Double-Layer Microparticle Coating for Heat and Moisture Protection
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Solution Overview
Problem
Existing encapsulation methods for bioactive substances in food products fail to protect them from heat, humidity, and acidic environments, particularly when water is involved, leading to degradation and inactivation during processing and storage.
Innovation Solution
A double-layer coated microparticle design comprising an inner layer of hydrophobic antioxidant and an outer layer of solid fat, which provides protection against undesirable conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solid fat encapsulation is used to protect bioactive substances from humidity, then moisture resistance is improved, but the coating is easily ruptured when water is added during food manufacturing
Solution Approach 1:
The patent uses a composite coating system combining solid fat and wax materials to create a multi-component protective layer. This composite structure provides both moisture resistance and mechanical strength, preventing coating rupture when water is added during food manufacturing processes.
Solution Approach 2:
The patent employs a multi-layer encapsulation structure where the bioactive substance is nested within an inner core, which is then coated with multiple protective layers including solid fat and wax. This nested arrangement provides progressive protection, with each layer contributing to overall coating integrity and moisture resistance.
2Reliability
If solid fat coating with high melting point is used to protect from humidity, then moisture protection is improved, but temperature sensitive bioactive substances are damaged during coating process
Solution Approach 1:
The patent modifies the melting point parameter of the coating materials by selecting solid fats and waxes with melting points below 40°C. This parameter change allows the coating to be applied at lower temperatures that do not damage temperature-sensitive bioactive substances like probiotics, while still providing effective moisture protection when solidified.
Solution Approach 2:
The patent utilizes phase transition of the solid fat and wax coating materials from liquid to solid state during the coating process. The materials are applied in a liquid or semi-liquid state at low temperatures, then undergo phase transition to form a solid protective barrier, avoiding heat exposure that would damage bioactive substances.
3Ease of manufacture
If water-soluble polymer encapsulation is used, then ease of incorporation into food products is improved, but protection from oxidation and degradation in aqueous conditions is lost
Solution Approach 1:
The patent introduces solid fat and wax materials as intermediary protective layers between the bioactive substance and the aqueous food matrix. These intermediary layers act as barriers to water and oxygen, preventing direct contact and subsequent oxidation or degradation, while still allowing the encapsulated product to be incorporated into food systems.
Solution Approach 2:
The patent employs thin film encapsulation using solid fat and wax coatings that form flexible yet protective barriers around the bioactive substance. These thin film layers provide effective protection against oxidation and moisture while maintaining compatibility with food product incorporation.
4Ease of operation
If conventional encapsulation methods are used, then conversion to free-flowing powder is achieved, but protection from heat and acidic incursions during processing is insufficient
Solution Approach 1:
The patent combines multiple protective materials (solid fat, wax, and potentially polymer layers) to create a composite encapsulation system. This composite structure provides enhanced protection against heat, acid, and oxidation while maintaining the free-flowing powder characteristics necessary for easy handling and incorporation into food products.
Solution Approach 2:
The patent adds protective dimensions to the encapsulation system by introducing multiple functional layers with different protective properties. Each layer addresses specific threats (heat, acid, moisture, oxidation), creating a multi-dimensional protective barrier that goes beyond conventional single-layer encapsulation.
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 double-layer coating maintains the integrity and activity of bioactive substances by preventing degradation from heat, oxidation, and humidity, even in acidic environments.
Implementation Method 1
The inner layer comprises a hydrophobic antioxidant
Implementation Method 2
protecting bioactive substances from heat, humidity, oxidation and acidic incursions
Implementation Method 3
The outer layer comprises a solid fat
Implementation Method 4
particles of a bioactive substance may be encapsulated with a single protective layer of solid fats
Implementation Method 5
maintains the integrity and activity of bioactive substances by preventing degradation from heat
Data Source
AI summary
A double-layer coated microparticle for protecting a bioactive substance is provided. The double-layer coated microparticle comprises a core, an inner layer and an outer layer, wherein the core is coated with the inner layer and the outer layer, the inner layer is between the core and the outer layer, the core comprises the bioactive substance, the inner layer comprises a hydrophobic antioxidant, and the outer layer comprises a solid fat. Also provided is a method for preparing the double-layer coated microparticle. The preparation method comprises contacting the core with an inner layer solution to form the inner layer on the core, whereby an inner-layer coated microparticle is obtained; and contacting the inner-layer coated microparticle with an outer layer solution to form the outer layer on the inner-layer coated microparticle.