Low Dusting Enzyme Granules via Viscoelastic Liquid Matrix
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Solution Overview
Problem
Existing methods for formulating enzyme granules fail to effectively reduce active dust release during mechanical stress, which can lead to irritation and allergenic reactions, and often require complex processes or result in agglomeration issues during processing.
Innovation Solution
A method involving mixer-granulation of a composition containing 6-30% non-volatile liquid with specific rheological properties, which includes progressive agglomeration of fine particles into larger granules, and optionally applying a coating to reduce dust release upon mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If solid formulations are used to improve enzyme stability, then enzyme stability is improved, but active dust release increases under mechanical stress
Solution Approach 1:
The invention uses a composite material system consisting of a viscoelastic liquid matrix (such as polyethylene glycol, polypropylene glycol, or polyethylene oxide) that encapsulates the enzyme particles. This liquid matrix provides both the stability of solid formulations and the dust-suppressing properties of liquids, creating a composite formulation that resolves the contradiction between stability and dust release.
Solution Approach 2:
The invention changes the physical state parameter of the formulation from solid to viscoelastic liquid, characterized by specific storage modulus (G') and loss modulus (G'') values. By controlling the viscoelastic parameters (G' between 10-1000 Pa and G'' between 10-1000 Pa at 1 Hz frequency), the formulation maintains structural integrity while suppressing dust generation under mechanical stress.
2Object-generated harmful factors
If liquid formulations are used to reduce active dust formation, then active dust release is reduced, but enzyme stability deteriorates due to degradation medium
Solution Approach 1:
The invention transforms the liquid formulation into a viscoelastic state by controlling the molecular weight and concentration of polymeric liquids, achieving storage modulus (G') and loss modulus (G'') values between 10-1000 Pa. This parameter change gives the liquid formulation solid-like mechanical properties that prevent enzyme degradation while maintaining the dust-suppressing benefits of liquid formulations.
Solution Approach 2:
The viscoelastic liquid matrix acts as a protective composite medium that combines the advantages of both liquid and solid formulations. It provides a stable environment for enzyme encapsulation while maintaining low dust release characteristics, effectively resolving the stability-dust release trade-off.
3Object-generated harmful factors
If complex coating processes are applied to reduce dust release, then active dust release is reduced, but device complexity increases
Solution Approach 1:
The invention merges the formulation and coating steps into a single integrated process. The viscoelastic liquid matrix itself serves as both the formulation medium and the protective coating, eliminating the need for separate coating equipment and processes while achieving effective dust release reduction.
Solution Approach 2:
The viscoelastic liquid matrix provides self-protective properties by forming a cohesive structure around enzyme particles that inherently resists dust generation under mechanical stress, without requiring additional protective coatings or complex processing steps.
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 achieves reduced active dust release comparable to undisturbed particles, even under shear stress, providing safer handling and processing of biological actives like enzymes, bacterial spores, and dehydrated yeast cells, while maintaining the stability and strength of the granules.
Implementation Method 1
mixer-granulation comprises progressive agglomeration of fine particles into larger granules
Implementation Method 2
the visco-elastic parameters η' (elastic parameter) and η" (viscous parameter) are between 10³ and 10⁶ Pa·s when measured in a rheometer using a sinusoidal frequency, ω, of 1 Hz at 25°C
Data Source
AI summary
The invention provides a method for preparing a plurality of granules comprising a biological active and a non-volatile liquid by using mixer-granulation, wherein the granules exhibit reduced dust release upon exposure to mechanical stress.