Melt Extrusion Encapsulation for Narrow Particle Size and Low Surface Oil
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Solution Overview
Problem
Current encapsulation processes, such as spray drying and extrusion, face challenges in achieving high flavor load, controlled solubility, low surface flavor, narrow particle size distribution, and storage stability, particularly with low molecular weight components, which are essential for fast and controlled flavor release in applications like food and personal care products.
Innovation Solution
A melt extrusion process that forms a glassy matrix with low molecular weight sugars, polyols, and modified starches, allowing for up to 20% flavor encapsulation, quick solubility in aqueous systems, and a narrow particle size distribution, while minimizing surface flavor and ensuring stability through die-face cutting and controlled cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spray drying is used to encapsulate flavors, then the encapsulation process can be performed, but the resulting particles have broad size distribution, high surface area, and rapid flavor release that cannot be controlled
Solution Approach 1:
The invention uses melt extrusion to transform the flavor-encapsulating material from liquid to glassy solid state through controlled cooling. This phase transition creates particles with uniform size and structure, enabling both precise manufacturing control and reliable, controlled flavor release properties that spray drying cannot achieve
Solution Approach 2:
The invention changes the physical parameters of the encapsulation process by using melt extrusion instead of spray drying. This involves controlling temperature, viscosity, and cooling rates to produce particles with narrow size distribution and controlled porosity, thereby achieving both manufacturing precision and reliable flavor release control
2Quantity of substance
If melt extrusion is used to generate glassy encapsulation compositions, then high flavor load and controlled release can be achieved, but the particle size and shape distribution becomes very broad
Solution Approach 1:
The invention performs preliminary action by pre-forming the encapsulated material as a unified glassy matrix during extrusion, before any size reduction occurs. This preliminary formation of a controlled structure allows subsequent milling to achieve narrow size distribution while preserving the high flavor load and controlled release properties that would be compromised by size reduction alone
3Speed
If high surface area particles are produced, then quick flavor release can be achieved, but the surface flavor level increases leading to oxidation and reduced shelf life
Solution Approach 1:
The invention applies local quality by creating a differentiated structure where the particle surface has different properties from the interior. The glassy matrix provides a protective barrier at the surface that limits flavor exposure and oxidation, while still allowing controlled release through the matrix structure, thus achieving both quick release and extended shelf life
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 process results in encapsulation compositions that are highly soluble, have low surface flavor, and maintain stability, achieving controlled flavor release and extended shelf life with a narrow particle size distribution, addressing the limitations of existing methods.
Implementation Method 1
Melt extrusion generates the glassy state mainly by cooling the melted material
Implementation Method 2
The glassy matrix comprises 10-50% of at least one low molecular weight sugar, polyol, corn syrup solids, organic acid or a salt of an organic acid
Implementation Method 3
shaping, extruding and die-face cutting said viscous dispersion, thereby obtaining said extrusion encapsulation composition
Data Source
AI summary
A glassy, particulate, melt extrusion encapsulation composition and a process of making the composition are described. The encapsulation composition is highly soluble in aqueous systems, has a low level of encapsulate on the surface of the particles, and has a narrow particle size and shape distribution. Food systems containing the encapsulation composition are also described.