Probiotic Tablet Briquetting Process for Viability Preservation
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Solution Overview
Problem
Existing methods for producing compressed tablets with probiotic bacteria often result in significant viability loss of the probiotics during the manufacturing process, leading to less effective final products.
Innovation Solution
A method involving a briquetting step where excipients are compressed into large briquettes, fractioned, and ground before being mixed with probiotics, which are then compressed into the final product, minimizing viability loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If excipients and probiotics are mixed and directly compressed to the final product, then the manufacturing process is simple and fast, but the viability of probiotics decreases significantly (about 70%) during tablet pressing
Solution Approach 1:
The manufacturing process is divided into separate stages: first, excipients are compressed into large briquettes; second, these briquettes are fractionated and ground; third, probiotics are mixed with the ground briquettes; and fourth, the mixture is compressed into final tablets. This segmentation allows probiotics to be added after the excipient structure is formed, reducing their exposure to compression stress and maintaining viability.
Solution Approach 2:
The excipients are compressed into briquettes and ground into granules before the probiotics are added. This preliminary preparation of the excipient matrix creates a suitable carrier form that can be easily mixed with probiotics and compressed together, reducing the overall compression force needed and protecting probiotic viability.
2Reliability
If a briquetting step is introduced where excipients are compressed to large briquettes and fractioned before mixing with probiotics, then probiotic viability is maintained (only 7% decrease), but the manufacturing process becomes more complex
Solution Approach 1:
The manufacturing process is divided into separate stages: first, excipients are compressed into large briquettes; second, these briquettes are fractionated and ground; third, probiotics are mixed with the ground briquettes; and fourth, the mixture is compressed into final tablets. This segmentation allows probiotics to be added after the excipient structure is formed, reducing their exposure to compression stress and maintaining viability.
Solution Approach 2:
The ground briquettes serve as an intermediary carrier form between the excipients and the final tablet. By first forming a structured excipient matrix and then mixing probiotics with this pre-formed granulate, the process protects probiotics from direct compression stress while still achieving the final compressed product.
3Ease of manufacture
If direct compression is used without briquetting, then the manufacturing process is simple, but the tablets become harder (90 N) and less stable (1.78% friability)
Solution Approach 1:
The excipients are compressed into briquettes and ground into granules before mixing with probiotics. This preliminary formation of a structured excipient matrix creates a carrier that, when compressed with probiotics, produces tablets with optimal hardness (75 N) and stability (1.28% friability), avoiding the excessive hardness and reduced stability associated with direct compression of all ingredients.
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 method achieves a high survival rate of probiotics, with only a 7% decrease in viability during tablet production, compared to a 70% decrease in traditional methods, while also producing tablets with lower hardness and higher stability.
Implementation Method 1
a briquetting step in which the excipients are compressed to large briquettes
Implementation Method 2
fractioned to the desired particle size and grinded with a granulator
Implementation Method 3
the probiotics are mixed with these granules, i.e. the grinded briquettes
Implementation Method 4
wherein this mixture is compressed to the final product
Data Source
AI summary
Provided is a method for producing a compressed product, in particular a tablet, which comprises probiotic bacteria as active ingredient. In particular, a method is provided which comprises a briquetting step in which the excipients are compressed to large briquettes and fractioned to the desired particle size before the probiotic bacteria are added for final compression.