Method for preparing an encapsulate composition for use in an edible composition
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Solution Overview
Problem
Conventional methods for preparing heat-sensitive active ingredients in comestibles require energy-intensive melting and mixing, which can degrade these ingredients.
Innovation Solution
A method using a twin screw extruder to mix and encapsulate active ingredients with encapsulating materials before melting, controlling specific mechanical energy input to form a homogenous encapsulate composition efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional melting and mixing methods are used to prepare active ingredients, then the encapsulation process can be completed, but the heat-sensitive active ingredients are degraded due to excessive heat and energy input
Solution Approach 1:
The encapsulating ingredient is ground into a fine powder before mixing with the active ingredient. This preliminary size reduction creates a larger surface area and more uniform distribution, enabling effective encapsulation at lower temperatures and reducing the need for excessive heat input during processing.
Solution Approach 2:
The invention changes the particle size parameter of the encapsulating ingredient from large pellets to fine powder. This parameter change fundamentally alters the mixing and encapsulation dynamics, allowing the process to proceed with reduced thermal energy input that protects heat-sensitive active ingredients from degradation.
2Device complexity
If large pellets of encapsulating ingredient are used, then the manufacturing process is simpler, but the mixing and encapsulation efficiency is reduced requiring more energy and heat
Solution Approach 1:
The encapsulating ingredient undergoes preliminary grinding to reduce particle size before the mixing stage. This pre-processing step, while adding a process stage, eliminates the need for excessive energy input during mixing and melting, ultimately reducing total energy consumption and improving encapsulation efficiency.
Solution Approach 2:
Changing the particle size of the encapsulating ingredient from large to fine powder fundamentally improves the energy efficiency of the mixing process. The fine powder form requires significantly less mechanical energy and thermal energy to achieve uniform distribution and encapsulation, resolving the energy consumption issue.
3Productivity
If the encapsulating ingredient is not ground to a fine powder, then the manufacturing process is faster, but the encapsulation efficacy is reduced leading to poor release profile control
Solution Approach 1:
The encapsulating ingredient is ground into a fine powder as a preliminary step before mixing with the active ingredient. This pre-grinding action ensures that when mixing occurs, the fine particles can rapidly and uniformly distribute around the active ingredient, achieving effective encapsulation quickly without compromising precision.
Solution Approach 2:
The particle size parameter of the encapsulating ingredient is changed to fine powder, which dramatically improves encapsulation efficacy. The fine particles provide better surface area contact and more uniform distribution, enabling precise control over the release profile of the active ingredient while maintaining manufacturing efficiency.
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 protects heat-sensitive ingredients and improves encapsulation efficacy, resulting in a controlled release profile with reduced initial dissolution, enhancing the stability and effectiveness of the active ingredients in comestibles.
Implementation Method 1
controlling specific mechanical energy input to form a homogenous encapsulate composition efficiently
Implementation Method 2
an encapsulating ingredient, provided to an extruder as large pellets, is melted before being mixed with one or more active ingredients
Implementation Method 3
A method using a twin screw extruder to mix and encapsulate active ingredients with encapsulating materials
Data Source
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AI summary
A method for preparing at least a first component of a comestible composition includes providing particles of an encapsulating ingredient having an average longest dimension of less than 1000 microns to a mixer. Particles of an active ingredient having an average longest dimension of less than 1000 microns are also provided to said mixer. A composition of said encapsulating ingredient and said active ingredient is formed.