Glassy Matrix Encapsulation with Insoluble Fiber
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Solution Overview
Problem
Existing encapsulation technologies face challenges with the integrity of encapsulated products, leading to premature release and loss of active ingredients due to cracking and fracturing during drying and storage, which affects the shelf life and consistency of flavors and other encapsulated materials.
Innovation Solution
A particulate extrusion encapsulation product is developed using a glassy matrix containing modified starch, low molecular weight carbohydrates, and insoluble fibers, which improves the integrity of the encapsulation by minimizing cracking and fracturing, and can include additional components like gums and anti-sticking agents to enhance stability and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If encapsulation is performed using conventional matrices, then the encapsulation process is simple, but the integrity of the encapsulation is compromised leading to cracking and fracturing
Solution Approach 1:
The patent applies composite materials by combining multiple components (starch, low molecular weight carbohydrate, and insoluble fiber) to form a glassy matrix that maintains encapsulation integrity. The composite structure prevents cracking and fracturing while protecting the encapsulated material, directly resolving the contradiction between reliability and complexity.
2Reliability
If the encapsulation matrix is made more robust to prevent cracking, then the integrity improves, but the manufacturing process becomes more complex
Solution Approach 1:
The patent changes the physical and chemical parameters of the matrix components, specifically creating a glassy state through controlled composition (starch, low molecular weight carbohydrate, insoluble fiber) and processing conditions. This parameter optimization achieves high crack resistance while maintaining manufacturability through extrusion and drying processes.
3Manufacturing precision
If the encapsulation integrity is improved by adding insoluble fiber, then particle breakage is reduced, but the manufacturing complexity increases
Solution Approach 1:
The patent incorporates insoluble fiber as a key component of the composite glassy matrix, which reinforces the structure and prevents particle breakage during drying and storage. The fiber reinforcement achieves high manufacturing precision (90% unbroken particles) while the formulation remains practical for production.
4Duration of action of stationary object
If the encapsulation protects against oxidation, then the shelf life is extended, but the matrix composition becomes more complex
Solution Approach 1:
The glassy matrix creates an inert, oxygen-barrier environment that protects the encapsulated material from oxidation. The tight, glassy structure formed by the starch-carbohydrate-fiber composite system excludes oxygen and prevents chemical reactions, extending shelf life without requiring additional active protective agents.
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 solution significantly reduces particle breakage and oxidation, maintaining the integrity and flavor functionality of encapsulated products, resulting in improved shelf life and consistency, with up to 90% of particles remaining unbroken and maintaining stability against fracturing and oxidation.
Implementation Method 1
a glassy matrix containing at least one modified starch, and at least one low molecular weight carbohydrate having a molar mass of less than 800g/mol
Implementation Method 2
The glassy matrix additionally contains 0.5% to 10% by weight of at least one insoluble fiber, resulting in improved integrity of the encapsulation product
Implementation Method 3
deleterious chemical reactions such as oxidation of encapsulated actives, e.g., flavors, medications, etc. can result on surfaces exposed both during and after drying
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 1e~1f
AI summary
High Integrity Encapsulation Product with Insoluble Fibers. A particulate extrusion encapsulation product in a glassy state is described including an encapsulate, encapsulated in a glassy matrix. The glassy matrix includes at least one modified starch, at least one carbohydrate and at least one insoluble fiber. The load of the encapsulate is typically from 0.01% to 20% by weight, based on the total weight of the encapsulation product. A method of making the particulate extrusion encapsulation product and food products containing the extrusion encapsulation product are also described.