Extruded Emulsion Particles With Low Water and Surface Oil
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Solution Overview
Problem
Existing methods for producing extrudates with oil-in-water emulsion droplets, such as those containing fat-soluble compounds, require high water content and energy-intensive drying due to the need for low viscosity emulsions, and result in large droplet size variability and surface oil content.
Innovation Solution
The process involves emulsification within an extruder, where the emulsion is formed into discrete solid particles, and then afterward the extrudates are further formed into discrete solid extruded particles, and then extruded particles, and the extrudates are further formed into discrete solid extruded particles, with emulsification occurring inside the extruder, followed by forming into discrete solid extruded particles, allowing for small droplet sizes, narrow distribution, and low surface oil content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If emulsification is performed using rotor-stator systems or high pressure homogenizers, then emulsion can be formed, but high water content is required leading to high energy consumption for drying
Solution Approach 1:
The patent combines emulsification and extrusion into a single integrated process. The emulsion is formed directly within the extruder by mixing the oil phase with the aqueous phase containing matrix material and emulsifier during the extrusion process, eliminating the need for separate emulsification equipment and reducing overall water content requirements.
Solution Approach 2:
The patent changes the viscosity parameter by using high viscosity aqueous phases containing matrix materials (such as starches, gums, or proteins) instead of low viscosity water-based solutions. This allows formation of stable emulsions with reduced water content, thereby reducing energy consumption for subsequent drying operations.
2Manufacturing precision
If emulsification is performed using conventional methods, then emulsion can be formed, but large droplet size variability and surface oil content occur
Solution Approach 1:
The patent uses the dynamic mixing conditions within the extruder, including shear forces and turbulent flow patterns, to achieve uniform emulsion formation. The continuous motion and varying shear rates during extrusion create consistent droplet sizes and prevent oil migration to the particle surface.
Solution Approach 2:
The patent employs composite matrix materials (such as combinations of starches, gums, and proteins) that provide both structural support and emulsification properties. These composite materials form a stable network that encapsulates oil droplets uniformly, preventing coalescence and surface oil accumulation.
3Ease of manufacture
If low viscosity emulsions are used, then emulsification can be achieved, but high water content is required which needs to be removed
Solution Approach 1:
The patent changes the viscosity parameter by using high viscosity aqueous phases containing matrix materials (such as starches, gums, or proteins) instead of low viscosity water-based solutions. This allows formation of stable emulsions with reduced water content, thereby reducing energy consumption for subsequent drying operations.
4Quantity of substance
If extrusion is used to process high viscosity solutions, then less water is required, but the process complexity increases
Solution Approach 1:
The patent combines emulsification and extrusion into a single integrated process. The emulsion is formed directly within the extruder by mixing the oil phase with the aqueous phase containing matrix material and emulsifier during the extrusion process, eliminating the need for separate emulsification equipment and reducing overall water content requirements.
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 achieves very small average droplet sizes, narrow and monomodal droplet distribution, continuous process capability, reduced water usage, and lower surface oil content, with improved flowability and reduced energy consumption.
Implementation Method 1
an oil-in-water emulsion wherein the aqueous phase contains a matrix material and/or a suitable emulsifier
Implementation Method 2
The emulsifying process is carried out in the extruder
Implementation Method 3
the temperature inside the extruder is between 20 and 100 °C
Implementation Method 4
an extrusion apparatus, wherein an oil-in-water emulsion is formed in the extrusion apparatus
Implementation Method 5
After drying, the fat soluble compound is embedded in the matrix material
Data Source
Figure 1
AI summary
The present invention relates to a process for the production of discrete solid extruded particles comprising emulsion droplets, to such particles as well as to the use of such particles in food, feed, pharmaceutical and personal care applications.