Rotating Winding Capsule Apparatus for Continuous Emulsion Encapsulation
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Solution Overview
Problem
There is a need for an apparatus capable of continuously manufacturing seamless capsules with a layer of gelled gel-forming polysaccharide, as existing methods are not efficient for large-scale production and require significant manual intervention.
Innovation Solution
A cylindrical drum with a rotatable winding forms a series of chambers, where an emulsion is continuously mixed with a gelling solution, and baffles provide agitation to form a capsule wall, allowing for controlled encapsulation and gelling of the polysaccharide, enabling high throughput and reduced residence time variation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a batch process method is used for capsule preparation, then manual intervention and control are simplified, but production efficiency and throughput are limited
Solution Approach 1:
The continuous processing apparatus is segmented into multiple distinct functional zones along the conveyor path: emulsion addition zone, gelling solution immersion zone, agitation zone with baffles, and drying zone. Each zone performs a specific operation, allowing continuous processing while maintaining controlled conditions similar to batch processes.
Solution Approach 2:
The apparatus enables continuous capsule production by maintaining uninterrupted flow of emulsion through the processing line. The conveyor continuously transports droplets through all processing stages without stopping, eliminating the cyclic nature of batch processes and significantly increasing throughput.
2Productivity
If residence time in the gelling solution is extended to ensure complete encapsulation, then capsule quality improves, but production throughput decreases
Solution Approach 1:
The apparatus dynamically adjusts the residence time of droplets in the gelling solution by controlling conveyor speed and the length of the immersion zone. This allows optimization of both encapsulation quality and production throughput by matching processing time to capsule size and gelation requirements.
Solution Approach 2:
The system incorporates monitoring to ensure complete encapsulation while maintaining continuous flow. By observing capsule formation and gelation progress, the apparatus can adjust operating parameters to maintain quality standards at high production rates.
3Stability of the object's composition
If high shear mixing is applied to ensure uniform emulsion distribution, then emulsion homogeneity improves, but sensitive or sticky materials may be damaged or aggregated
Solution Approach 1:
Instead of continuous high-shear mixing, the apparatus uses periodic gentle agitation through baffles that create mild turbulent flow as droplets move through the gelling solution. This provides sufficient mixing for uniform encapsulation without subjecting sensitive materials to damaging shear forces.
Solution Approach 2:
The gelling solution acts as an intermediary medium that facilitates uniform emulsion distribution through gentle convection and diffusion rather than direct high-shear mixing. The baffles create mild flow patterns that ensure complete encapsulation without damaging sticky or sensitive materials.
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 apparatus enables continuous and efficient encapsulation of objects, such as emulsions, with a gelled polysaccharide capsule wall, improving production rates and maintaining the integrity of encapsulated materials, including sticky or sensitive substances, while minimizing waste and operational complexity.
Implementation Method 1
adding portions of the emulsion to an aqueous gelling solution comprising a gel-forming polysaccharide, thereby encapsulating the portions of the emulsion in a layer of gelled gel-forming polysaccharide
Implementation Method 2
The rotation of the winding transports a volume of material added to a chamber from the drum input end through the length of the drum to the drum output end in a predetermined time
Implementation Method 3
Baffles are added for introduction of proper agitation during the encapsulation process
Data Source
AI summary
An apparatus for a continuous encapsulation process is provided. The apparatus is a vibrating tubing used alone, in series, or in combination with an encapsulation apparatus, which is used alone or in series. The vibrating tubing is a flat coil, a standing spiral, or a flume. The encapsulation apparatus includes a winding having coils disposed in an aqueous gelling solution. The winding is rotatable about its longitudinal center axis. The winding has adjacently spaced coils forming a plurality of chambers. Objects to be encapsulated are added to the apparatus such that when the winding is rotated, the chambers transport a volume of objects through the length winding in the aqueous gelling solution in a predetermined time.