Phospholipid Fractionation via Counter-Current Extraction
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Solution Overview
Problem
Existing methods for phospholipid fractionation are inefficient and not suitable for industrial-scale continuous processes, often requiring large amounts of adsorbents, multiple centrifugation steps, and low phospholipid extract yields.
Innovation Solution
A multistage counter-current extraction process using C1 to C3 aliphatic alcohols as extractants, combined with centrifugal separation, to achieve a high yield of phospholipid-enriched extracts with at least 25% phosphatidyl choline and over 50% Acetone Insolubles, while producing a phospholipid-depleted raffinate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a one-stage extraction process is used, then the process is simple, but the maximum extract yield of phospholipids is relatively low
Solution Approach 1:
The extraction process is divided into multiple stages (typically 3-5 stages) where the phospholipid-containing material is sequentially contacted with fresh extractant in each stage. This segmentation allows progressive extraction of phospholipids, achieving high overall yield (over 90%) while maintaining process simplicity through modular design
Solution Approach 2:
The patent implements a continuous extraction process where the material flows through multiple extraction stages without interruption. The extractant continuously contacts the material in each stage, maintaining continuous phospholipid transfer from material to extractant, thereby maximizing extraction efficiency and yield
2Manufacturing precision
If multiple centrifugation steps are used, then phospholipid separation is improved, but the process becomes cumbersome and time-consuming
Solution Approach 1:
The patent extracts phospholipids from the material matrix into a separate liquid extractant phase through the multistage extraction process. This takes the phospholipids out of the complex material structure and places them in a soluble form in the extractant, enabling efficient separation in a single centrifugation step without requiring multiple processing steps
Solution Approach 2:
The extractant (alcohol or ketone) serves as an intermediary medium that selectively dissolves phospholipids from the material. This intermediary phase facilitates the separation process by creating a distinct liquid phase containing the extracted phospholipids, which can be easily separated from the solid material residue in one centrifugation step
3Manufacturing precision
If large amounts of aluminium oxide adsorbent are used, then phosphatidylcholine purification is improved, but the process requires more material and filtration steps
Solution Approach 1:
The patent changes the extraction parameter from using solid adsorbents (aluminium oxide) to using liquid extractants (alcohols or ketones). This parameter change allows phosphatidylcholine to be extracted and concentrated directly into the liquid phase, achieving high purity through selective solubility rather than adsorption, thereby eliminating the need for large quantities of adsorbent material
Solution Approach 2:
The patent replaces the mechanical adsorption system (aluminium oxide adsorbent requiring filtration) with a chemical dissolution system (liquid extractant). The phosphatidylcholine dissolves in the extractant through chemical interaction, and separation is achieved through phase separation and filtration of the liquid extractant, which is simpler and requires no solid adsorbent handling
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 significantly increases phospholipid extraction yield, reduces processing time, and produces fractions with distinct compositions suitable for various applications, including food and pharmaceutical products, by employing counter-current flow and centrifugal forces in a multistage extraction apparatus.
Implementation Method 1
contacting the phospholipid-containing starting material under agitation with an extractant comprising an aliphatic alcohol selected from C 1 to C 3 alcohols and mixtures thereof for a period of time sufficient to effectuate the transfer of at least a fraction of the phospholipids into the extractant
Implementation Method 2
effectuate the transfer of at least a fraction of the phospholipids into the extractant
Implementation Method 3
separating the obtained mixture into a phospholipid-enriched extract from a residual raffinate by a process comprising applying centrifugal forces
Data Source
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AI summary
The present invention relates to a counter-current extraction process involving a plurality of mixing and separation stages for fractionating a phospholipid-containing feed material into two or more fractions enriched in one or more phospholipids, comprising (a) contacting the phospholipid-containing starting material under agitation with an extractant comprising an aliphatic alcohol selected from C1 to C3 alcohols; (b) separating the obtained emulsion into a phospholipid-enriched extract from a residual raffinate.