Spray-Dried Powder Processing With Split Emulsification for Low Filter Residue
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Solution Overview
Problem
Existing methods struggle to produce water-dispersible powders with high fat-soluble compound content, such as beta-carotene, due to particle collapse during solvent removal, leading to high filter residue and poor dispersion quality.
Innovation Solution
A bimodal particle-solvent distribution is achieved by splitting the emulsification and evaporation steps, allowing for the production of a high-quality aqueous dispersion that is spray-dried, using a setup with multiple evaporation and mixing units to maintain particle stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the dispersion is concentrated to achieve high fat-soluble compound content, then the powder content increases, but particle collapse occurs during solvent removal leading to high filter residue
Solution Approach 1:
The patent divides the emulsification process into two distinct stages: first emulsifying fat-soluble compounds with a water-immiscible solvent to form particles, then removing the solvent to create a stable aqueous dispersion. This segmentation prevents particle collapse by avoiding excessive concentration during a single emulsification step, thereby reducing filter residue while maintaining high final powder content.
Solution Approach 2:
The patent extracts and removes the water-immiscible solvent from the emulsion after particle formation. By taking out the solvent through separation, the system achieves high fat-soluble compound content in the final powder without the filter residue problems caused by retaining excessive solvent, thus resolving the contradiction between concentration and filtration quality.
2Device complexity
If conventional emulsification is used to create water-dispersible powders, then the process is simple, but particle stability is poor leading to high filter residue
Solution Approach 1:
The patent segments the emulsification process into two stages: first forming particles with water-immiscible solvent, then removing the solvent to stabilize the aqueous dispersion. This segmentation improves particle stability and reduces filter residue while adding only minimal process complexity through a straightforward separation step.
Solution Approach 2:
The patent changes the physical-chemical parameters by using water-immiscible solvents with specific properties (boiling point 50-120°C, low viscosity) and controlling the emulsification conditions. These parameter changes enhance particle stability and reduce filter residue without significantly complicating the overall process.
3Quantity of substance
If high fat-soluble compound content is achieved by increasing dispersion concentration, then powder content increases, but dispersion quality deteriorates
Solution Approach 1:
The patent segments the process into particle formation (with solvent) and solvent removal (to stabilize dispersion). This segmentation allows high powder content to be achieved without sacrificing dispersion quality, as the two-stage process prevents particle collapse and maintains stability even at high concentrations.
Solution Approach 2:
The water-immiscible solvent acts as an intermediary that facilitates particle formation and then is removed to stabilize the final aqueous dispersion. This intermediary enables high fat-soluble compound content while maintaining dispersion quality, as the solvent temporarily assists particle formation then is extracted to prevent aggregation and maintain 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 process enables the production of water-dispersible powders with high fat-soluble compound content, ensuring low filter residue and excellent dispersion quality, even with low-performing solvents like ethyl acetate or isopropyl acetate, and supports industrial-scale manufacturing.
Implementation Method 1
The dispersion to be spray-dried is obtained by removing the solvent of an intermediate composition in an evaporator
Implementation Method 2
The dispersion to be spray-dried is obtained by removing the solvent of an intermediate composition in an evaporator
Data Source
AI summary
Methods and industrial scale set-ups for manufacturing spray-dried powders are provided. During the process, a solvent is used. The process is done batchwise such that the emulsification mass ratio is low when removal of the solvent is started. Preferred solvents are isopropyl acetate and ethyl acetate.