Spray-Dried Powder Manufacturing via Segmented Emulsification
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Solution Overview
Problem
The existing methods for manufacturing water-dispersible powders with high fat-soluble compound content, such as beta-carotene, face challenges in achieving low filter residue and high compound concentration during the spray-drying process, often resulting in poor quality powders due to particle collapse and agglomeration issues.
Innovation Solution
A process involving a bimodal particle-solvent distribution is achieved by splitting the emulsification and evaporation steps into multiple stages, using a specialized apparatus with multiple mixing and evaporation units, to control the solvent removal and maintain particle stability, thereby producing high-quality, water-dispersible powders with enhanced fat-soluble compound content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the emulsification and evaporation steps are performed in a single stage, then the process is simple, but the particle distribution becomes unimodal leading to particle collapse and agglomeration
Solution Approach 1:
The manufacturing process is divided into multiple stages: first emulsification stage forming initial particles, then evaporation stage removing solvent, then second emulsification stage adding more fat-soluble compound, and finally second evaporation stage. This segmentation creates a bimodal particle distribution that prevents collapse and agglomeration, resolving the contradiction between process simplicity and particle quality.
2Quantity of substance
If a high content of fat-soluble compound is used in the dispersion, then the powder has high colorant content, but the filter residue increases
Solution Approach 1:
The first emulsification and evaporation stages are performed before adding the remaining fat-soluble compound. This preliminary action creates a stable particle distribution framework that can accommodate additional compound without causing agglomeration, allowing high final compound content while maintaining low filter residue.
3Productivity
If the solvent is completely removed in one evaporation step, then the process is efficient, but particle stability is compromised leading to collapse
Solution Approach 1:
The evaporation process is segmented into at least two separate evaporation stages interspersed with emulsification stages. This segmentation allows partial solvent removal followed by particle stabilization through additional emulsification, maintaining particle stability while achieving complete solvent removal ultimately, thus resolving the contradiction between evaporation efficiency and particle stability.
4Manufacturing precision
If small particle size is achieved for good coloration, then the powder quality is high, but the manufacturing process becomes more difficult
Solution Approach 1:
The process uses periodic alternating action between emulsification and evaporation stages. Each cycle refines the particle size distribution and prevents agglomeration, achieving small uniform particle sizes suitable for high-quality coloration while keeping the process manageable through rhythmic repetition of standardized operations.
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
This approach significantly reduces filter residue and allows for the production of powders with higher fat-soluble compound content, ensuring excellent quality and dispersibility, even with low-performing solvents like ethyl acetate or isopropyl acetate, by preventing particle collapse and agglomeration.
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
Water-dispersible powders comprising a fat-soluble compound may be manufactured by spray-drying
Data Source
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AI summary
The present invention relates to a method of manufacturing spray-dried powders. During the process, a solvent is used. The process is done in multiple steps such that the emulsification mass ratio is low when removal of the solvent is started. Preferred solvents are isopropyl acetate and ethyl acetate. The invention also relates to a set-up to run the inventive process at industrial scale.