Water-Soluble Lutein Ester Microcapsules via Twice Drying
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Solution Overview
Problem
The high cost and complexity of producing lutein ester microcapsules due to the requirement for high-purity lutein ester crystals and stringent storage and transportation conditions, which increases production costs and equipment requirements.
Innovation Solution
A method for extracting lutein esters directly from marigold flower particles, followed by concentration and microencapsulation using a twice embedding (drying twice) process, which simplifies equipment needs and reduces costs while maintaining stability and health benefits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high-purity lutein ester crystals are used for microencapsulation, then product purity is improved, but production cost and equipment complexity increase substantially
Solution Approach 1:
The patent extracts only the necessary lutein ester component from marigold flowers through solvent extraction, rather than requiring complete purification to high-purity crystals. This allows obtaining sufficient lutein ester for microencapsulation while avoiding complex refining equipment, directly resolving the contradiction between purity requirements and equipment complexity
Solution Approach 2:
The patent applies partial purification by removing major impurities through washing with ethanol or ethyl acetate, rather than achieving complete purification to high-purity crystals. This partial action is sufficient for microencapsulation purposes while significantly reducing equipment complexity and production costs
2Manufacturing precision
If high-purity lutein ester crystals are used for microencapsulation, then product purity is improved, but production cost increases due to stringent storage and transportation conditions
Solution Approach 1:
The patent uses relatively crude lutein ester extract that can be processed immediately through microencapsulation, rather than investing in expensive high-purity crystal production and associated storage/transport infrastructure. The microencapsulation process itself serves as the purification step, making separate high-purity production unnecessary
Solution Approach 2:
The patent introduces the microencapsulation process as an intermediary step between crude extraction and final product. This intermediary process handles the purification and stabilization functions, allowing the use of crude extract without requiring expensive intermediate purification to high-purity crystals
3Stability of the object's composition
If conventional microencapsulation methods are used, then capsule stability is improved, but production cost and process complexity increase
Solution Approach 1:
The patent combines the extraction, purification, and microencapsulation steps into an integrated process. The crude extract is directly used for microencapsulation after simple washing, merging multiple separate operations into a unified flow that reduces equipment requirements while maintaining capsule stability through the protective wall 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
This method reduces production costs and simplifies the process, maintaining product quality and stability, and allows for easier storage and transportation of lutein ester microcapsules, with improved bioavailability and shelf life compared to conventional methods.
Implementation Method 1
mixing marigold flower particles with an extracting solvent, refluxing at 65-85°C; removing the extracting solvent to obtain a crude extract
Implementation Method 2
washing the crude extract with a washing solvent; removing the washing solvent to obtain a crude lutein ester
Implementation Method 3
adding the lutein ester oil phase to the water phase under a high-speed shearing, mixing evenly, and homogenizing by a high-pressure homogenizer to obtain a lutein ester emulsion
Implementation Method 4
homogenizing by a high-pressure homogenizer to obtain a lutein ester emulsion
Implementation Method 5
drying the lutein ester emulsion twice to obtain semi-finished lutein ester microcapsules
Implementation Method 6
The core material is wrapped in a capsule composed of a wall material, and the active ingredients of the core material are preserved from the influence of external adverse factors
Data Source
AI summary
A method of preparing water-soluble lutein ester microcapsules includes: mixing marigold flower particles with an extracting solvent, refluxing at 65-85° C.; removing the extracting solvent to obtain a crude extract; washing the crude extract with a washing solvent; removing the washing solvent to obtain a crude lutein ester; adding an oil-phase antioxidant and a vegetable oil to the crude lutein ester, mixing and heating at 90-100° C. to obtain a lutein ester oil phase; adding a wall material, an emulsifier, a water-phase antioxidant, and a water-phase filler into water, and heating to obtain a water phase; adding the lutein ester oil phase to the water phase under a high-speed shearing, mixing evenly, and homogenizing to obtain a lutein ester emulsion; drying twice to obtain semi-finished lutein ester microcapsules; and solidifying to obtain the lutein ester microcapsules. Water-soluble lutein ester microcapsules prepared by the method are also disclosed.