Static Mixer Infant Formula Emulsion
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Solution Overview
Problem
Existing processes for preparing infant or follow-on formulae fail to produce lipid globules that closely resemble those in human milk, leading to nutritional disadvantages and inefficient, costly production methods due to high pressure homogenization, which results in unstable and less desirable fatty acid profiles and increased energy consumption.
Innovation Solution
A process using a static mixer to combine an aqueous phase with a lipid phase, applying low shear forces to achieve lipid globules with a volume-weighted mode diameter of 2 to 12 μm, coated with polar lipids, thereby mimicking the structure of human milk lipid globules, while reducing production costs and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If high pressure homogenization is used to mix lipid and aqueous phases, then a stable emulsion is achieved, but the lipid globule size becomes too small (0.1 to 0.5 μm) and energy consumption increases
Solution Approach 1:
The patent changes the key parameter from high pressure (conventional homogenization) to low shear stress conditions using a static mixer, while maintaining emulsion stability through controlled mixing geometry and flow patterns. This parameter change achieves the desired lipid globule size (2 to 12 μm) without the high energy input required by traditional high-pressure homogenizers.
2Stability of the object's composition
If high pressure homogenization is used to create small lipid droplets, then creaming is prevented, but the lipid globule surface area increases causing insufficient polar lipid coverage
Solution Approach 1:
The patent changes the mixing parameters to produce larger lipid globules (2 to 12 μm) that have lower surface area to volume ratio, thereby reducing the total amount of polar lipid required for coverage while still preventing creaming through stable emulsion formation in the oil-in-water system.
3Ease of manufacture
If conventional batch mixers are used to mix lipid and aqueous phases, then mixing is achieved, but heterogeneous mixing conditions produce broad lipid droplet size distribution
Solution Approach 1:
The patent replaces the mechanical batch mixing system with a static mixer that uses controlled shear flow patterns to achieve homogeneous mixing. This substitution eliminates the heterogeneous mixing conditions of batch mixers and produces a narrow lipid droplet size distribution (2 to 12 μm) with high manufacturing precision.
4Stability of the object's composition
If high pressure homogenization is used to process infant formula, then lipid phase compartmentalization is achieved, but production costs increase
Solution Approach 1:
The patent employs a static mixer, which is a simpler and less expensive device compared to high-pressure homogenizers. The static mixer achieves effective lipid phase compartmentalization and emulsion stability at lower capital and operational costs, making the manufacturing process more economically viable while maintaining product quality.
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 produces a stable oil-in-water emulsion with lipid globules that closely resemble human milk, offering improved nutritional benefits and cost efficiency by avoiding high-pressure homogenization, resulting in a more controllable and reproducible product with enhanced shelf-life stability.
Implementation Method 1
mixing the lipid phase with the aqueous phase in a ratio of 5 to 50% (w/w) using a static mixer so as to obtain a lipid and protein component-containing composition comprising lipid globules
Data Source
AI summary
The present invention relates to a process for preparing a lipid and protein component-containing composition comprising large lipid globules, preferably coated with polar lipids, and to the compositions obtained thereby. Optionally, the lipid and protein component-containing composition is spray-dried. The obtained compositions are for feeding infants and young children.