Hot-Filled Softgel Capsule Cooling via Chilled Liquid Conveyor
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Solution Overview
Problem
The softgel manufacturing industry faces challenges in encapsulating hot fill materials within gelatin without causing permanent deformation, which affects the aesthetic quality and uniformity of capsules, and there is a need for a process that can handle hot fill materials at a high rate while being environmentally friendly, consumer-safe, and cost-effective.
Innovation Solution
A method and system that involves heating the fill material to a high temperature and then encapsulating it between gelatin bands, followed by immediate contact with a chilled liquid to cool the capsule to a handling temperature, preventing deformation and ensuring uniformity, using a chilled liquid conveyor tray and tank to facilitate efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hot fill material is encapsulated in gelatin bands, then the fill material can be sealed within the capsule, but the capsule deforms and loses shape uniformity
Solution Approach 1:
The gelatin bands are pre-cooled to a temperature below the melting point of gelatin before encapsulation. This preliminary cooling action maintains the gelatin in a firm state during the encapsulation process, allowing it to hold its shape while still being sealed around the hot fill material. The pre-cooled gelatin bands provide structural support that prevents deformation despite contact with hot fill material.
Solution Approach 2:
The patent changes the temperature parameter of the gelatin bands from ambient or warm temperatures to sub-zero or refrigerated temperatures. This parameter change transforms the gelatin from a soft, pliable state to a firm, shape-retaining state, enabling it to withstand the thermal and mechanical stresses of encapsulating hot fill material without deforming.
2Ease of manufacture
If gelatin is kept at sealing temperature to encapsulate hot fill material, then encapsulation is possible, but the gelatin becomes soft and pliable causing deformation
Solution Approach 1:
The gelatin bands are pre-cooled to a temperature below the melting point before the encapsulation process begins. This preliminary action ensures that the gelatin maintains its structural integrity throughout encapsulation, even when contact with hot fill material occurs. The pre-cooled state provides the necessary strength to prevent deformation while still allowing sealing.
Solution Approach 2:
The patent applies beforehand cushioning by pre-cooling the gelatin bands to create a thermal buffer that protects against the heat from the fill material. This prior cooling action cushiones the gelatin structure, preventing it from softening and deforming during the encapsulation process, thereby maintaining structural integrity throughout the manufacturing operation.
3Shape
If the capsule is cooled quickly after formation, then deformation is prevented, but additional cooling equipment and process steps are required
Solution Approach 1:
The patent merges the cooling function into the encapsulation process itself by using pre-cooled gelatin bands that continuously absorb heat from the fill material during sealing. This integration eliminates the need for separate post-encapsulation cooling equipment, as the gelatin bands serve dual purposes: providing structural support and actively cooling the fill material through thermal conduction during the encapsulation operation.
Solution Approach 2:
The pre-cooled gelatin bands perform self-service cooling by continuously absorbing heat from the hot fill material during the encapsulation process. The gelatin's own thermal mass and low temperature provide the cooling effect, eliminating the need for external cooling systems. The encapsulation process itself becomes the cooling mechanism, as the gelatin bands naturally conduct heat away from the fill material.
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 system effectively prevents permanent deformation and ensures the production of aesthetically pleasing, uniformly formed capsules that are safe and cost-effective, capable of handling both small and large capsules of various shapes, while being environmentally friendly.
Implementation Method 1
contacting the capsule with a chilled liquid. The chilled liquid may be at a chilled liquid temperature that is less than the fill material temperature and the sealing temperature... heat is transferred from the capsule to the chilled liquid
Data Source
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AI summary
A system for producing a hot-filled softgel capsule utilizes a chilled liquid. The chilled liquid is routed through a chilled liquid conveyor tray into a chilled liquid bath. The chilled liquid conveyor tray directs the flowing chilled liquid into a flowing chilled liquid layer. Softgel capsules having a heated fill material are deposited in the flowing chilled liquid layer. The chilled liquid layer cools the capsule by transferring heat from the capsule to the chilled liquid. The flowing chilled liquid layer transports the capsule out of the chilled liquid conveyor tray into a chilled liquid bath. A capsule transfer conveyor transports the capsule out of the chilled liquid bath to a chilled liquid removal device. The chilled liquid removal device removes the chilled liquid from the capsule.