Emulsion Production Using Cavity Transfer Mixer
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Solution Overview
Problem
Current methods for producing emulsions, particularly concentrated oil-in-water emulsions with finely dispersed lipophilic compounds like phytosterols and carotenoids, face challenges in achieving high concentration and stability with low energy input and high throughput, especially for applications in food, personal care, and pharmaceutical products.
Innovation Solution
A method using a Controlled Deformation Dynamic Mixer (CDDM) or Cavity Transfer Mixer (CTM) to create a water-continuous emulsion with a mean Sauter diameter of less than 1 micrometer and a dispersed phase concentration of at least 20% by weight, involving mixing water with an oil-in-water emulsifier and a lipophilic compound in a distributive and dispersive mixing process, which induces extensional flow and requires lower pressures compared to high-pressure homogenizers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high-pressure homogenizers are used to produce concentrated emulsions, then fine dispersion is achieved, but energy consumption and equipment material requirements increase
Solution Approach 1:
The patent changes the operational parameters by using moderate pressure (avoiding extremely high pressures) combined with specific mixer geometry (cavity transfer mixer with defined cavity dimensions and arrangements) to achieve fine dispersion without the energy-intensive high-pressure homogenization process
Solution Approach 2:
The patent replaces the high-pressure mechanical homogenization system with a cavity transfer mixer system that uses controlled fluid dynamics and cavity-induced flow patterns to achieve dispersion, substituting a different mechanical approach that consumes less energy
2Reliability
If conventional mixing methods are used, then equipment simplicity is maintained, but emulsion stability and fineness are insufficient
Solution Approach 1:
The mixer incorporates segmented cavities in both the stator and rotor that create multiple discrete mixing zones, allowing the emulsion to undergo repeated cycles of deformation and relaxation as it passes through each cavity, thereby achieving fine dispersion and stable emulsion formation
Solution Approach 2:
The cavity transfer mixer features nested cavity structures where cavities in the rotor are positioned to interact with cavities in the stator, creating a multi-level mixing architecture that enhances dispersion effectiveness while maintaining a compact overall structure
3Quantity of substance
If high concentrations of dispersed phase are used, then product efficiency is improved, but mixing difficulty and energy requirements increase
Solution Approach 1:
The patent optimizes the concentration parameter by formulating emulsions with high dispersed phase content (at least 20 wt%) while adjusting other parameters such as cavity dimensions, gap sizes, and flow rates to maintain efficient mixing without excessive energy input
4Manufacturing precision
If prolonged mixing is used to achieve fine dispersion, then droplet size is reduced, but production time increases
Solution Approach 1:
The cavity transfer mixer creates periodic flow patterns as the rotor rotates, causing the emulsion to undergo cyclic deformation and relaxation as it passes through the cavities. This periodic action enhances droplet breakup efficiency and achieves fine dispersion in a single pass or few passes, maintaining high production throughput
Solution Approach 2:
The mixer geometry is designed to create preliminary high-shear zones at the cavity entrances and exit regions, preparing the emulsion for efficient droplet breakup before the material completes a full rotation, thereby reducing the number of passes needed to achieve target droplet sizes
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 achieves stable, finely dispersed emulsions with high lipophilic compound concentrations, reducing energy consumption and equipment material requirements, and enhances bio-accessibility of phytosterols by maintaining them in an amorphous state, suitable for various product applications.
Implementation Method 1
The cavities are arranged on the relevant surfaces such that shear is applied to the liquid as it flows between the surfaces
Implementation Method 2
material is also subjected to extensional deformation. The extensional flow and efficient dispersive mixing is secured by having confronting surfaces with cavities arranged such that the cross sectional area for bulk flow of the liquid through the mixer successively increases and decreases
Implementation Method 3
mixing water and an oil-in-water emulsifier to form an aqueous phase
Implementation Method 4
an oil-in-water emulsifier
Data Source
AI summary
The present invention has as an objective to provide a new emulsification method, which can produce concentrated water-continuous emulsion containing lipophilic compounds in a dispersed phase, with a very fine dispersed phase droplet size less than a micron, and a narrow size distribution of the dispersed phase. This objective has been met by a method wherein a water-continuous emulsion is made using a Controlled Deformation Dynamic Mixer or a Cavity Transfer Mixer.