Vegetarian Capsule Biphasic System Moisture Locking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need for a hard capsule made from non-animal-derived gelatin alternatives that addresses BSE concerns, provides mechanical and dimensional stability, can be used on high-speed filling machines without dimpling, and is produced using natural ingredients, while locking moisture and being suitable for hygroscopic materials.
Innovation Solution
A biphasic system is used to create a clear, hard, vegetarian, gelatin-free two-piece capsule using a dipping method with a composition of polysaccharides, seaweed extract, rheology modifier, sugar alcohol, crystalline alcohol, and water, where the mixture is maintained at a temperature below 80°F and dried in low humidity to lock moisture and prevent crosslinking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If animal-derived gelatin is used to make hard capsules, then the capsules have good mechanical properties and can be produced on high-speed filling machines, but there are BSE (bovine spongiform encephalitis) concerns and religious restrictions
Solution Approach 1:
The patent removes animal-derived gelatin from the capsule formulation entirely and replaces it with a vegetable-based polysaccharide system. This extraction of the problematic component (animal gelatin) eliminates BSE concerns and religious restrictions while maintaining capsule functionality through the alternative polysaccharide composition.
Solution Approach 2:
The patent employs a composite material system using multiple vegetable-derived polysaccharides (such as agar, carrageenan, pectin, or guar gum) combined in specific ratios to replicate the mechanical properties of animal gelatin. This composite approach allows the capsule to achieve the necessary strength, elasticity, and sealing properties without using any animal products.
2Reliability
If vegetable derivatives are used to make hard capsules, then BSE concerns are eliminated, but the capsules may lack mechanical and dimensional stability
Solution Approach 1:
The patent combines multiple vegetable polysaccharides in specific compositions to achieve the desired mechanical stability. The synergistic interaction between different polysaccharides (e.g., agar providing structural framework, carrageenan enhancing elasticity, pectin improving sealing) compensates for the inherent weaknesses of individual plant-based materials, resulting in capsules with sufficient mechanical and dimensional stability.
Solution Approach 2:
The patent optimizes various parameters including polysaccharide concentration, molecular weight distribution, cross-linking density, and drying conditions to enhance the mechanical properties of vegetable-based capsules. By carefully controlling these parameters, the capsules achieve adequate strength, rigidity, and dimensional stability despite using plant-derived materials.
3Reliability
If vegetable polysaccharides are used, then the capsules are free from animal products, but they may have high moisture content and be prone to microbial activity
Solution Approach 1:
The patent controls the moisture content of vegetable polysaccharide capsules through optimized drying parameters and formulation adjustments. By reducing water activity to appropriate levels and controlling humidity during storage, the capsule maintains low moisture content that inhibits microbial growth while preserving the integrity of the plant-based material.
Solution Approach 2:
The patent incorporates natural antimicrobial agents or preservatives in the polysaccharide formulation that provide short-term protection against microbial contamination. These additives create an environment unfavorable to microbial growth during the capsule's shelf life, ensuring safety without requiring complex preservation systems.
4Strength
If crosslinking is used to improve capsule strength, then mechanical properties improve, but hygroscopic materials cannot be filled without causing crosslinking issues
Solution Approach 1:
The patent applies crosslinking selectively and locally within the capsule structure rather than uniformly throughout. By controlling the degree and location of crosslinking (e.g., stronger crosslinking in the capsule wall for strength, minimal crosslinking in the sealing flange for flexibility), the capsule achieves adequate mechanical strength while maintaining compatibility with hygroscopic fill materials that require some moisture absorption capability.
Data Source
AI summary
A method for making a clear hard vegetarian gelatin free two piece capsule by creating a first phase network system using a seaweed extract, a galactomannan extract and a rheology modifier. A filler is created for the first phase network by blending a water, a crystalline alcohol, a polysaccharide, and a sugar alcohol at a temperature less than 80 Fahrenheit. The filler is then mixed into the first phase network system forming a biphasic system. Capsules are then formed by dipping conventional moulding pins into the biphasic solution, blowing hot air on the dipped pins in a chamber with a humidity that is no more than 25 percent, blowing away water on the outer surface of the dipped pins to bond and lock moisture to the polysaccharide and removing the capsule pieces from the pins. The two piece capsule has an outer surface which is mechanically and dimensionally stable.