Live Bacteria Particulates with Protective Layers

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Solution Overview

Problem

Current methods for preparing probiotic bacteria powders, such as spray-drying and freeze-drying, often result in reduced viable bacterial count due to high temperatures or ice crystal damage, making it challenging to maintain live bacteria activity during storage and transport.

Innovation Solution

A three-stage fermentation process is used to concentrate live bacteria, followed by mixing with a protective agent and drying to create live bacteria-containing particulates with a high viable bacterial count and low residual moisture, utilizing specific carbohydrate and polysaccharide layers for protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If spray-drying is used to prepare bacteria powder, then drying efficiency is improved, but high temperature kills live bacteria reducing viable bacterial count

Engineering Contradiction:

Improvedrying efficiencyVSAvoidviable bacterial count

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The invention changes the temperature parameter during drying by using freeze-drying instead of spray-drying, maintaining low temperature to preserve bacterial viability while achieving adequate drying through extended processing time and vacuum conditions

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention applies freezing before drying to protect bacteria from thermal damage, using ice crystal formation as a cushioning mechanism that prevents direct thermal contact between bacteria and high-temperature drying environment

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If freeze-drying is used to prepare bacteria powder, then bacterial viability is improved, but ice crystals damage bacteria reducing viable bacterial count

Engineering Contradiction:

Improveviable bacterial countVSAvoidice crystal damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention creates different freezing conditions for different regions of the bacterial suspension, using controlled nucleation to form smaller, less damaging ice crystals in critical areas while allowing larger crystals in less sensitive regions

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention introduces protective agents as intermediaries between ice crystals and bacteria, using substances like sugars and proteins to cushion mechanical damage from ice crystal formation and maintain bacterial integrity during freeze-drying

Inventive Principle:

Principle #24Intermediary (Mediator)

3Loss of time

If conventional fermentation is used, then production time is reduced, but bacterial concentration in the broth is insufficient

Engineering Contradiction:

Improvefermentation timeVSAvoidbacterial concentration

Core Design Contradiction:

Loss of timeVSQuantity of substance

Solution Approach 1:

The invention uses periodic harvesting and reinoculation cycles, removing high-concentration bacterial broth at peak growth phases and adding fresh medium to maintain optimal growth conditions and sustain high bacterial concentration throughout extended fermentation

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The invention maintains continuous bacterial growth and multiplication by continuously replenishing nutrients and removing waste products, ensuring the fermentation process operates at maximum efficiency throughout the extended duration needed to achieve high bacterial concentration

Inventive Principle:

Principle #20Continuity of useful action

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 method effectively preserves a high concentration of live bacteria, maintaining viability and reducing moisture content, allowing for stable storage and transport of probiotic products.

Implementation Method 1

subjecting a bacterial strain to a three-stage fermentation to obtain a fermentation broth

Methodology Applied

Scientific EffectFermentation: Fermentation

Implementation Method 2

drying the mixture to provide live bacteria-containing particulates

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS11066637B1Particulate structure with a high concentration of live bacteria and method of preparing the same

Publication Date: 2021.07.20 TCI CO LTD(CN)

AI summary

A live bacteria-containing particulate is provided, wherein the particulate comprises a bacterial strain, a first covering layer, and a second covering layer, and wherein the first covering layer is in-between the cell membrane and cell wall of the bacterial strain and the bacterial strain is dispersed in the second covering layer. A method of preparing a live bacteria-containing particulates is also provided, wherein the method comprises the following steps: (a) subjecting a bacterial strain to a three-stage fermentation to obtain a fermentation broth; (b) concentrating the fermentation broth to provide a concentrated bacterial solution; (c) mixing the concentrated bacterial solution with a protective agent; and (d) drying the mixture to provide live bacteria-containing particulates.