Gellan Capsule Co-Extrusion Without Calcium Salts
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Solution Overview
Problem
The production of gellan capsules through the co-extrusion process results in poor quality capsules due to gelling issues during the process, leading to non-spherical and non-homogeneous breakable capsules, which are not suitable for applications requiring seamless and breakable capsules.
Innovation Solution
A process involving co-extrusion of an external hydrophilic liquid phase containing gellan gum and a metal sequestering agent without calcium salts, followed by immersion in a divalent metal ion solution or organic acid to create a breakable shell, ensuring spherical and homogeneous capsules with controlled crush strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If co-extrusion process is used to produce gellan capsules, then capsule production is achieved, but gelling occurs during the process resulting in poor quality capsules
Solution Approach 1:
The patent removes calcium salts from the external liquid phase during co-extrusion. This extraction of the problematic divalent metal ion prevents unwanted gelling of gellan gum during the extrusion process, allowing the formation of spherical capsules with homogeneous size and shape, thereby resolving the quality issues while maintaining production capability
Solution Approach 2:
The patent applies a post-treatment step where capsules are contacted with divalent metal ions (such as calcium or magnesium) or organic acid solution after extrusion. This preliminary formation of the shell without calcium during extrusion, followed by controlled addition of divalent ions post-extrusion, ensures spherical shape and homogeneity are achieved during manufacturing, while breakability is enhanced in the subsequent treatment step
2Stability of the object's composition
If calcium salts are present in gellan during co-extrusion, then gelling occurs during the process, but this prevents obtaining spherical and homogeneous breakable capsules
Solution Approach 1:
The patent specifically removes calcium salts from the external liquid phase composition during co-extrusion. This extraction prevents the premature gelling of gellan gum that would otherwise occur in the presence of divalent metal ions, thereby enabling the formation of capsules with spherical shape and homogeneous size distribution
Solution Approach 2:
The patent changes the chemical composition parameter of the external liquid phase by eliminating calcium salts and other divalent metal ions. This parameter change prevents unwanted gelling during extrusion while maintaining the gellan gum's ability to form a shell, resulting in capsules with improved spherical shape and homogeneity
3Shape
If co-extrusion is performed without calcium salts, then spherical and homogeneous capsules are obtained, but the shell becomes too soft and capsules are not breakable
Solution Approach 1:
The patent performs the shell strengthening action after extrusion by contacting the formed capsules with divalent metal ion solutions (such as calcium chloride) or organic acid solutions. This sequential approach allows the capsules to first be formed with spherical shape and homogeneity in the absence of calcium during extrusion, then subsequently gain the required shell strength and breakability through the post-treatment step
Solution Approach 2:
The patent divides the capsule manufacturing process into distinct sequential stages: (1) co-extrusion without calcium salts to form spherical capsules with homogeneous shape, (2) post-extrusion treatment with divalent metal ions or organic acids to develop shell strength. This segmentation allows each stage to optimize for its specific function without interfering with the other, resolving the contradiction between shape quality and shell breakability
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 process produces capsules that are spherical, homogeneous, and breakable, with a crush strength suitable for various applications, such as oral care and pharmaceutical products, by preventing unwanted gelling and ensuring the shell's strength and integrity.
Implementation Method 1
Gellan gum, first discovered in 1978, is produced by the microorganism Sphingomonas elodea. The Applicant has found that the production of gellan capsule through the Fuji process was not satisfactory and resulted in poor quality capsules, because the gellan was actually gelling during the co-extrusion
Implementation Method 2
the Applicant found a solution to this subsequent technical problem by contacting the capsules with divalent metal ions, preferably calcium or magnesium ions, or by using organic acid solution, once the co-extrusion process is finished, and this finally lead to satisfactory breakable capsule
Implementation Method 3
Fuji patent application JP10291928 describes a capsule obtained through a co-extrusion process, wherein the external liquid phase comprises gellan and calcium salts
Data Source
Figure 1
AI summary
The invention relates to a process for manufacturing a seamless breakable capsule, comprising - co-extruding an external and hydrophilic liquid phase, and an internal and lipophilic liquid phase, in order to form a capsule constituted of a core comprising the internal and lipophilic phase, and a shell comprising the external and hydrophilic phase, - immersing into an aqueous solution containing a curing agent , wherein the external liquid phase includes a gelling agent comprising gellan gum alone or in combination with another gelling agent, a filler, and a divalent metal sequestering agent, and to breakable capsules comprising a core and a shell, wherein the shell includes a gelling agent comprising gellan gum alone or in combination with another gelling agent, a filler, and a divalent metal sequestering agent.