Microbial Biomass Coating on Granular Support
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Solution Overview
Problem
Current methods for preserving and using microbial biomass in dry form for breadmaking and probiotic applications face challenges such as low viability, agglomeration, and limited shelf life, leading to extended fermentation times and risks of undesirable flora development, especially under non-ideal storage conditions.
Innovation Solution
A composition and process where a high concentration of microbial biomass is sprayed onto a granular support using a fluidized air bed, allowing for simultaneous drying and coating, which enhances bacterial viability and resistance to temperature, acid, and oxygen stresses, resulting in a stable and effective fermentation activator or probiotic.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a high concentration of microbial biomass is sprayed on a support, then the biomass concentration increases, but agglomeration occurs and viability is lost
Solution Approach 1:
The support is pre-treated with a coating agent (such as maltodextrin, starch, or other protective carriers) before spraying the microbial biomass. This preliminary coating creates a protective matrix that prevents direct contact between biomass cells, thereby preventing agglomeration while maintaining high biomass concentration and viability during storage
Solution Approach 2:
A coating agent or carrier material is introduced as an intermediary substance between the microbial biomass and the support surface. This intermediary layer distributes the biomass uniformly, prevents cell-to-cell contact that causes agglomeration, and maintains viability even at high concentration levels
2Duration of action of stationary object
If mixing operations and oxygen-free atmosphere are used, then shelf life is extended, but process complexity and cost increase
Solution Approach 1:
The invention uses a disposable or single-use coating formulation that provides sufficient protection for the required shelf life without requiring complex preservation infrastructure. The coating itself acts as a simple, inexpensive barrier that eliminates the need for expensive oxygen-free atmosphere systems or complex mixing operations
Solution Approach 2:
The invention extracts the critical protection function from complex systems (oxygen-free atmosphere, controlled mixing) and incorporates it directly into the coating formulation itself. The coating contains all necessary protective properties (oxygen barrier, moisture control, cell protection) in a single applied layer, eliminating the need for complex external control systems
3Reliability
If freeze-drying is used, then biomass is preserved, but production cost and complexity increase
Solution Approach 1:
The invention changes the preservation mechanism from extreme parameter conditions (freeze-drying at -20°C or lower) to ambient temperature preservation through the protective coating. The coating modifies the local environment around each cell, allowing preservation at much milder temperatures and simpler processing conditions
Solution Approach 2:
The coating formulation serves as a simple, inexpensive alternative to expensive freeze-drying equipment and energy consumption. A single application of the coating provides sufficient protection for the required shelf life, eliminating the need for costly freeze-drying infrastructure
4Productivity
If long fermentation times are used, then complete utilization occurs, but risk of undesirable flora development increases
Solution Approach 1:
The coating provides preliminary protection to the microbial biomass, ensuring higher viability and more consistent performance during fermentation. This preliminary protection allows for more reliable and potentially faster fermentation completion, reducing the time window for undesirable flora development
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 achieves a high concentration of viable bacteria on the support, maintaining stability and acidifying performance even after one year at room temperature or in air, reducing the risk of undesirable flora growth and improving bread quality.
Implementation Method 1
using a fluidized air bed, allowing for simultaneous drying and coating
Implementation Method 2
spraying - also hereinafter called 'spraying' - a high level of microbial biomass
Data Source
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AI summary
The present invention relates to a composition comprising a substrate capable of being evenly coated with a microbial biomass, wherein said biomass represents from 10% to 30% by dry matter of the total dry matter of the coated substrate. It also relates to a method for preparing said composition and to a starter fermentation activator and to a probiotic comprising said composition.