Spray Drying Polymer Additive for Fine Particle Reduction
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Solution Overview
Problem
Existing spray drying methods for polypeptides and enzymes often produce small particles that pose industrial hygiene challenges for factory workers and product consumers, as they are not effective in substantially reducing the production of fine particles.
Innovation Solution
Incorporating a high molecular weight, water-soluble, flexible polymer such as polyethylene oxide with a molecular weight of 300,000 to 4,000,000 Daltons into the aqueous composition during the spray drying process to increase the yield of larger particles and reduce the formation of fine droplets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional spray drying methods are used for polypeptides and enzymes, then the process is simple and quick, but it produces small particles that pose industrial hygiene challenges
Solution Approach 1:
The patent changes the physical-chemical parameters of the spray drying process by introducing a high molecular weight polymer (300,000-4,000,000 Daltons) at specific concentrations (0.01-1.0% w/v). This parameter change modifies the droplet formation and drying characteristics, resulting in larger particles with reduced fine particle generation while maintaining productivity
Solution Approach 2:
The high molecular weight polymer acts as an intermediary substance that mediates between the spray drying process and the particle formation. It influences droplet coalescence, surface tension, and drying rates to promote larger particle formation, thereby reducing harmful fine particles without significantly impacting overall production efficiency
2Productivity
If high molecular weight polymer is added to increase particle yield, then manufacturing efficiency improves, but process complexity increases
Solution Approach 1:
The patent optimizes the polymer concentration parameter within a specific range (0.01-1.0% w/v) to achieve the desired particle yield improvement. By defining this optimal parameter range, the process complexity is managed, as concentrations outside this range may not provide additional benefits and could increase complexity without proportional gains
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 method increases the yield of particles by at least 5% and significantly reduces the production of small particles, improving industrial hygiene and manufacturing efficiency by minimizing the need for frequent filter bag emptying and reducing manufacturing downtime.
Implementation Method 1
Involving a high molecular weight, water soluble, flexible polymer... to increase the yield of larger particles and reduce the formation of fine droplets
Implementation Method 2
spray drying the aqueous composition to produce particles
Data Source
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AI summary
The present invention generally relates to particulate compositions and methods for making the compositions. It specifically relates to improved spray drying methods that substantially reduce the production of small particles that pose industrial hygiene concerns for factory workers and product consumers. In a composition aspect, the present invention provides an atomized aqueous composition. The composition is formed using a spray-drying apparatus. It includes 0.001 to 0.10 weight percent of a polymer, which is selected from a group consisting of a cellulose-based polymer, a gum, and a synthetic polymer. It further includes at least one polypeptide, which is present in the aqueous composition at a concentration greater than 0.01 weight percent.