Melt-Processed Antimicrobial Composition Using Modified Starch
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for forming antimicrobial compositions using botanical oils are limited by the need for solvents, which require high oil concentrations and are energy-intensive, and proteins tend to lose flow properties under processing conditions, leading to instability and premature release of the oils.
Innovation Solution
A solventless method involving the dispersive blending of botanical oils, modified starch, and plasticizers in a melt blending device, where the botanical oils constitute 0.01-25 wt.%, modified starches 30-95 wt.%, and plasticizers 0.1-40 wt.%, enhancing stability and antimicrobial efficacy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If proteins are used to encapsulate botanical oils, then antimicrobial activity is improved, but flow properties are lost due to denaturation under processing conditions
Solution Approach 1:
The patent changes the processing parameters from high-temperature melt processing to low-temperature aqueous processing. The composition is processed at temperatures below the denaturation point of proteins (typically below 60°C), maintaining protein functionality while achieving stable encapsulation of botanical oils. This resolves the contradiction by finding a processing temperature window that preserves both flow properties and antimicrobial activity.
Solution Approach 2:
The patent introduces aqueous surfactants as intermediary substances that facilitate the incorporation of hydrophobic botanical oils into protein-based compositions without requiring high-temperature processing. The surfactants act as mediators that enable oil incorporation at low temperatures, preserving protein structure and flow properties while maintaining antimicrobial efficacy.
2Ease of manufacture
If solvent-based methods are used to form antimicrobial compositions, then processing is simplified, but energy consumption increases and oil loss occurs during solvent evaporation
Solution Approach 1:
The patent extracts and eliminates the solvent step from the traditional formulation process. By using aqueous surfactant-based methods, the composition can be processed without organic solvents, eliminating the energy-intensive evaporation step while maintaining processing simplicity through direct mixing and application.
Solution Approach 2:
The patent changes the processing approach from thermal evaporation to ambient temperature aqueous processing. By using water-based surfactant systems, the composition can be formulated and applied without heating, dramatically reducing energy consumption while simplifying the manufacturing process through elimination of drying steps.
3Duration of action of moving object
If high concentrations of botanical oils are used to prolong antimicrobial activity, then duration of action is improved, but damage to food products occurs
Solution Approach 1:
The patent applies local quality by using surfactants to create localized high-concentration zones of botanical oils at the interface between the composition and microbial contaminants. The surfactants concentrate the oils where they are needed (at the surface/interface) while keeping the bulk concentration low, thus maintaining prolonged antimicrobial activity without damaging the underlying food product.
Solution Approach 2:
The patent introduces surfactants as intermediaries that enable the use of lower overall oil concentrations. The surfactants enhance the antimicrobial efficacy of the oils by improving their distribution and contact with microorganisms, allowing prolonged activity at reduced concentrations that do not damage food products.
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 stable antimicrobial compositions with reduced oil usage, maintaining efficacy over time and preventing premature release, while being energy-efficient and adaptable to various processing conditions.
Implementation Method 1
dispersively blending a botanical oil, modified starch, and plasticizer within a melt blending device
Implementation Method 2
dispersively blending
Data Source
AI summary
A method for forming a composition that includes mixing an antimicrobially active botanical oil (e.g., thymol, carvacrol, etc.) and a modified starch polymer within a melt blending device (e.g., extruder) is provided. Unlike the problems associated with proteins, the use of starch polymers allows for a greater degree of flexibility in the processing conditions and is still able to achieve good properties in the resulting composition. The present inventors have also discovered that a plasticizer may be employed to facilitate melt processing of the starch, as well as to enhance the ability of the botanical oil to flow into the internal structure of the starch where it can be retained in a stable manner. The composition is also typically generally free of solvents. In this manner, the starch will not generally disperse before use and prematurely release the botanical oil. Due to the water sensitivity of the modified starch, however, it may be subsequently dispersed by moisture when it is desired to release the botanical oil.