Solid Glucose Matrix Composition for Faster, Lower-Waste Production
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Solution Overview
Problem
Existing processes for producing solid glucose are time-consuming, costly, and inefficient, requiring high-purity glucose syrups and result in significant waste streams, with products exhibiting poor handling, stability, and dissolution properties.
Innovation Solution
A process for producing solid glucose in a matrix phase with amorphous glucose and carbohydrate crystals, optionally coated with a dry powder coating, to enhance glass transition temperature and improve flowability, wettability, and dissolution speed, using a glucose solution with lower purity and minimizing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If glucose syrup is produced in solid crystalline form through conventional processes, then the product has good flowability and handling properties, but the process is time-consuming, costly, and results in significant waste streams
Solution Approach 1:
The invention changes the physical state parameters of glucose from crystalline to amorphous solid form. This is achieved by controlling the glass transition temperature (Tg) through composition adjustment (adding substances like fructose, sorbitol, or starch) and temperature control during processing. The amorphous form maintains good flowability and handling properties while enabling a simplified, faster production process without crystallization steps.
Solution Approach 2:
The invention utilizes the glass transition phase transition of amorphous carbohydrates instead of crystallization. By controlling the Tg of the amorphous glucose matrix through composition and temperature, the product achieves stable solid form with good handling properties, eliminating the need for time-consuming crystallization and centrifugation steps.
2Manufacturing precision
If high-purity glucose syrup is used as starting material, then the solid glucose product has high quality, but the cost increases and waste streams are generated
Solution Approach 1:
The invention changes the approach from purification to acceptance of impurities. Instead of requiring high-purity glucose syrup and performing multiple purification steps, the process accepts lower-purity starting materials and uses the impurities (other carbohydrates) as functional components that raise the glass transition temperature and stabilize the amorphous matrix, eliminating costly purification and waste generation.
Solution Approach 2:
The invention converts the previously harmful impurities in glucose syrup into beneficial functional components. Substances like fructose, sorbitol, starch, and other carbohydrates that were considered waste or contaminants are now intentionally used to raise the glass transition temperature and stabilize the amorphous glucose structure, eliminating the need for expensive purification while improving product stability.
3Weight of moving object
If glucose syrup with high water content is transported, then shipping costs increase, but the product remains stable
Solution Approach 1:
The invention uses the glass transition of amorphous carbohydrates to achieve stable solid form at ambient temperatures. By controlling the Tg through composition (adding fructose, sorbitol, starch, etc.), the product remains in a stable glassy state during transport, preventing crystallization and microbial growth, while being transportable as a solid powder without the high water content that would require refrigeration.
4Productivity
If conventional crystallization processes are used, then solid glucose is obtained, but the process requires multiple steps including centrifugation and results in mother liquor waste
Solution Approach 1:
The invention extracts and eliminates the crystallization and separation steps from the conventional process. Instead of forming crystals that require centrifugation and washing, the process directly produces amorphous solid glucose powder through controlled glass transition, removing the need for complex separation equipment and multiple processing steps.
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 process achieves high-yield, cost- and time-efficient production of stable, easily handled, and quickly dissolving solid glucose powder with improved flowability and wettability, eliminating the need for high-purity starting materials and reducing waste.
Implementation Method 1
Cooling the aqueous slurry to a temperature of at most the glass transition temperature of the slurry obtained in step (iii) thereby obtaining a product containing solidified glucose
Data Source
AI summary
A glucose in solid form containing a matrix phase and a plurality of carbohydrate crystals within said matrix phase, the matrix phase containing amorphous glucose and water, wherein the carbohydrate crystals comprise glucose and optionally one or more other carbohydrate(s), and optionally wherein the glucose in solid form is coated with a dry powder coating. The glucose in solid form may comprise at least 50 wt % dry substance (DS) glucose and may comprise one or more other carbohydrate(s) besides glucose. A method for manufacturing solidified glucose is also provided.