Microencapsulated Probiotic Powder via Laminar Flow Drip Casting
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Solution Overview
Problem
Existing microencapsulated probiotic substances have limited viability when stored at physiological temperatures and are sensitive to temperature fluctuations, requiring refrigeration, which increases storage and transportation costs and reduces their effectiveness.
Innovation Solution
A microencapsulated probiotic substance with a dried powder composition of spherical particles, produced using laminar flow drip casting, which maintains high viability even at elevated temperatures and provides a stable, evenly distributed particle size for enhanced shelf life and resistance to external factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If microencapsulated probiotic substances are stored at physiological temperatures, then storage and transportation costs are reduced, but the viability of probiotic microorganisms decreases rapidly
Solution Approach 1:
The invention uses a composite encapsulation system consisting of an inner matrix phase (alginate, gelatin, or pectin) and an outer protective coating phase (ethylcellulose, hydroxypropyl methylcellulose, or carboxymethyl cellulose). This multi-layer composite structure provides both structural support and environmental protection, enabling the probiotics to survive at physiological temperatures without refrigeration while maintaining viability.
Solution Approach 2:
The invention changes the physical and chemical parameters of the encapsulation materials to achieve temperature stability. Specifically, it selects materials with appropriate glass transition temperatures, molecular weights, and compositional ratios (e.g., alginate 1-10%, gelatin 1-10%, pectin 1-10%) that maintain structural integrity and protective function at physiological temperatures, preventing rapid viability loss.
2Productivity
If the particle size is reduced to improve dissolution and release, then the surface area to volume ratio increases, but the probiotic microorganisms become more sensitive to external factors
Solution Approach 1:
The invention applies different material properties to different layers of the encapsulation structure. The inner matrix phase provides a protective microenvironment for the probiotics with appropriate porosity and degradation characteristics, while the outer coating phase provides enhanced mechanical strength and environmental barrier. This local differentiation allows smaller particles to maintain protection while achieving fast dissolution.
Solution Approach 2:
The invention uses flexible polymer coatings (ethylcellulose, hydroxypropyl methylcellulose, carboxymethyl cellulose) that can adapt to particle size reductions. These thin film coatings provide continuous protective barriers that prevent microorganism exposure to harmful external factors even as particle size decreases, while still allowing controlled dissolution and release.
3Reliability
If refrigeration is used to maintain probiotic viability, then the survival rate is improved, but the storage and transportation costs increase enormously
Solution Approach 1:
The invention extracts the temperature dependency requirement from the probiotic formulation by using encapsulation materials that provide thermal protection. The multi-layer encapsulation structure with specific material compositions creates a microenvironment that buffers temperature fluctuations, allowing the probiotics to maintain high survival rates without refrigeration, thus eliminating the need for cold chain storage and transportation.
4Ease of manufacture
If a broad particle size distribution is present, then the manufacturing process is simpler, but the release characteristics and stability are compromised
Solution Approach 1:
The invention introduces dynamic control of particle size through adjustable manufacturing parameters. The homogenization process uses controllable speed, time, and energy input to achieve a narrow particle size distribution (d10-d90 span of 50-200 μm). This dynamic control allows optimization of both manufacturing efficiency and product performance, ensuring consistent dissolution and release characteristics while maintaining manufacturing feasibility.
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 laminar flow drip casting method ensures a narrow particle size distribution and high survival rates of probiotic microorganisms, maintaining viability at room temperature and elevated temperatures, thus extending shelf life and improving the probiotics' stability and release characteristics.
Implementation Method 1
laminar flow drip casting
Implementation Method 2
laminar flow drip casting
Implementation Method 3
enteric coating composition
Data Source
AI summary
Dried powder solid particles containing a probiotic microorganism and a carrier phase wherein said probiotic microorganism is encapsulated, said carrier phase further comprising at least a nutritious source, said dried powder solid particles present a particle size distribution between n and (n+400) pm, wherein n is comprised between 100 and 10000 µ?t?, preferably between 300 and 5000 pm, more preferably between 400 and 1000 pm.