Vacuum Effervescent Granule Production Control
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Solution Overview
Problem
Existing methods for producing effervescent granules lack standardized, reproducible process control, leading to uncontrollable reactions and inefficient production due to variations in raw material qualities and batch-specific differences, making automation challenging.
Innovation Solution
The method involves reacting reactive constituents in a vacuum within a specified pressure range (200-900 mbar) with controlled evacuation cycles, allowing for precise control of the reaction by adjusting vacuum values and cycle parameters, enabling automated, batch-to-batch consistency without intermediate drying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the reaction is carried out at atmospheric pressure with stepwise addition of liquid, then the reaction can be better controlled, but the production time is much too slow for efficient production
Solution Approach 1:
The patent applies parameter changes by conducting the reaction in a vacuum environment (reduced pressure) rather than at atmospheric pressure. This parameter change accelerates the reaction rate and allows for more efficient production while maintaining control through the vacuum conditions, directly resolving the contradiction between reaction control and production time.
2Duration of action of moving object
If the reaction takes place under atmospheric pressure for 25-40 minutes, then the reaction can proceed, but it is uncontrollable and too slow for efficient production
Solution Approach 1:
The patent changes the pressure parameter from atmospheric to vacuum conditions, which fundamentally alters the reaction kinetics and controllability. The vacuum environment enables the reaction to proceed under controlled conditions with appropriate duration, resolving both the time and controllability issues simultaneously.
Solution Approach 2:
The patent employs periodic action through cyclic evacuation and pressure equalization during the reaction process. This periodic modulation of pressure conditions allows for controlled reaction progression, preventing uncontrolled reactions while maintaining efficient production rates.
3Reliability
If intermediate drying and repeated addition of liquid is used to control the reaction, then the reaction can be managed, but the production time is lengthened in an undesired manner
Solution Approach 1:
The patent achieves continuous reaction progression under vacuum conditions without requiring intermediate drying steps. The vacuum environment maintains appropriate moisture levels and reaction conditions continuously, eliminating time-consuming intermediate steps while preserving reaction control.
4Loss of substance
If the vacuum is as low as possible (10-20 mbar) during vacuum treatment, then the solvent can be removed, but the reaction can easily lead to overreaction and undesired considerable granulation
Solution Approach 1:
The patent applies dynamics by using a modifiable vacuum level rather than a fixed extreme vacuum. The vacuum pressure is dynamically adjusted to appropriate levels that balance solvent removal with prevention of overreaction, allowing flexible control of the reaction process.
Solution Approach 2:
The patent employs periodic evacuation cycles with specific vacuum levels rather than continuous extreme vacuum. This periodic action with controlled vacuum intensity prevents overreaction and unwanted granulation while still achieving adequate solvent removal through repeated cycles.
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
This approach allows for controlled and reproducible reactions, preventing overreaction and agglomeration, significantly reducing production time and enabling fully automated, computer-controlled production of effervescent granules with improved stability and consistency.
Implementation Method 1
the reactants are reacted in a vacuum in an evacuatable container with evolution of gas
Implementation Method 2
the pressure in the container due to the gasses forming during the reaction is then allowed to increase with a specified pressure difference up to a second vacuum value
Implementation Method 3
Effervescent granules and effervescent tablets can be prepared by mixing of alkaline constituents eliminating carbon dioxide, in particular bicarbonates or carbonates, with preferably edible, organic acids
Implementation Method 4
reacted in a vacuum in an evacuatable container with evolution of gas
Data Source
AI summary
The invention relates to a method for producing effervescent granules, in which the reaction partners edible, organic acid components and alkaline effervescent components separating carbon dioxide are reacted with each other in a vacuum under the effect of gas in a container that can be evacuated. The container is evacuated to a first vacuum value within a vacuum range of 200-900 mbar, whereupon the pressure inside the container is increased to a second vacuum value as a result of the gases produced during the reaction. The steps are cyclically repeated while the reaction continues. A maximum number of cycles, a maximum reaction time, and optionally, a maximum load for the stirring apparatus are defined before the reaction begins, and the reaction is terminated after reaching the first of the maximums. In an alternative embodiment, the invention also relates to a method for improving the shelf life of effervescent granules by a treatment with carbon dioxide during and/or following the production of the effervescent granules, and effervescent particles treated in this manner.