Extruder Emulsification for Low-Water Fat-Soluble Compound Formulations
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Solution Overview
Problem
Existing methods for producing extruded formulations with fat-soluble compounds, such as oils and vitamins, require high water content and energy-intensive drying due to the need for low viscosity emulsions, which limits the efficiency and scalability of the process.
Innovation Solution
Emulsification is carried out within an extruder, allowing for the production of extrudates with small, uniformly sized oil-in-water emulsion droplets using minimal water and no organic solvents, enabling a continuous process with reduced energy requirements and improved droplet distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If emulsification is carried out using rotor-stator systems or high pressure homogenizers, then emulsion can be produced, but high amounts of water are required leading to high water content in the emulsion
Solution Approach 1:
The patent combines the emulsification process with the extrusion process into a single integrated operation. The emulsifier is mixed with the fat-soluble compound and water within the extruder, and the mechanical shear forces generated during extrusion simultaneously achieve both mixing/emulsification and shaping of the final product. This eliminates the need for separate emulsification equipment and reduces overall water content.
Solution Approach 2:
The patent changes the physical parameters of the extrusion process, specifically using high shear rates and controlled temperature profiles within the extruder to achieve effective emulsification. By optimizing the screw speed, barrel temperature, and feed rate, the process achieves proper emulsion formation with minimal water content (typically 10-30% w/w).
2Use of energy by stationary object
If high water content emulsion is used, then emulsification can be achieved, but high energy is required for drying the extrudate
Solution Approach 1:
The patent performs preliminary emulsification within the extruder before the drying stage. By achieving proper emulsion formation during the extrusion process itself, the need for extensive subsequent drying is reduced. The extrudate is formed with optimal water content already established during extrusion, eliminating the need for high-energy drying operations.
3Productivity
If low viscosity emulsion is required, then emulsification can be achieved, but high amounts of water are needed which limits process efficiency
Solution Approach 1:
The patent merges emulsification and extrusion into a single process step, eliminating the need for separate emulsification equipment and the associated high water content requirements. This integrated approach significantly improves process efficiency and productivity while reducing water content to optimal levels.
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 results in extrudates with narrow, monomodal droplet size distributions, enabling precise dosing and reduced water usage, while maintaining the stability and bioavailability of fat-soluble compounds like vitamins A, E, and D3, suitable for food, feed, and personal care applications.
Implementation Method 1
emulsification is carried out inside the extruder
Implementation Method 2
emulsifying process is carried out in the extruder
Data Source
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Figure 4
AI summary
The present invention relates to a process for the production of extruded formulations comprising oil-in-water emulsion droplets, to such formulations as well as to the use.