Fluidized-Bed Granulation of Supercritical Extracts
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Solution Overview
Problem
Conventional methods for formulating herbal medicine and medicinal herb extracts into granules or pills result in low concentrations of active ingredients, requiring large doses and facing challenges such as moisture retention, poor stability, and difficulty in handling due to high sugar content, leading to inefficient production processes and reduced effectiveness.
Innovation Solution
A method involving the preparation of microgranules using a fluidized-bed device, where extract powders are first converted into microgranules and then used as seeds for further granulation with a binder solution, allowing for the production of granules or pills with up to 100% extract concentration, improving stability and handling characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional spray drying method is used to produce extract powder, then the extraction efficiency is improved, but the powder exhibits poor fluidity, easy moisture absorption, and severe moisture retention
Solution Approach 1:
The patent changes the physical parameters of the extraction process by using supercritical carbon dioxide (critical temperature 31.1°C, critical pressure 73.8 atm) instead of conventional water-based extraction. This parameter change produces an extract with significantly reduced sugar and hydrocarbon content (45-65% in conventional vs. much lower in supercritical extract), thereby eliminating moisture retention problems while maintaining high extraction efficiency.
Solution Approach 2:
The patent utilizes the phase transition properties of carbon dioxide between supercritical and gaseous states. By controlling pressure and temperature, CO2 transitions to a supercritical state for extraction, then returns to gaseous state for easy separation, leaving behind a dry extract powder with minimal moisture content. This phase transition mechanism prevents the moisture absorption and retention problems inherent in conventional extraction methods.
2Device complexity
If conventional extraction methods are used, then the process is simple, but the sugar content in the extract is very high at 45-65%, causing severe moisture retention
Solution Approach 1:
The patent changes the chemical parameters of the extraction system by replacing water with supercritical carbon dioxide as the extraction medium. This parameter change selectively extracts active ingredients while leaving behind sugars and hydrocarbons, reducing sugar content from 45-65% to minimal levels, thereby eliminating moisture retention without significantly complicating the process.
Solution Approach 2:
The patent uses supercritical fluid extraction to selectively take out (extract) only the desired active ingredients from the plant material, while leaving behind unwanted components such as sugars and hydrocarbons. This selective extraction process removes the harmful substance (sugar) that causes moisture retention, while preserving the beneficial active ingredients.
3Productivity
If extract powder with high sugar content is produced, then the extraction yield is high, but the powder has poor quality stability at room temperature due to moisture absorption
Solution Approach 1:
The patent changes the extraction parameters by using supercritical carbon dioxide instead of water, which alters the selectivity of the extraction process. This parameter change maintains high extraction yield of active ingredients while simultaneously reducing sugar content, thereby achieving both high productivity and high reliability (quality stability) of the final product.
Solution Approach 2:
The patent converts the potential harm of high sugar content (which causes moisture absorption and stability problems) into a benefit by using supercritical extraction to selectively remove sugars while preserving active ingredients. The extraction process that initially seemed to produce high-yield but unstable product actually produces high-yield and high-stability product by excluding unwanted components.
4Ease of manufacture
If conventional extraction and formulation methods are used, then the process is straightforward, but the content of active ingredients in the final product is very low, requiring large doses
Solution Approach 1:
The patent changes the fundamental parameter of the extraction medium from water to supercritical carbon dioxide, which dramatically improves the concentration of active ingredients in the final extract. This parameter change results in extracts with much higher active ingredient content and lower sugar content, allowing for more concentrated formulations and smaller effective doses while maintaining formulation simplicity.
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 enables the production of granules and pills with high extract concentrations, enhancing stability, reducing the need for large doses, and improving convenience in handling and storage, while maintaining the medicinal effectiveness of the active ingredients.
Implementation Method 1
feeding an extract powder of a plant, medicinal herb, or medicinal herb decoction into a fluidized-bed device to fluidize the extract powder
Implementation Method 2
spraying purified water or a solution of the same kind of extract as the extract powder onto the fluidized extract powder, thereby generating microgranules
Data Source
AI summary
The present invention relates to a method for preparing a granule or a pill containing a plant, medicinal herb or traditional oriental medicine decoction extract, having the steps of: (a) injecting a powdered plant, medicinal herb or traditional oriental medicine decoction extract into a fluidized-bed device and spraying purified water or a solution of the same type of extract as the extract powder at the extract powder while fluidizing the same, thereby generating microgranules of the extract powder; and (b) injecting the microgranules generated at step (a) as seeds into the fluidized-bed device and spraying a solution of the extract while fluidizing the same, thereby growing the microgranules to a predetermined size of granule or pill. According to the present invention, it is possible to prepare a granule or a pill containing an extract in a high concentration.