Dried Microbial Formulations with Controlled Moisture
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Solution Overview
Problem
Current methods for formulating microbial insecticides and fungicides in dry form face challenges such as cell death and stability issues during the drying process, leading to reduced viability and efficacy due to heat exposure, and existing solutions like silica-based compositions have limitations in microorganism concentration and water content optimization.
Innovation Solution
A dried biological composition is created by formulating microorganisms like mold spores and bacteria onto specific substrates with controlled moisture content between 0.01 wt.% and 15 wt.% and water activity levels, using substrates like precipitated silica, diatomaceous earth, and clays, to achieve high colony-forming units (CFU) and maintain viability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If microorganisms are formulated into dried form for ease of handling, then ease of storage and transportation is improved, but cell death and stability issues occur due to the heat of drying
Solution Approach 1:
The patent applies parameter changes by precisely controlling the drying temperature (maintaining it below the microorganism's heat tolerance threshold) and optimizing the water content range (0.01-15 wt%) to achieve a state where microorganisms remain viable while the formulation is sufficiently dry for stable storage and handling. This resolves the contradiction by finding an optimal parameter window that satisfies both ease of handling and cell viability requirements.
2Reliability
If liquid formulations are used to maintain viability and efficacy, then microorganism stability is improved, but storage and transportation require low temperature which is cumbersome and not cost effective
Solution Approach 1:
The patent employs phase transition by transforming the formulation from liquid state to a controlled dry state with specific water content (0.01-15 wt%). This phase change allows the product to be stored and transported at ambient temperatures without refrigeration, while the controlled residual moisture maintains microorganism viability. The formulation transitions between states to optimize both stability and convenience.
3Ease of operation
If silica is loaded with 25-75% living microorganisms to achieve dry mode delivery, then ease of handling is improved, but the concentration and water content are not optimized resulting in quick loss in activity
Solution Approach 1:
The patent optimizes the water content parameter to a specific range (0.01-15 wt%) and controls the drying conditions to achieve low water activity. This parameter optimization prevents excessive microbial respiration that would deplete activity quickly, while maintaining enough moisture for viability. The refined parameter control extends the duration of microorganism activity compared to conventional dry formulations.
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 results in stable dried biological compositions with CFU levels greater than 10^7/g, maintaining viability over time, even at room temperature and elevated humidity, without the need for exogenous protectants like alginate encapsulation.
Implementation Method 1
the silica in Trevino et al. acts as an absorbent and is loaded with 25-75% of living microorganisms
Implementation Method 2
microorganisms can be formulated and dried at a particular temperature onto the surface of various substrates
Data Source
AI summary
Dried and stable biological compositions may have high colony-forming units. Such compositions may include (1) a substrate and (2) micro-organism(s) loaded onto the surface of the substrate, wherein the composition has a total moisture content of about 0.01 wt. % to about 15 wt. %, preferably, about 0.01 wt. % to about 8 wt. %, preferably, about 3 wt. % to about 8 wt. %, preferably, about 5 wt. % to about 8 wt. %, still preferably, selected from 3 wt. %, 5 wt. % and 7 wt. %.