Carotenoid Agent Preparation via Low-Temperature Solvent Dissolution
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Solution Overview
Problem
Existing preparation methods for carotenoids face challenges in preventing isomerization reactions during dissolution in organic solvents, leading to low content of all-trans isomers and reduced biological activity in feed additive products.
Innovation Solution
A method involving mixing a suspended organic dispersion phase of carotenoid crystals with a first organic solvent in a spiral coil heat exchanger, followed by emulsification, homogenization, and spray granulation to form a stable carotenoid agent with a high content of all-trans forms, using specific temperature and solvent ratios, and antioxidants to minimize isomerization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional high-temperature melting method is used to prepare carotenoid emulsion, then the carotenoid can be dissolved and emulsified, but the oxidation and deterioration process of carotenoids is accelerated and isomer content changes greatly, resulting in poor long-term preservation
Solution Approach 1:
The patent changes the temperature parameter from traditional high-temperature melting to low-temperature processing (below the melting point of carotenoid crystals), and changes the dissolution method from direct heating to solvent dissolution at low temperature, thereby avoiding thermal oxidation and isomerization while maintaining emulsification capability
Solution Approach 2:
The patent introduces organic solvents (such as ethanol, isopropanol, acetone) as intermediaries to dissolve carotenoid crystals at low temperatures, replacing the traditional direct high-temperature melting method. The solvent acts as a mediator that enables dissolution without requiring high temperature, thus protecting carotenoid stability
2Productivity
If high-temperature and high-pressure superheated steam is used for dissolution, then carotenoid can be processed, but significant loss in carotenoid content occurs and all-trans form content drops to only 70%, with expensive equipment and complicated process requirements
Solution Approach 1:
The patent fundamentally changes the dissolution parameters from high-temperature steam (200°C) to low-temperature solvent dissolution (below carotenoid melting point), and changes the pressure condition from high-pressure steam to atmospheric or mild pressure solvent system, thereby eliminating thermal degradation and isomerization while maintaining dissolution efficiency
Solution Approach 2:
The patent replaces the mechanical/thermal system of high-temperature steam dissolution with a chemical dissolution system using organic solvents at low temperature, substituting thermal energy with chemical solvation to achieve dissolution without thermal damage
3Quantity of substance
If carotenoid is dissolved in organic solvent traditionally, then dissolution occurs, but isomerization reactions happen easily leading to low content of all-trans isomers and reduced biological activity
Solution Approach 1:
The patent changes the temperature parameter to low temperature (below carotenoid melting point) during solvent dissolution, and controls the residence time in the dissolution system, thereby preventing thermal and temporal conditions that promote isomerization while maintaining effective dissolution
Solution Approach 2:
The patent takes preliminary protective actions by using low-temperature solvent dissolution to prevent isomerization before it can occur, and by quickly proceeding to emulsification and drying steps to remove solvents, thereby preventing subsequent isomerization reactions that would reduce all-trans content
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 method achieves a carotenoid agent with a content of all-trans forms greater than or equal to 90% and enhanced stability, maintaining high biological activity and reducing isomerization.
Implementation Method 1
mixing a suspended organic dispersion phase of carotenoid crystal with a first organic solvent in a spiral coil of a coil heat exchanger to form a mixed solution, with the carotenoid crystal in the suspended organic phase of the carotenoid crystal being dissolved in the first organic solvent to obtain an oil phase matrix of the carotenoid dissolution solution, wherein the temperature inside the spiral coil is from 50°C to 70°C
Implementation Method 2
the carotenoid crystal in the suspended organic phase of the carotenoid crystal being dissolved in the first organic solvent
Implementation Method 3
mixing the aqueous phase matrix of the colloidal solution with the oil phase matrix of the carotenoid dissolution solution, and performing emulsification and dispersion as well as homogenization treatment successively to obtain a carotenoid nanodispersion
Implementation Method 4
performing emulsification and dispersion as well as homogenization treatment successively to obtain a carotenoid nanodispersion
Implementation Method 5
removing the organic solvent from the carotenoid nanodispersion and concentrating the moisture to obtain a carotenoid emulsion; subjecting the carotenoid emulsion to spray granulation and drying successively to obtain the carotenoid agent
Data Source
AI summary
The present disclosure provides a preparation method of carotenoid agent. The preparation method provided in present disclosure includes: mixing a suspended organic dispersion phase of a carotenoid crystal with a first organic solvent in a spiral coil of a coil heat exchanger to form a mixed solution, with the carotenoid crystal in the suspended organic phase of the carotenoid crystal being dissolved in the first organic solvent to obtain an oil phase matrix of the carotenoid dissolution solution, wherein the temperature inside the spiral coil is from 50°C to 70°C. In the present disclosure, the carotenoid crystal is dissolved in the first organic solvent at 50°C to 70°C, effectively avoiding the drawbacks of isomerization reaction of the carotenoid agent when it is dissolved in traditional preparation methods.