Starch-Based Hard Capsule Shell Film Formulation

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Solution Overview

Problem

Current gelatin-free and starch-based film-forming compositions for hard capsule shells lack transparency, stability, and mechanical resistance, and are costly, making them unsuitable for industrial applications.

Innovation Solution

A film-forming composition comprising hydrolyzed starch, gellan gum, isosorbide, sorbitol, and glycerol, which acts as a partial or total replacement for gelatin, providing improved mechanical resistance, solubility, transparency, and flexibility, and can be easily manufactured and handled without significant equipment changes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If gelatin is replaced by vegetarian-acceptable alternatives such as HPMC, pullulan, or carrageenan, then religious and ethical compatibility is improved, but production cost increases significantly

Engineering Contradiction:

Improvereligious and ethical compatibilityVSAvoidproduction cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent uses a composite formulation combining starch with multiple additives (plasticizers, humectants, crosslinking agents) to create a material that mimics gelatin's properties while using inexpensive, vegetarian-friendly components. This composite approach achieves both religious compatibility and cost-effectiveness.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies starch through chemical crosslinking and physical processing to change its properties, transforming it from an inadequate capsule material into one that matches gelatin's mechanical and functional characteristics. This parameter transformation enables cost-effective gelatin replacement.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If starch-based formulations are used to replace gelatin, then production cost is reduced, but film transparency, stability, and mechanical resistance deteriorate

Engineering Contradiction:

Improveproduction costVSAvoidfilm mechanical resistance

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent applies crosslinking agents and plasticizers to fundamentally change starch's physical and chemical parameters, improving its mechanical strength, flexibility, and stability to match or exceed gelatin's performance while maintaining low cost.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The formulation combines starch with multiple functional additives including plasticizers for flexibility, crosslinking agents for strength, and humectants for stability, creating a composite material that overcomes pure starch's deficiencies in mechanical resistance.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If starch-based formulations are used to replace gelatin, then production cost is reduced, but film transparency deteriorates

Engineering Contradiction:

Improveproduction costVSAvoidfilm transparency

Core Design Contradiction:

Ease of manufactureVSIllumination intensity

Solution Approach 1:

The patent uses processing conditions and additives to modify starch's optical properties, achieving transparency in the final capsule shell film while maintaining the cost advantages of starch-based materials.

Inventive Principle:

Principle #35Parameter changes

4Ease of manufacture

If starch-based formulations are used to replace gelatin, then production cost is reduced, but dip time increases from 1-2 seconds to 20 seconds

Engineering Contradiction:

Improveproduction costVSAvoiddip time

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent adjusts the viscosity and flow properties of the starch formulation through plasticizers and processing parameters, enabling rapid dipping (1-2 seconds) comparable to gelatin, thus maintaining high productivity while using inexpensive starch-based materials.

Inventive Principle:

Principle #35Parameter changes

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 composition enables the production of hard capsule shells with excellent mechanical resistance, solubility, transparency, and stability, suitable for various industries, including pharmaceutical and cosmetic, while being cost-effective and easy to use.

Implementation Method 1

film-forming compositions for hard capsule shells which are based on starchy material

Methodology Applied

Scientific EffectFilm formation:

Implementation Method 2

comprise starch, gellan gum, isosorbide, sorbitol and glycerol

Methodology Applied

Scientific EffectGelling: Gel

Implementation Method 3

the consistency of which may be adjusted by the addition of a plasticizer such as glycerol or sorbitol

Methodology Applied

Scientific EffectPlasticization:

Implementation Method 4

characterized by the fact that it comprises isosorbide and a plasticizer. The capsules obtained thereof had good stability and transparency

Methodology Applied

Scientific EffectFilm forming enhancement:

Data Source

PatentUS11040105B2Film-forming compositions for hard capsule shells and hard capsule shells obtained thereof

Publication Date: 2021.06.22 ROQUETTE FRERES SA

AI summary

The instant invention relates to film-forming compositions suitable for the manufacture of hard capsule shells, which are based on starchy material. The instant invention also relates hard capsule shells made from the film-forming compositions of the invention.