Semisolid Softgel Fill Material for Structural Integrity
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Solution Overview
Problem
Conventional softgel drying methods struggle with maintaining structural integrity and shape when containing water or polar components, leading to misshapen and uncured softgels.
Innovation Solution
A semisolid softgel fill material comprising a combination of waxy and non-waxy oils, a surfactant like d-α-tocopheryl polyethylene glycol succinate (TPGS), and water or other polar solvents, with specific ratios and components that form a stable emulsion, allowing for conventional drying without losing structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If water or polar components are included in the fill material to enhance digestion and absorption, then the digestibility and absorption rate are improved, but the softgel loses structural integrity and becomes misshapen during conventional drying
Solution Approach 1:
The patent changes the chemical composition parameters of the fill material by incorporating specific ratios of waxy oil (40-80 wt%), non-waxy oil (20-60 wt%), and water (5-20 wt%). This parameter optimization allows the fill material to maintain structural integrity during drying while preserving enhanced digestibility and absorption properties.
Solution Approach 2:
The patent creates a composite fill material system combining multiple components: waxy oil, non-waxy oil, water, and optional additives. This composite formulation leverages the complementary properties of each component to achieve both rapid digestion and drying stability, resolving the contradiction between these two requirements.
2Productivity
If conventional drying methods are used to expedite the drying process, then the drying speed is improved, but softgels with water in the fill material become misshapen and uncured
Solution Approach 1:
The patent modifies the fill material composition parameters to include specific ratios of waxy oil (40-80 wt%), non-waxy oil (20-60 wt%), and water (5-20 wt%). This compositional parameter change enables the fill material to withstand conventional drying conditions without losing shape or structural integrity, allowing fast drying to proceed.
Solution Approach 2:
The waxy oil component acts as an intermediary substance that mediates between the water content and the drying process. It provides a structural framework that prevents water migration during drying, enabling conventional drying methods to proceed at high speed while maintaining softgel shape and integrity.
3Reliability
If water is removed from the fill material to maintain softgel shape during drying, then structural integrity is preserved, but the digestibility and absorption rate are reduced
Solution Approach 1:
The patent develops a composite fill material where water (5-20 wt%) is integrated with waxy oil (40-80 wt%) and non-waxy oil (20-60 wt%). This composite structure allows water to remain in the fill material, providing enhanced digestibility and absorption, while the oil components maintain structural integrity during drying.
Solution Approach 2:
The patent optimizes the concentration parameters of water (5-20 wt%) and oils in the fill material. This parameter optimization ensures sufficient water content for enhanced digestion and absorption while maintaining oil content levels that provide structural integrity during the drying process.
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 proposed fill material enables softgels to retain their shape and structural integrity during conventional drying, ensuring they are fully formed and suitable for packaging, with enhanced digestion and absorption properties due to the water-in-oil emulsion.
Implementation Method 1
The semisolid fill material also includes a surfactant, such as d-α-tocopheryl polyethylene glycol succinate ('TPGS') or a derivative thereof
Implementation Method 2
A semisolid softgel fill material comprising a combination of waxy and non-waxy oils, a surfactant like d-α-tocopheryl polyethylene glycol succinate (TPGS), and water or other polar solvents, with specific ratios and components that form a stable emulsion
Data Source
AI summary
Provided is a semisolid softgel fill material that includes water and/or other polar solvents, along with a high amount of a nonpolar component, such as an oil. Also provided are methods and systems for producing softgels including the fill material. The softgels produced by the methods and systems provided herein have a normal appearance and retain their structural integrity, even when dried according to conventional methods. Further, when the fill material is added to water or other liquid, as it would be following ingestion, the fill material forms small droplets, thereby enhancing digestion and absorption of the fill material.