Lactose Purification Adsorbent Resin System
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Solution Overview
Problem
The traditional process for producing high purity lactose is labor-intensive and generates solid waste by-products, and food-grade adsorbent resins like Amberlite FPX66 are not FDA-approved for pharmaceutical applications.
Innovation Solution
A system and technique that includes a clarification step to remove insoluble impurities and an adsorption system using a food-grade resin to decolorize and purify lactose, eliminating the need for activated carbon and filter aids, and allowing for continuous processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If activated carbon is used to remove riboflavin and filter aids are used for filtration, then high purity lactose is produced, but labor-intensive operations and solid waste disposal are required
Solution Approach 1:
The patent extracts and removes the problematic components (activated carbon and filter aids) from the process by replacing them with an alternative adsorbent resin system that does not require filtration, thereby eliminating the associated labor and waste disposal issues while maintaining purification effectiveness
Solution Approach 2:
The patent changes the material parameter from activated carbon to a specific adsorbent resin that has different properties - specifically, one that does not require filter aids and can be removed by simple filtration or centrifugation, thus changing the operational parameters from labor-intensive to automated
2Manufacturing precision
If activated carbon and filter aids are used for purification, then riboflavin and insoluble impurities are removed, but solid waste by-products are generated requiring disposal
Solution Approach 1:
The patent applies the principle of discarding harmful substances (activated carbon and filter aids that create waste) and recovering/better managing the adsorbent material by using an alternative resin system that can be more easily separated and potentially regenerated, thus reducing waste disposal requirements
Solution Approach 2:
The patent extracts the waste-generating components from the process and replaces them with an alternative system that minimizes waste generation, specifically using an adsorbent resin that does not require filter aids and generates minimal solid waste
3Manufacturing precision
If traditional filtration with filter aids is used, then activated carbon is removed, but contamination risks from filter voids or vacuum filter malfunction occur
Solution Approach 1:
The patent replaces the complex, failure-prone vacuum filtration system with a simpler, more reliable alternative using adsorbent resin that can be removed by simple filtration or centrifugation, reducing the risk of contamination from filter voids or equipment malfunction
Solution Approach 2:
The patent uses an intermediary substance (adsorbent resin) that mediates the purification process differently - instead of requiring complex filtration infrastructure with potential failure points, the resin adsorbs impurities and can be removed by simpler, more reliable methods
4Reliability
If food-grade adsorbent resin is used instead of activated carbon, then FDA approval is obtained for pharmaceutical applications, but the resin must be effective at removing riboflavin
Solution Approach 1:
The patent changes the material parameter from activated carbon to FDA-approved food-grade adsorbent resin that has been specifically selected and characterized to maintain effective riboflavin removal capability while providing regulatory compliance for pharmaceutical and infant formula applications
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 reduces labor costs, eliminates waste disposal issues, and produces high yields of pharmaceutical-grade lactose that meets regulatory standards, avoiding contamination risks and environmental concerns.
Implementation Method 1
A technique for purifying edible grade lactose may include adding activated carbon to a solution of edible grade lactose to remove the riboflavin by adsorption onto the activate carbon, followed by filtering the solution to remove the insoluble impurities and the activated carbon
Implementation Method 2
The adsorbent resin in the adsorption system removes colorants or contaminants, for example, riboflavin, from the clarified stream, to decolorize the clarified stream
Data Source
AI summary
An example system for purifying a supply stream including lactose includes a clarification system configured to separate insoluble impurities from the stream to produce a clarified stream. The system includes an adsorption system fluidically coupled to the clarification system. The adsorption system includes an adsorbent resin configured to purify the clarified stream. An example technique for purifying a supply stream including lactose includes separating insoluble impurities from the supply stream to produce a clarified stream and passing the clarified stream over an adsorbent resin to produce a decolorized stream.