Microchannel Emulsion Processing for High-Oil-Load Microcapsules
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Solution Overview
Problem
Existing methods for preparing microcapsules using alcohol-soluble proteins as wall materials face challenges such as low oil load, poor emulsion production efficiency, and the need for organic solvents, limiting their application in the food industry.
Innovation Solution
A microchannel device is used to prepare high-oil-load microcapsules through pH adjustment, utilizing a dual-channel high-pressure homogenization chamber, deceleration cooling channel, acidity regulation channel, ultrafiltration desalination chamber, and spray dryer, without organic reagents, to form a core-shell structure with alcohol-soluble proteins like gliadin, zein, and kafirin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If water-soluble proteins (whey protein, casein protein) are used as wall material, then the wall material is cheap and readily-available, but the film-forming property is poor and extensibility is low, resulting in low oil loading capacity
Solution Approach 1:
The patent changes the solvent polarity parameter from water to alcohol to dissolve alcohol-soluble proteins. This parameter change enables the use of proteins with superior film-forming properties and extensibility, thereby increasing oil loading capacity while maintaining cost-effectiveness through the use of readily-available wall materials
Solution Approach 2:
The patent employs composite wall materials comprising alcohol-soluble proteins combined with appropriate carriers or adjuvants. This composite approach leverages the excellent film-forming properties of alcohol-soluble proteins while ensuring the overall system remains practical and cost-effective for industrial application
2Quantity of substance
If alcohol-soluble proteins are used as wall material, then the film-forming property is good and oil load is high, but the water solubility is low, greatly limiting their application
Solution Approach 1:
The patent introduces an intermediary carrier system that facilitates the dissolution and uniform distribution of alcohol-soluble proteins in aqueous environments. This intermediary approach enables the utilization of proteins with superior film-forming properties while overcoming their inherent water insolubility, thereby maintaining high oil loading capacity across diverse application scenarios
Solution Approach 2:
The patent modifies the solubility parameter of alcohol-soluble proteins through controlled pH adjustment and the use of specific carriers. These parameter changes enable the proteins to dissolve and function effectively in water-based systems while preserving their excellent film-forming properties and high oil loading capacity
3Quantity of substance
If organic solvent precipitation method is used to prepare microcapsules, then the oil load can be increased, but the emulsion production efficiency is poor and organic reagents are consumed
Solution Approach 1:
The patent replaces the organic solvent precipitation method with a microfluidic emulsion system that uses controlled shear forces and pressure gradients to achieve high oil loading. This substitution eliminates the need for organic reagents while significantly improving emulsion production efficiency through precise control of flow parameters and droplet formation mechanisms
Solution Approach 2:
The patent employs hydraulic principles through microfluidic flow control to achieve efficient emulsion formation and high oil loading. By utilizing pressure gradients, flow rates, and shear forces within the microchannel system, the process achieves superior emulsion production efficiency without requiring organic solvents, thereby resolving the contradiction between oil loading capacity and productivity
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 high oil loads and encapsulation rates up to 90% with uniform microdroplets, overcoming inefficiencies and solvent requirements of traditional processes, and producing stable, spherical microcapsules with a solid core-shell structure.
Implementation Method 1
a dual-channel high-pressure homogenization chamber
Implementation Method 2
The first high-pressure acceleration pipe and the second high-pressure acceleration pipe are arranged perpendicularly on the sidewall of the aqueous phase feed pipe and the sidewall of the oil phase feed pipe, respectively, instead of the end of the aqueous phase feed pipe or the oil phase feed pipe. As the inner diameter decrease from the feed pipe to the high-pressure acceleration pipe, a high pressure is formed. Besides, the first high-pressure acceleration pipe and the second high-pressure acceleration pipe are arranged perpendicularly on the sidewall of the aqueous phase feed pipe and the sidewall of the oil phase feed pipe, respectively, instead of the end of the aqueous phase feed pipe or the oil phase feed pipe. This arrangement facilitates the occurrence of interfacial coalescence.
Implementation Method 3
an acidity regulation channel; wherein the acidity regulation channel is arranged between the cooling water circulating device and the microchannel reaction chamber
Implementation Method 4
the first high-pressure acceleration pipe and the second high-pressure acceleration pipe are arranged perpendicularly on the sidewall of the aqueous phase feed pipe and the sidewall of the oil phase feed pipe, respectively, instead of the end of the aqueous phase feed pipe or the oil phase feed pipe. This arrangement facilitates the occurrence of interfacial coalescence.
Implementation Method 5
an ultrafiltration desalination chamber; wherein the ultrafiltration desalination chamber is connected to an outlet end of the microchannel reaction chamber
Implementation Method 6
a spray dryer; wherein the spray dryer is connected to the ultrafiltration desalination chamber and is configured for drying the reaction material
Data Source
AI summary
A microchannel device, including a homogenization chamber, a deceleration-cooling channel, an acidity regulation channel, a microchannel reaction chamber, and an ultrafiltration desalination chamber. A method for preparing high-oil-load microcapsules using the aforementioned microchannel device, including: preparing an aqueous phase and an oil phase; feeding the aqueous phase and the oil phase to the homogenization chamber to form a first emulsion; cooling the first emulsion; adjusting pH of the first emulsion with dilute hydrochloric acid; feeding the first emulsion to the microchannel reaction chamber to form a second emulsion with a core-shell structure; removing Na+ and Cl− from the second emulsion; and subjecting the second emulsion to spray drying to obtain the high-oil-load microcapsule powder.