Fat Matrix Encapsulation for Ambient Stable Probiotics

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Solution Overview

Problem

Existing methods for microencapsulating probiotics, such as lactic acid bacteria, fail to maintain viability during storage at ambient temperatures for extended periods, leading to post-acidification and reduced effectiveness in functional foods and supplements.

Innovation Solution

A method involving the encapsulation of microbial cultures in a fat matrix, using a blend of hydrogenated vegetable oil and waxes like candelilla wax, with optional excipients like calcium carbonate, to create a stable coating that protects the cultures during pasteurization and storage, maintaining viability for at least 12 weeks at ambient temperature.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of stationary object

If probiotics are stored at ambient temperature, then storage convenience and shelf life are improved, but microbial viability deteriorates due to post-acidification

Engineering Contradiction:

Improvestorage shelf lifeVSAvoidmicrobial viability

Core Design Contradiction:

Duration of action of stationary objectVSReliability

Solution Approach 1:

The patent applies beforehand cushioning by incorporating cryoprotectants and lyoprotectants into the fat matrix coating before storage. These protective compounds cushion the probiotic cells against thermal stress and post-acidification during ambient storage, maintaining viability without requiring refrigeration.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent uses a composite fat matrix system combining multiple fats (hydrogenated vegetable oil, palm stearin) with waxes (candelilla, carnauba, bees) and protective compounds. This composite material provides enhanced thermal stability and protection against post-acidification, enabling ambient storage while maintaining microbial viability.

Inventive Principle:

Principle #40Composite materials

2Reliability

If probiotics are coated with protective compounds, then viability during storage is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvemicrobial viabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges multiple protective functions into a single fat matrix coating system. The coating simultaneously provides thermal protection, prevents post-acidification, and maintains cell viability, eliminating the need for separate protective measures and simplifying the overall manufacturing process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent optimizes specific parameters of the fat matrix system, including the ratio of hydrogenated vegetable oil to palm stearin (64:36), the combination of specific waxes, and the water activity level (0.35). These parameter optimizations enable effective protection while maintaining a straightforward manufacturing process.

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If water activity is reduced to 0.35, then storage stability is improved, but processing difficulty increases

Engineering Contradiction:

Improvestorage stabilityVSAvoidprocessing ease

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The patent sets the water activity to an optimal value of 0.35 through careful formulation of the fat matrix and protective compound mixture. This parameter optimization achieves maximum storage stability while maintaining sufficient moisture for cell viability, balancing stability and manufacturability.

Inventive Principle:

Principle #35Parameter changes

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 fat matrix encapsulation significantly enhances the storage stability of microbial cultures, reducing log10 loss of colony-forming units (CFU) by 3.5-fold compared to non-coated samples, ensuring high viability and preventing post-acidification, thus extending the shelf life and effectiveness of probiotic products.

Implementation Method 1

Methodology Applied

Scientific EffectEncapsulation:

Implementation Method 2

In one embodiment, the method further comprises the step of adjusting the water activity (aw) of the mixture of pellet and excipient to about 0.35

Methodology Applied

Scientific EffectWater activity control:

Data Source

PatentUS20250019639A1Fat and wax microencapsulated ambient stable bacteria and probiotics

Publication Date: 2025.01.16 CHR HANSEN AS

AI summary

The present invention relates to encapsulation of microbial cultures to improve the robustness and stability upon storage. In particular, the present invention relates to dry preparations of microbial cultures, such as lactic acid bacteria (LAB), coated by a fat-matrix that increase survivability and mitigate post-acidification upon storage at ambient temperature for extended periods of time.