotenoid microcapsules with a high content of all-trans-isomers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If carotenoids are ground into fine particles using colloid mill, then particle size is reduced to 2-10 μm, but grinding efficiency is low and power consumption is high
Solution Approach 1:
The patent replaces the mechanical grinding system (colloid mill) with a chemical dissolution-precipitation system. Carotenoids are dissolved in organic solvents and then precipitated to form fine particles, eliminating the need for high-power mechanical grinding while achieving comparable or finer particle sizes.
Solution Approach 2:
The patent changes the physical state of carotenoids from solid crystalline form to dissolved state in organic solvent, then to precipitated fine particles. This parameter change from solid to solution to precipitate enables particle size reduction without mechanical grinding, improving efficiency and reducing power consumption.
2Length of moving object
If carotenoids are processed using high pressure and high temperature methods, then particle size is reduced to less than 0.5 μm, but equipment requirements become strict and operation becomes difficult to control
Solution Approach 1:
The patent uses parameter changes through solvent selection and temperature control during dissolution and precipitation, rather than extreme high pressure and temperature. This achieves fine particle sizes with simpler equipment and easier operational control.
Solution Approach 2:
The patent introduces organic solvents as intermediaries to facilitate the dissolution and precipitation process. The solvents act as mediators that enable particle size control without requiring complex high-pressure equipment, simplifying the overall process.
3Stability of the object's composition
If solvents are used to dissolve carotenoids, then dissolution is achieved, but a large volume of solvents must be removed taking a long time and residual solvents remain
Solution Approach 1:
The patent utilizes phase transitions of solvents (evaporation from liquid to gas) to remove solvents efficiently. By controlling the dissolution and precipitation processes with appropriate solvent selection, the solvent removal is accelerated and residual solvent content is minimized.
Solution Approach 2:
The patent optimizes solvent selection and process parameters (temperature, pressure, solvent-to-carotenoid ratio) to enable faster solvent removal and more complete evaporation, reducing both time and residual solvent content in the final product.
4Ease of manufacture
If conventional methods are used to prepare carotenoid powders, then water-dispersible preparation is achieved, but content of all-trans-isomer is low (less than 85%)
Solution Approach 1:
The patent performs preliminary action by carefully controlling the dissolution conditions and selecting appropriate solvents before precipitation occurs. This preliminary control of dissolution parameters ensures that when precipitation happens, the all-trans-isomer content is maximized (greater than 85%).
Solution Approach 2:
The patent uses parameter changes in the dissolution and precipitation process, including temperature, solvent type, and concentration, to control the isomer composition during particle formation, thereby achieving high all-trans-isomer content in the final product.
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
This method results in high bioavailability, reduced residual solvents, simplified operation, and high content of all-trans-isomers (>90%) without requiring high-pressure equipment, enabling continuous production and improved industrial applicability.
Implementation Method 1
dissolution in a high gravity rotating packed bed, rapid desolventization
Implementation Method 2
spray drying with antioxidants and protective colloids to produce nano-dispersed high-all-trans-carotenoid microcapsules
Data Source
AI summary
A method of preparing nano-dispersed high-all-trans-carotenoid microcapsules is provided, comprising: preparing 10-20% carotenoid suspension by milling the high-all trans-carotenoid crystals with dichloromethane until the particle size thereof is in the range of 2-5 μm, then supplying the suspension together with preheated dichloromethane of another pass into a dissolving tank to obtain a solution of 0.5-2%; delivering the solution together with ethanol or isopropanol into a crystallization device having high gravity rotating packed bed simultaneously and continuously, and then into a wiped-film evaporator for desolvation until the solid content is 10-20%, then a transparent alcohol dispersion of carotenoid is obtained; mashing the alcohol dispersion together with an aqueous solution containing an antioxidant and protective colloid and spray drying to obtain nano-dispersed high-all-trans-carotenoid microcapsules. As the crystals are nano-dispersed and the content of trans-isomer is more than 90%, the carotenoid microcapsules of present inventions exhibit high bioavailability.