Enzyme Granule Melt-Delayed Layer Coating
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Solution Overview
Problem
Existing methods for producing enzyme granules are prone to irreversible inactivation during industrial processes like pelleting, leading to reduced enzyme activity, and previous attempts at using melted coatings have resulted in manufacturing challenges such as clogging and temperature control issues.
Innovation Solution
A method involving a core with an enzyme active agent, a melt-delayed layer applied in an un-melted form, and a melt-resistant coating layer that melts at a higher temperature, allowing the melt-delayed layer to be melted without agglomeration, forming a stable granule.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coating is applied in melted form to create a continuous coating, then barrier properties are improved, but particles agglomerate and fuse together causing manufacturing defects
Solution Approach 1:
The coating is applied in un-melted form first, establishing a continuous coating structure before melting occurs. This preliminary application prevents agglomeration during the coating process while still achieving the desired continuous barrier layer, as the material is melted after application rather than during application.
Solution Approach 2:
The coating process is divided into two distinct stages: application in un-melted form and subsequent melting. This segmentation allows the coating material to be applied as discrete particles that do not agglomerate, then transformed into a continuous melted layer, resolving the contradiction between achieving continuous coating and preventing particle fusion.
2Productivity
If enzymes are subjected to heat treatment during pelleting, then processing is enabled, but irreversible inactivation and reduced enzyme activity occur
Solution Approach 1:
The melting point of the coating material is specifically adjusted to be higher than the pelleting temperature. This parameter change ensures that while the coating provides thermal protection during pelleting, it still melts at controlled conditions to form the desired continuous barrier layer, thereby protecting enzyme activity while enabling processing.
Solution Approach 2:
The granule consists of a composite structure with the enzyme core protected by a coating layer with specific thermal properties. This composite design allows the coating to withstand pelleting temperatures without melting (protecting the enzyme) while being capable of melting at higher temperatures to form the continuous barrier structure.
3Reliability
If the melt-delayed layer is melted to form a continuous coating, then barrier properties are improved, but agglomeration occurs destroying granule intactness
Solution Approach 1:
The continuous coating structure is established in advance by applying the material in un-melted form, before the melting step occurs. This preliminary continuous layer prevents agglomeration during melting because the material is already in its final continuous configuration, eliminating the harmful fusion of particles.
Solution Approach 2:
The conventional approach is inverted: instead of melting material and then applying it (which causes agglomeration), the material is first applied in un-melted form to create a continuous coating, and then melted in place. This reversal of the sequence eliminates agglomeration while achieving the desired continuous barrier properties.
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 approach prevents agglomeration and maintains enzyme activity, improving the durability and performance of the granules by ensuring the melt-resistant layer remains intact, thus enhancing the stability of enzyme granules during pelleting processes.
Implementation Method 1
applying a melt-resistant coating layer that melts at a higher temperature than the melt-delayed layer
Implementation Method 2
melting the melt-delayed layer, thereby forming the granule
Data Source
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AI summary
The present teachings provide an improved layered granule comprising a melt-delayed layer located internal to a melt-resistant layer. The melt-delayed granules can be used in a variety of contexts, including animal feed. Methods of making and using the melt-delayed granules are also provided.