Probiotic Beadlets via Spray Drying and Powder Coating
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Solution Overview
Problem
Current methods for formulating probiotics, such as freeze-drying and spray-drying, are time-consuming, expensive, and can negatively affect the viability of bacteria, while existing beadlet formulations for fat-soluble substances have low active content and require emulsification steps, making them unsuitable for high-probiotic formulations with good storage stability and handling properties.
Innovation Solution
The production of beadlets comprising probiotic compounds and starch/starch derivatives using a powder coating process, where an aqueous solution of probiotics and starch is spray-dried to create beadlets with a high probiotic content and improved storage stability, coated with a powder catch medium like starch or silicate compounds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If freeze-drying is used for probiotic formulation, then storage stability is improved, but production time and cost increase significantly
Solution Approach 1:
The patent uses spray-drying process which involves phase transition from liquid to solid particles through rapid evaporation of solvent, creating stable probiotic formulations without the extended time requirements of freeze-drying. The aqueous probiotic suspension is atomized into droplets that rapidly dry in the spray-dryer chamber, achieving storage stability through controlled phase change rather than slow freeze-drying.
2Productivity
If spray-drying is used for probiotic formulation, then production cost is reduced, but bacterial viability decreases due to high temperatures
Solution Approach 1:
The patent modifies the spray-drying parameters to use lower inlet temperatures and optimized atomization conditions, changing the thermal parameters from conventional high-temperature spray-drying to a gentler process that preserves probiotic viability while maintaining production efficiency. The process parameters are specifically adjusted to keep product temperature below harmful thresholds.
3Ease of operation
If existing beadlet formulations for fat-soluble substances are used, then handling properties are improved, but probiotic content is limited to low concentrations
Solution Approach 1:
The patent creates homogeneous aqueous probiotic-starch suspensions that are uniformly distributed throughout the beadlet matrix, allowing high probiotic loading (30-80 wt%) without aggregation or phase separation. The homogeneity of the aqueous phase enables high concentrations of water-soluble probiotics to be incorporated while maintaining the beadlet form's superior handling properties.
4Adaptability or versatility
If emulsification is used in beadlet production, then fat-soluble substances can be incorporated, but process complexity increases
Solution Approach 1:
The patent extracts the emulsification step from the beadlet production process, eliminating the need for emulsifiers and emulsification equipment. By focusing on water-soluble probiotics and using a straightforward spray-drying approach, the process removes the complex emulsion formation and stabilization steps while still achieving effective probiotic delivery.
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
This process allows for the creation of beadlets with high probiotic content (30-80 wt-%) and excellent storage stability, handling properties, and simplified production, overcoming the limitations of existing methods by maintaining bacterial viability and avoiding the need for emulsification.
Implementation Method 1
converting the solution into a dry powder by spray drying
Implementation Method 2
These beadlets are coated with a layer of the powder catch medium
Data Source
AI summary
The present invention relates a process of production of beadlets comprising probiotic compounds in a matrix comprising at least one starch and/or starch derivative, to such beadlets and to the use of such specific beadlets in food (for humans and animals) as well as in premixes.