Continuous Melt Granulation Torque Management

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Solution Overview

Problem

Continuous melt granulation processes face challenges with torque overload, leading to inefficient production of flowable and storage-stable water-dispersible granules, particularly when using extruders, which can result in poor granule quality and increased energy consumption due to the need for solvent evaporation or risk of hydrolysis.

Innovation Solution

A continuous melt granulation method using a mixture of mannitol as filler and sorbitol as binder, with specific weight ratios and melting temperatures, is employed in a twin-screw extruder to produce flowable and water-dispersible granules, reducing the risk of torque overload and maintaining granule quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If continuous melt granulation is performed in an extruder, then productivity is improved, but torque overload occurs leading to process instability

Engineering Contradiction:

Improvecontinuous manufacturing efficiencyVSAvoidprocess stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The invention changes the physical parameters of the binder material by selecting substances with low melting points (below 100°C) and specific viscosity characteristics. This parameter optimization allows the binder to remain molten at processing temperatures without causing excessive torque, enabling continuous operation without torque limiter disconnections

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention utilizes the phase transition of the binder from solid to liquid state at controlled temperatures. The binder is heated above its melting point to become molten for effective granulation, then cooled to solidify and form stable granules. This phase transition mechanism enables continuous processing while maintaining process stability

Inventive Principle:

Principle #36Phase transitions

2Manufacturing precision

If wet granulation using water as solvent is performed, then granule formation is improved, but energy consumption increases due to evaporation requirements

Engineering Contradiction:

Improvegranule formation qualityVSAvoidenergy consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The invention replaces the thermal evaporation mechanism with a mechanical extrusion process. Instead of using heat to evaporate water solvent, the process uses mechanical force in the extruder to force the molten binder through a screen, forming granules without requiring energy-intensive evaporation steps

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention exploits the phase transition of the binder material from solid to liquid and back to solid. The binder is heated to melt, extruded through a screen in liquid form to form granules, then cooled to solidify. This phase transition approach eliminates the need for solvent evaporation while maintaining effective granule formation

Inventive Principle:

Principle #36Phase transitions

3Manufacturing precision

If wet granulation using organic solvents is performed, then granule formation is improved, but harmful residues and environmental impacts occur

Engineering Contradiction:

Improvegranule formation qualityVSAvoidharmful residues

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The invention uses food-grade binder materials that are safe for consumption and leave no harmful residues. These binders are designed to be completely incorporated into the granule structure or easily removable, eliminating the environmental and health concerns associated with persistent organic solvent residues

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention replaces chemical solvents with a mechanically-driven molten binder system. The binder is heated to a liquid state for granulation but requires no evaporation or removal step, as it becomes part of the granule matrix upon cooling. This eliminates harmful volatile organic compound emissions and residue concerns

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 effectively prevents torque overload and produces granules that are flowable, storage-stable, and water-dispersible, with improved consistency and reduced energy requirements, enabling a stable and efficient continuous manufacturing process.

Implementation Method 1

During continuous melt granulation, the binder of the mixture is molten or at least softened

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

When cooling to room temperature, the binder solidifies and forms bridges between individual powder particles

Methodology Applied

Scientific EffectSolidification: Freezing

Data Source

PatentUS20250009674A1Granules obtainable by continuous melt granulation

Publication Date: 2025.01.09 DSM IP ASSETS BV

AI summary

The present invention relates to water-soluble or water-dispersible granules that are obtainable by continuous melt granulation. The granules comprise at least one binder, at least one filler and at least one active ingredients. Torque overload may be avoided when using a combination of the herein disclosed filler (e.g. mannitol or an HIMO) and binder (e.g. sorbitol).