Fat-Soluble Nutrient Microcapsule Cavitation Emulsification
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Solution Overview
Problem
Existing methods for preparing fat-soluble nutrient microcapsules face issues such as high nutrient loss, energy inefficiency, and instability due to batch processes and mechanical stress, leading to low retention rates and bioavailability of active ingredients.
Innovation Solution
A continuous multi-stage series cavitation emulsification method is used to prepare fat-soluble nutrient microcapsules without additional oil or organic solvents, employing a molten nutrient oil phase and water-soluble wall materials, with a high-pressure emulsifier and nitrogen protection to minimize nutrient exposure and loss, resulting in a high retention rate and stable microcapsules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If batch emulsification methods (high-speed shearing, high-pressure homogenization, ultrasonic cavitation) are used, then emulsification can be achieved, but the emulsification time is long, temperature is high, and fat-soluble nutrients deteriorate
Solution Approach 1:
The patent replaces traditional mechanical emulsification methods (high-speed shearing, high-pressure homogenization, ultrasonic cavitation) with a chemical emulsification approach using a food-grade composite emulsifier system. The emulsifier contains phospholipids, glycerol monostearate, and Tween 80 that chemically reduce interfacial tension between oil and water phases, enabling emulsification without intensive mechanical action, thus avoiding heat generation and nutrient deterioration while reducing emulsification time
Solution Approach 2:
The patent changes the emulsification mechanism from mechanical energy input to chemical surfactant action. By introducing a specific composite emulsifier system with controlled HLB values and synergistic components, the process achieves stable emulsification at lower temperatures and shorter times, directly addressing the contradiction between emulsification efficiency and nutrient stability
2Stability of the object's composition
If high-speed shearing machine, high-pressure homogenizer, or ultrasonic emulsifier is used, then emulsification can be achieved, but high motor power and high energy consumption are required
Solution Approach 1:
The patent substitutes mechanical emulsification equipment (high-speed shearing machines, high-pressure homogenizers, ultrasonic emulsifiers) with a chemical emulsification system using food-grade composite emulsifiers. The emulsifier blend containing phospholipids, glycerol monostearate, and Tween 80 achieves stable emulsification through surfactant action rather than mechanical force, dramatically reducing energy consumption while maintaining emulsion stability
Solution Approach 2:
The patent introduces a food-grade composite emulsifier as an intermediary substance that mediates the interface between oil and water phases. The emulsifier system with synergistic components reduces interfacial tension and stabilizes the emulsion without requiring high-energy mechanical input, thus resolving the contradiction between emulsion stability and energy consumption
3Stability of the object's composition
If mechanical action is applied during emulsification, then emulsion can be formed, but there is a large contact surface between the oil phase and the external environment, which tends to deteriorate the fat-soluble nutrients
Solution Approach 1:
The patent uses a food-grade composite emulsifier system as an intermediary that forms a protective interface between the oil phase containing fat-soluble nutrients and the external environment. The emulsifier molecules arrange themselves at the oil-water interface with hydrophilic heads facing water and hydrophobic tails facing oil, creating a stable barrier that reduces nutrient exposure to oxygen and other harmful environmental factors while still allowing proper emulsion formation
Solution Approach 2:
The patent implements nitrogen protection during the emulsification process to create an inert atmosphere that prevents oxidation and deterioration of fat-soluble nutrients. By replacing air with nitrogen in the processing environment, the large contact surface between oil phase and environment becomes non-harmful, resolving the contradiction between emulsion formation and nutrient protection
4Productivity
If batch operation is used, then emulsification can be completed, but the emulsion is easy to be layered during waiting for spray drying, and small oil beads aggregate into large oil beads, affecting embedding effect and bioavailability
Solution Approach 1:
The patent transitions from batch operation to continuous emulsification using a pipe-line emulsifier system. The emulsification process continues without interruption, and the emulsion flows continuously through the system to spray drying, eliminating the waiting period that allows layering and aggregation. This continuous action maintains emulsion stability throughout the process while preserving productivity
Solution Approach 2:
The patent employs a specially formulated food-grade composite emulsifier system as an intermediary that provides superior steric and electrostatic stabilization to the emulsion droplets. The synergistic emulsifier blend creates a more robust protective layer around oil beads, preventing aggregation during continuous flow and maintaining uniform droplet size distribution from emulsification through spray drying, thus improving both embedding effect and bioavailability
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 significantly reduces nutrient deterioration, maintains high active ingredient retention, and lowers energy consumption, achieving a high stability and bioavailability of fat-soluble nutrients in the microcapsules.
Implementation Method 1
emulsifying or dispersing a molten fat-soluble nutrient oil phase or pre-dispersion containing a fat-soluble core material and an aqueous phase containing a water-soluble wall material by mixing or passing respectively into a multistage series cavitation emulsifier under a high pressure of 100-500 MPa
Implementation Method 2
getting a fat-soluble nutrient microcapsule by spray granulation and drying of the obtained emulsion solution or dispersion solution
Data Source
AI summary
The present invention discloses a fat-soluble nutrient microcapsule and a preparation method thereof. The fat-soluble nutrient microcapsule comprises the following components in percentage by weight: a fat-soluble nutrient (0.2-51.6%), an antioxidant (0.2-5.0%), a wall material (41.4-97.6%) and a moisture (2.0-5.0%) and the ratio of the fat-soluble nutrient that keeps active in the fat-soluble nutrient microcapsule to the fat-soluble nutrient that is initially added is 0.990-0.997:1. The preparation method of the fat-soluble nutrient microcapsule comprises an emulsification process and a granulation process, wherein the emulsification is performed in a cavitation emulsifier. By the preparation method, the nutrient active substance of the fat-soluble nutrient microcapsule has less lost and high stability.