Stable Microcapsule Powder via Twice-Embedded Emulsion
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Solution Overview
Problem
Existing methods for preparing microcapsules of fat-soluble nutrients with multiple double bonds face challenges in achieving stability due to high pressure and temperature, leading to degradation and unpleasant odors, with complex processes and low efficiency.
Innovation Solution
A method involving dissolving a part of the capsule shell material in water to create an aqueous phase, mixing and emulsifying with the oil phase, followed by low-pressure homogenization, and then adding the remaining capsule shell material to form a twice-embedded emulsion, which is then spray granulated to produce stable microcapsule powders or microparticles without objectionable odors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high pressure homogenization is used to reduce droplet size, then manufacturing precision is improved, but stability deteriorates due to nutrient degradation
Solution Approach 1:
The patent applies preliminary action by adding the first capsule shell material to the oil phase before homogenization to form a pre-coated emulsion. This preliminary coating protects the nutrient from degradation during subsequent high-pressure homogenization, allowing achievement of small droplet sizes without compromising nutrient stability.
Solution Approach 2:
The patent segments the capsule shell material into two distinct addition stages: first adding part of the capsule shell material before homogenization, then adding the remaining portion after homogenization. This segmentation allows the emulsion to achieve both small droplet size (through high-pressure homogenization) and high stability (through protective coating at both stages).
2Length of moving object
If high pressure and temperature are applied during homogenization, then droplet size is reduced, but harmful factors increase due to nutrient degradation and odor formation
Solution Approach 1:
The patent applies beforehand cushioning by forming a protective layer of capsule shell material around the oil phase droplets before they undergo high-pressure homogenization. This preliminary coating acts as a cushion that protects the sensitive polyunsaturated nutrients from thermal and mechanical stress during homogenization, preventing degradation and odor formation while still achieving small droplet sizes.
3Device complexity
If single-stage encapsulation is used, then device complexity is reduced, but stability deteriorates
Solution Approach 1:
The patent segments the encapsulation process into two distinct stages: first encapsulation before homogenization and second encapsulation after homogenization. This segmentation creates a double-protected microcapsule structure that achieves superior stability compared to single-stage encapsulation, while the process remains integrated and does not require separate equipment.
Solution Approach 2:
The patent applies nested doll principle by creating a double-layer protective structure where the first capsule shell material forms an inner protective layer around the nutrient, and the second capsule shell material forms an outer protective layer. This nested structure provides enhanced protection against degradation while maintaining a unified microcapsule product.
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 results in highly stable microcapsule products with retention rates exceeding 90% after 3 months, maintaining bioavailability and stability even after tabletting, and preventing degradation, thus overcoming the limitations of previous methods.
Implementation Method 1
dissolving a part of a capsule shell material into water to obtain an aqueous phase
Implementation Method 2
mixing with an oil phase and shearing and emulsifying to form an emulsion
Implementation Method 3
homogenizing the emulsion at low pressure
Implementation Method 4
spray granulated to produce stable microcapsule powders or microparticles
Data Source
AI summary
The present invention provides a method of preparing highly stable microcapsule powders or microparticles containing a fat-soluble nutrient having multiple double bonds, comprising a) dissolving the fat-soluble nutrient having multiple unsaturated double bonds to prepare an oil phase; b) dissolving a part of a capsule shell material into water to prepare an aqueous phase; c) shearing the aqueous phase and the oil phase, and mixing and emulsifying the same to obtain an emulsion; d) homogenizing the emulsion by a standard high-pressure homogenizer, to make the emulsion obtain droplets in the emulsion with an average particle diameter at a nanometer level, thereby producing a nanometer scale emulsion; e) directly adding a remaining part of the capsule shell material into the homogenized nanometer scale emulsion, and shearing, mixing, and dissolving the same to obtain a twice-embedded emulsion; and f) performing spray granulation on the twice-embedded emulsion, and drying resultant granules to obtain the highly stable microcapsule powder or microparticles. The microcapsule powders or microparticles obtained by the method of the present invention are quite stable without objectionable odor.