Composite Microcapsule Wall for Heat and Shear Resistance
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Solution Overview
Problem
Existing microcapsules fail to provide adequate protection for bioactive substances during high-temperature sterilization and high-shear food processing, leading to inactivation of probiotics and other sensitive ingredients.
Innovation Solution
A heat-resistant and shear-resistant microcapsule is developed, comprising a core material of oil and fat, a protein coating layer, and a wall material formed by heat-curing a colloid, which provides enhanced protection through phase change endothermic effects and further resistance to high temperatures and shear forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high temperature sterilization is applied to kill microorganisms, then sterilization effectiveness is improved, but the wall material melts and bioactive substances become inactivated
Solution Approach 1:
The patent employs a composite wall material structure consisting of an outer polysaccharide gel layer and an inner protein layer. This composite structure combines the heat-resistant properties of polysaccharides with the protective and functional properties of proteins, creating a wall that can withstand high-temperature sterilization while protecting bioactive substances from heat inactivation.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the wall material by controlling the gelation process of polysaccharides and the denaturation temperature of proteins. By adjusting parameters such as gelation temperature, protein concentration, and molecular weight, the wall material is designed to maintain structural integrity at sterilization temperatures while protecting sensitive bioactive substances.
2Productivity
If high temperature stirring is applied during food processing, then processing efficiency is improved, but bioactive substances are inactivated due to heat and shear force
Solution Approach 1:
The composite wall structure combines polysaccharide gel (providing heat resistance) with protein (providing mechanical strength and shear resistance). This composite material can withstand the combined effects of high temperature and shear force generated during industrial processing, protecting bioactive substances from inactivation while allowing efficient processing.
Solution Approach 2:
The patent creates a protective barrier beforehand by forming a gelified polysaccharide-protein wall around bioactive substances. This pre-formed protective layer acts as a cushion against subsequent heat and shear force during processing, preventing direct contact and inactivation of the sensitive bioactive substances.
3Ease of manufacture
If ordinary microcapsule wall material is used, then manufacturing simplicity is maintained, but the microcapsule detaches from core material due to shear force during stirring
Solution Approach 1:
The patent uses a composite wall material system where polysaccharide gel provides the bulk structure and protein provides mechanical strength and adhesion. This composite approach maintains manufacturing simplicity through a straightforward gelation process while significantly improving the attachment strength between the microcapsule wall and core material, preventing detachment during processing.
Solution Approach 2:
The patent optimizes parameters such as polysaccharide concentration, gelation temperature, and protein content to achieve the right balance between manufacturing simplicity and structural stability. By controlling these parameters, the wall material forms strong adhesion to the core material while maintaining ease of fabrication through conventional microencapsulation techniques.
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 microcapsule significantly improves the stability and viability of bioactive substances, offering over 1 million times better resistance to high temperature shear and gastric acid, reducing loss during processing and gastrointestinal digestion.
Implementation Method 1
the wall material is formed by heat-curing of a colloid
Implementation Method 2
the wall material is formed by heat-curing of a colloid
Implementation Method 3
a protein coating layer wrapping the core material
Data Source
AI summary
A heat-resistant and shear-resistant microcapsule, comprising a core material, a protein wrapping layer wrapping the core material, and a wall material wrapping the protein wrapping layer. The core material comprises grease. The wall material is formed by heating and curing a colloid. According to the microcapsule, first, an internal environment in which moisture and oxygen are isolated is provided by wrapping internal phase grease with a protein, and the survival rate and stability of active substances in a heat treatment process are improved by means of heat absorption in phase change at melting points; then, the wall material is used for further protection, so that the microcapsule has relatively high stability, has relatively strong shear resistance while having high temperature resistance, and also has relatively high acid resistance.