Enzyme Granule Coating for Narrow Particle Size Control
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Solution Overview
Problem
Existing methods for producing small enzyme-containing granules in top-spray fluid bed coating processes face challenges with agglomeration, leading to broad particle size distributions, poor flow characteristics, and inefficient coating, especially when dealing with granules smaller than 300 microns.
Innovation Solution
The production of enzyme-containing granules with a single core of inorganic salts, coated with an enzyme layer and optionally a barrier salt and outer polymer layer, using a fluidized bed spray coater to achieve a narrow particle size distribution and minimize agglomeration, with at least 95% of granules having a diameter of 150 to 300 microns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If small granules are produced in top-spray fluid bed coating process, then better enzyme protection and reduced dust are achieved, but agglomeration occurs leading to broad particle size distribution
Solution Approach 1:
The patent changes the physical parameters of the core particles (size, shape, surface properties) and process parameters (spray rate, fluidization velocity, coating solution composition) to achieve small granule production without agglomeration. Specifically, using cores with diameter of 50-150 microns and controlling the coating solution spray rate and composition prevents the agglomeration that normally occurs with small granules in fluid bed coating.
2Stability of the object's composition
If small granules are produced, then better blending homogeneity is achieved, but agglomeration and poor flow characteristics occur
Solution Approach 1:
The patent optimizes particle size parameters (producing granules with diameter of 150-350 microns) and surface property parameters (through controlled coating) to achieve a balance where granules are small enough for good blending homogeneity but maintain sufficient flow characteristics. The controlled coating process ensures uniform surface properties that prevent agglomeration while maintaining flowability.
3Object-affected harmful factors
If coating is applied to small granules, then enzyme protection is improved, but coating efficiency decreases due to agglomeration
Solution Approach 1:
The patent applies preliminary action by pre-coating the core particles with a binding layer before applying the enzyme-containing coating. This preliminary binding layer prevents agglomeration during the coating process, ensuring that the coating material is efficiently deposited on individual granules rather than being lost to interstitial zones in agglomerates, thus maintaining high coating efficiency while providing enzyme protection.
4Stability of the object's composition
If narrow particle size distribution is achieved, then homogeneous quality is improved, but production complexity increases
Solution Approach 1:
The patent uses preliminary classification of core particles by size before the coating process, ensuring that only cores within the desired size range (50-150 microns) are used. This preliminary action simplifies the overall production process by preventing agglomeration-related quality issues rather than requiring complex post-processing to achieve narrow particle size distribution, thus maintaining quality homogeneity without excessive complexity.
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 results in small, uniformly coated, discrete enzyme-containing granules with improved homogeneity, reduced dust generation, and enhanced mechanical stability, allowing for efficient coating and better handling properties.
Implementation Method 1
a bed of particles is suspended in a randomly circulating or churning bed produced by upward flow of air through a screen or retaining plate at the base of the vessel
Implementation Method 2
into which liquid coating solutions can be directed via spray nozzles inserted into the bed
Data Source
AI summary
The invention provides small enzyme-containing granules having an inorganic salt core and an enzyme-containing layer coated over the core, and methods for producing such granules. The majority of the enzyme granules are less than 300 μm in diameter. The granules are suitable for incorporation into compositions such as cleaning, textile processing, and animal feed compositions.