Electrostatic Spray Drying for Viable Microorganism Encapsulation
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Solution Overview
Problem
Conventional spray drying methods are ineffective for drying living microorganisms due to the adverse effects of electrostatic charges on viability, and existing electrostatic methods are inefficient for encapsulation and require high viscosity solutions, making them unsuitable for preserving microbial viability.
Innovation Solution
An electrostatic spray drying process is developed where a suspension with a solvent having a higher dielectric constant than the additive, which has a higher dielectric constant than the microorganism, is charged to form droplets with polar components at the surface and less polar components at the center, using controlled electrostatic charging and low oxygen conditions to encapsulate microorganisms efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If electrostatic charging is applied to suspension for spray drying, then droplet formation and collection are improved, but microorganism viability is reduced due to high voltage effects
Solution Approach 1:
The patent changes the dielectric constant parameter of the solvent to be higher than the additive, which has a higher dielectric constant than the microorganism. This parameter change enables selective positioning of components during electrostatic charging while maintaining microorganism viability through controlled electrostatic fields rather than direct high voltage exposure.
Solution Approach 2:
The patent creates local quality differences by positioning polar components (solvent and additive) at the droplet surface and less polar components (microorganisms) at the center. This spatial differentiation protects microorganisms from direct electrostatic stress while maintaining overall drying efficiency.
2Productivity
If conventional spray drying is used for microorganisms, then manufacturing scalability is achieved, but encapsulation efficiency is poor and microbial integrity is compromised
Solution Approach 1:
The patent introduces dielectric constant as a key parameter for selecting solvent and additive materials. By ensuring the solvent has a higher dielectric constant than the additive, and the additive has a higher dielectric constant than the microorganism, the process achieves both scalable manufacturing and precise encapsulation through electrostatic differentiation.
Solution Approach 2:
The patent uses the additive as an intermediary substance between the solvent and microorganisms. The additive positions itself at the droplet surface through electrostatic effects, creating a protective barrier that encapsulates microorganisms while allowing the process to scale efficiently.
3Manufacturing precision
If high viscosity solutions are used for electrostatic spray drying, then encapsulation is improved, but drying efficiency decreases and process complexity increases
Solution Approach 1:
The patent changes the viscosity parameter by selecting appropriate solvent and additive combinations based on dielectric constant relationships. This allows the process to achieve effective encapsulation without requiring excessively high viscosity solutions, thereby maintaining faster drying speeds and simpler process conditions.
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 preserves the viability of microorganisms by encapsulating them in a protective additive, allowing for rapid solvent evaporation and efficient drying while maintaining microbial integrity.
Implementation Method 1
Applying an electrostatic charge to said suspension; forming droplets of said suspension
Implementation Method 2
the solvent has a higher dielectric constant than the additive, and the additive has a higher dielectric constant than the microorganism
Implementation Method 3
drying said droplets, thereby forming dried particles
Implementation Method 4
rapidly dried by the use of a gaseous hot drying medium
Implementation Method 5
The drying process of the formed droplets is accelerated due to a resulting coulomb fission process wherein the formed droplets shed smaller daughter droplets due to electrostatic interactions
Data Source
Figure 1
Figure 2~3B
Figure 4
AI summary
The present disclosure relates to a process for electrostatic spray drying of a living microorganism, the process comprising the following steps: a. Providing a suspension, comprising a number of components, including a microorganism, a solvent and an additive; b. Applying an electrostatic charge to said suspension; c. Forming droplets of said suspension; d. Drying said droplets, thereby forming dried particles; and e. (Optionally) collecting the dried particles.