Surface-Reacted Calcium Carbonate Granules by Binder-Free Spray Drying
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Solution Overview
Problem
Conventional methods for producing surface-reacted calcium carbonate granules suffer from inferior bulk density, flow properties, and mechanical stability, particularly when binder-free, limiting their effectiveness in applications like pharmaceutical, nutraceutical, and cosmetic products.
Innovation Solution
A method involving the production of surface-reacted calcium carbonate granules through an aqueous suspension homogenization followed by spray drying, without the use of binders, to achieve high bulk density, flow properties, and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional granulation methods are used without binder, then the process is simpler and cost-effective, but the granules have inferior bulk density, flow properties, and mechanical stability
Solution Approach 1:
The invention changes the physical-chemical parameters of the granulation process by conducting it in an aqueous environment with controlled pH (using carbonates or bicarbonates) and specific moisture content (10-50%). This parameter optimization allows binder-free granulation to achieve both high mechanical stability (≥10 N) and good flow properties without compromising process simplicity.
Solution Approach 2:
The invention creates composite granule structures where calcium carbonate particles are bound together through carbonate-bicarbonate buffer systems and water-mediated bonding. The composite nature of the granules, combining multiple calcium carbonate particles with the aqueous buffer system, provides both mechanical stability and desired flow properties without requiring external binders.
2Strength
If wet granulation with binder is used, then mechanical stability is improved, but the process complexity and cost increase
Solution Approach 1:
The invention extracts and eliminates the binder component from the granulation process while maintaining mechanical stability through alternative mechanisms. By removing the binder and replacing it with an aqueous carbonate-bicarbonate system, the process becomes simpler and more cost-effective while achieving the same or better mechanical properties (≥10 N).
Solution Approach 2:
The calcium carbonate particles themselves serve their own binding function through the aqueous carbonate-bicarbonate buffer system. The particles undergo surface reactions and form interparticle bonds without requiring external binders, making the system self-sufficient and reducing process complexity.
3Quantity of substance
If granules are produced with high bulk density, then storage and transport efficiency is improved, but flow properties may deteriorate
Solution Approach 1:
The invention optimizes multiple parameters simultaneously: bulk density (0.3-0.7 g/mL), moisture content (10-50%), and particle size distribution. By carefully controlling these parameters within specific ranges, the granules achieve both high bulk density for storage efficiency and good flowability for processing, resolving the trade-off between these two properties.
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 produces granules with enhanced bulk density, flowability, and mechanical stability, suitable for various applications including nutraceutical, agricultural, cosmetic, and pharmaceutical products, without the need for binders.
Implementation Method 1
removing the liquid from the aqueous suspension comprising a surface-reacted calcium carbonate of step b) by means of spray drying
Data Source
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AI summary
The present invention refers to a method for the production of granules comprising surface-reacted calcium carbonate, granules comprising a surface-reacted calcium carbonate having a bulk density ranging from 0.25 to 0.70 g/mL, preferably from 0.28 to 0.65 g/mL, more preferably from 0.30 to 0.60 g/mL, and most preferably from 0.35 to 0.60 g/mL and the use of the granules n a nutraceuticalproduct, agricultural product, veterinary product, cosmetic product, preferably in a dry cosmetic and/or dry skin care composition, home product, food product, packaging product or personal care product, preferably in an oral care composition, or as excipient in a pharmaceutical product.