One-Step Spray Drying for Large Particles
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Solution Overview
Problem
Conventional spray drying methods are inadequate for producing particles with diameters between 100 to 2000 µm, as they result in significant losses of volatile active ingredients and require additional steps for larger particle sizes, and are not cost-effective, while other methods like extrusion and coacervation face challenges with viscosity and pressure issues.
Innovation Solution
A one-step spray-drying process involving the simultaneous introduction of a powdering agent and a substance that modifies the carrier matrix during spray drying, allowing for the production of larger particles with controlled dissolution properties, using a multi-stage drying apparatus to achieve particles with diameters up to 2000 µm and reduced volatile losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional spray drying is used to produce particles, then volatile active ingredients are lost through evaporation, but particle size cannot be increased beyond 100 µm without additional steps
Solution Approach 1:
The invention introduces a powdering agent into the spray drying chamber before or during the spraying process. This powdering agent accumulates on the droplets during drying, forming a coating that prevents volatile active ingredients from evaporating while also enabling the formation of larger particles (100-2000 µm) in a single spray drying step
Solution Approach 2:
The powdering agent acts as an intermediary substance between the liquid droplet and the hot drying air. It forms a protective barrier that mediates the drying process, allowing larger particles to be formed without direct exposure of volatile ingredients to high temperatures, thus preventing their evaporation
2Volume of moving object
If additional steps are added to produce larger particles, then particle size increases to 100-2000 µm, but production costs increase and process complexity increases
Solution Approach 1:
The invention merges multiple functions into a single spray drying process: particle formation, volatile protection, and size enlargement are all achieved simultaneously by introducing the powdering agent into the spray drying chamber, eliminating the need for separate agglomeration or coating steps
3Quantity of substance
If viscosity of suspension is increased to reduce water content, then active ingredient concentration is maintained, but atomization quality deteriorates
Solution Approach 1:
The powdering agent serves as an intermediary that allows higher viscosity suspensions to be processed. By providing a particulate matrix for the suspension to adhere to during drying, it enables better atomization of viscous materials while maintaining high active ingredient concentrations without requiring excessive water addition
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 process enables the production of cost-effective, larger particles with controlled release properties and reduced volatile losses, offering improved handling and retention of active ingredients, and is more efficient than traditional methods.
Implementation Method 1
the formed droplets are put in contact with a hot gas, air or nitrogen for example. Water is then evaporated very quickly from the droplets
Implementation Method 2
there is introduced into the spraying tower a substance capable of reacting with said carrier material to modify the dissolution properties of the obtained capsules
Data Source
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AI summary
Capsules encapsulating an active or functional ingredient are obtainable by a process in which a feed comprising this ingredient is dispersed in the form of drops in a spraying tower and exposed to a temperature in the range of -20°C to 500°C. In the tower, a cloud of suspended powdering agent provides a coating and prevents the capsules from sticking together and a reactant is provided to react with a polymer or film-forming carrier of the active ingredient so as to modify the water solution properties of the capsule walls.