Sodium Lactate Crystallization for Free-Flowing Solid Particles
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Solution Overview
Problem
Existing methods for producing sodium lactate powder face issues such as hygroscopicity leading to stickiness, formation of lumps, and poor processability, along with the risk of impurities and the need for additional purification steps due to high shear in extrusion, and the introduction of undesirable additives through coatings.
Innovation Solution
A method involving the crystallization of sodium lactate melt on a cooling surface with seed particles, controlling temperature and humidity, and collecting the crystallized particles to form solid particles with high purity and low water content, avoiding additives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If spray drying is used to produce sodium lactate powder, then the production process is simple, but the powder becomes hygroscopic and sticky over time
Solution Approach 1:
The invention changes the physical state parameter from powder to solid particles, and controls the water content parameter to less than 5% wt., which prevents hygroscopicity and stickiness while maintaining manufacturing simplicity
Solution Approach 2:
The invention uses crystallization phase transition to transform the sodium lactate from melt to solid particles, creating a stable crystalline structure that resists hygroscopicity and maintains powder stability without requiring complex processing
2Productivity
If extrusion method is used to produce sodium lactate powder, then the production process is efficient, but high shear forces cause impurities from extruder wear
Solution Approach 1:
The invention extracts the harmful high-shear extrusion step from the process and replaces it with a crystallization method that forms solid particles directly from melt, eliminating the source of mechanical wear impurities while maintaining production efficiency
Solution Approach 2:
The invention replaces the mechanical extrusion system with a thermal crystallization system, where the melt is applied to a cooling surface and crystallizes into solid particles, eliminating mechanical shear forces and associated contamination
3Ease of operation
If coating layer is applied to lactate salt particles, then processability is improved, but additional additives are introduced to the product
Solution Approach 1:
The invention uses the sodium lactate melt itself as the coating material, applying it directly to the cooling surface where it crystallizes to form the final particles. This self-coating approach improves processability through controlled crystallization without introducing external additives
4Ease of operation
If sodium lactate powder is stored or processed, then it becomes sticky and forms lumps, but the invention produces solid particles that maintain non-tackiness
Solution Approach 1:
The invention changes the physical form from powder to solid particles with controlled size and crystalline structure, and maintains water content below 5% wt., which fundamentally alters the material's behavior to prevent stickiness and lump formation while improving storage stability
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 resulting solid sodium lactate particles exhibit improved processability, stability, and reduced risk of impurities, maintaining non-tackiness and free-flowing properties without the need for anti-caking agents, suitable for various applications.
Implementation Method 1
crystallizing the applied NaL on the cooling surface forming solid NaL
Implementation Method 2
The cooling surface is kept at a temperature below the melting temperature of the NaL
Data Source
Figure 1
AI summary
The invention pertains to a method for manufacturing sodium lactate (NaL) solid particles, characterized in that the method comprises the following steps: - providing a melt of NaL wherein the melt has a chemical purity of at least 95 %. wt., and a water content of less than 5% wt.; - providing a cooling surface, which surface is provided with at least partially crystalline seed particles of NaL; - applying at least a part of said melt on a cooling surface; - crystallizing the applied NaL on the cooling surface forming solid NaL, and; - collecting at least part of the solid NaL from the cooling surface as solid NaL particles. The invention also pertains to particles of NaL wherein the NaL particles are at least partially crystalline, with a chemical purity of at least 95 %.wt., and a water content of less than 5%, and an average weight from 1-100 mg per particle. Use of the particles is also claimed.