Xanthophyll Crystal Preparation via Anhydrous Transesterification
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Solution Overview
Problem
Current methods for isolating and purifying xanthophylls like lutein and zeaxanthin require the use of water, high temperatures, and excessive solvents, which are costly and can degrade the material, making them unsuitable for industrial scale-up.
Innovation Solution
A transesterification process that eliminates the use of water and minimizes the use of organic solvents, achieving high yields of xanthophylls by combining a xanthophyll ester-containing plant oleoresin with an alkali alcoholate and alcohol, with optional aprotic solvents, to form a homogeneous liquid and then isolating the xanthophyll solids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to isolate and purify xanthophylls, then purification can be achieved, but water and high temperatures cause degradation and isomerization of the material
Solution Approach 1:
The patent changes the chemical parameters of the reaction medium by using organic solvents (hexane, ethyl acetate, ethanol) instead of water, and controls temperature parameters to conduct reactions at moderate temperatures (reflux conditions of the solvent) rather than high temperatures, thereby preventing degradation and isomerization while achieving purification
Solution Approach 2:
The patent introduces organic solvents as intermediary substances to facilitate the transesterification reaction and purification process. These solvents act as mediators that enable the reaction to proceed without water, preventing hydrolysis and degradation of the xanthophyll esters
2Quantity of substance
If conventional saponification methods are used, then xanthophylls can be obtained, but excessive use of solvents increases cost and environmental impact
Solution Approach 1:
The patent implements solvent recovery by distilling and reusing the organic solvents (hexane, ethyl acetate, ethanol) after the reaction and filtration steps. This reduces solvent consumption and waste, lowering costs and environmental impact while maintaining high xanthophyll yields
Solution Approach 2:
The patent uses a multi-step extraction process with different solvents (hexane for initial extraction, ethyl acetate for transesterification, ethanol for washing) that can be sequentially applied and recovered, creating an efficient solvent management system that minimizes loss
3Productivity
If high temperatures are applied to speed up the reaction, then reaction rate increases, but isomerization and saponification occur
Solution Approach 1:
The patent changes the temperature parameter to match the reflux temperature of the chosen solvent (e.g., ethanol reflux at ~78°C, ethyl acetate at ~77°C) rather than using high temperatures, which is sufficient to achieve acceptable reaction rates while preventing isomerization and saponification of the xanthophyll esters
4Manufacturing precision
If water is used in the process, then saponification can occur, but it leads to formation of unwanted byproducts and reduces purity
Solution Approach 1:
The patent extracts and eliminates water from the reaction system by using anhydrous organic solvents (hexane, ethyl acetate, ethanol) and conducting the reaction under conditions that prevent water introduction. This removes the source of saponification and eliminates unwanted byproduct formation, achieving high product purity
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 process achieves high yields (at least 85%) of pure xanthophylls, enriched with trans-lutein, while avoiding isomerization and saponification, resulting in a cost-effective and environmentally friendly method for producing xanthophyll crystals suitable for food and nutraceutical applications.
Implementation Method 1
combining a xanthophyll ester containing plant oleoresin with an alkali alcoholate, optionally with an aprotic organic solvent, to form a mixture; adding a sufficient quantity of alcohol to the mixture until xanthophyll ester(s) cannot be detected
Implementation Method 2
adding a sufficient quantity of alcohol to the mixture until xanthophyll ester(s) cannot be detected and xanthophyll solids are formed; cooling the reaction products of step c), thereby providing a xanthophyll solid
Data Source
AI summary
The invention describes the preparation and isolation of xanthophylls from plant sources, whereby a transesterification process is utilized without the necessity of an aqueous format.