Probiotic Pet Food Packaging with Desiccant Barrier
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Solution Overview
Problem
Existing pet food products face challenges in maintaining the stability and effectiveness of Probiotics during manufacturing and storage due to sensitivity to extrusion processes, oxygen, and moisture, leading to issues like uneven coating, agglomeration, and adhesion, which affects the delivery of these beneficial microorganisms to animals.
Innovation Solution
A packaging system with a permeability coefficient of no more than 75 grams/day/m²/bar, containing a desiccant to maintain a water activity of less than 0.3, ensuring the Probiotics retain at least 90% of their initial activity level after 6 months, and preventing a two-log loss over the same period, thereby maintaining their effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If Probiotics are incorporated into kibble during extrusion process, then the food production is efficient and cost-effective, but the Probiotics decompose or lose activity due to heat and pressure
Solution Approach 1:
The patent divides the kibble production process into two separate stages: (1) extrusion of the kibble base without Probiotics, and (2) post-extrusion application of Probiotics to the cooled kibble surface. This segmentation allows the Probiotics to be added after the harsh thermal processing, preserving their viability while maintaining production efficiency.
Solution Approach 2:
The kibble is prepared in advance by extruding and cooling without Probiotics, creating a ready substrate. The Probiotics are then applied in a subsequent step after the kibble has cooled, ensuring the thermal stress is already gone before the sensitive biological material is introduced.
2Stability of the object's composition
If carrier agents are used to protect Probiotics, then stability during storage is improved, but uneven coating and agglomeration occur
Solution Approach 1:
The patent removes the problematic carrier agent step entirely. Instead of mixing Probiotics with carrier agents that cause agglomeration and uneven coating, the Probiotics are applied directly to the kibble surface in a controlled manner, eliminating the intermediary substance that creates manufacturing defects.
Solution Approach 2:
The cooled kibble surface itself serves as the intermediary substrate for Probiotic application. Rather than using a carrier agent as the medium, the Probiotics are applied directly to the prepared kibble surface, which provides a stable, non-agglomerating base that ensures uniform distribution.
3Duration of action of stationary object
If Probiotics are exposed to oxygen and moisture during storage, then shelf life is extended, but the Probiotics decompose and lose effectiveness
Solution Approach 1:
The patent employs packaging with barrier properties (flexible shells/films) that control the permeability to oxygen and moisture. This allows the package to protect the Probiotics from environmental degradation while maintaining a balance that prevents condensation and excessive drying, thereby preserving Probiotic activity throughout the shelf life period.
Solution Approach 2:
The patent creates a protected environment within the package by controlling the internal atmosphere to minimize oxygen and moisture exposure. This inert-like environment prevents oxidative decomposition and hydrolysis of the Probiotics, maintaining their viability throughout the intended shelf life without requiring excessive packaging complexity.
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 packaging system effectively maintains Probiotic activity and stability, ensuring a target dose level is delivered to animals over an extended shelf life, enhancing gastrointestinal health without significant loss in potency.
Implementation Method 1
a package having a permeability coefficient of no more than 75 grams/day/m2
Implementation Method 2
containing a desiccant to maintain a water activity of less than 0.3
Data Source
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AI summary
A method of providing an animal food having an active. A Probiotic animal food having a low water activity that can be contained within a package having a low vapor transmission rate. The animal food can have a shelf life sufficient to deliver a target dose of Probiotic to an animal. The water activity of the animal food can be controlled. The activity level of the Probiotic can be controlled.