Zilpaterol Premix via Supersaturated Solution
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Solution Overview
Problem
Current manufacturing processes for zilpaterol animal feed premixes are costly, time-consuming, and fail to achieve uniform distribution of zilpaterol at concentrations below 4 ppm due to particle size requirements and issues with dust generation and moisture content, leading to poor physical properties and safety concerns.
Innovation Solution
A supersaturated solution of zilpaterol is created by dissolving it in propylene glycol and combining it with a solid carrier, eliminating the need for specific particle size control and reducing solvent use, which simplifies the manufacturing process and improves uniformity and safety by minimizing dust and excess moisture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing processes are used to produce zilpaterol premixes, then the process follows standard procedures, but the distribution of zilpaterol is non-uniform at concentrations below 4 ppm and particle size control is required
Solution Approach 1:
The patent changes the physical state of zilpaterol from solid particles to a liquid state by dissolving it in propylene glycol. This parameter change eliminates the need for particle size control while enabling uniform distribution at concentrations as low as 4 ppm, directly resolving the technical contradiction between manufacturing precision and device complexity
Solution Approach 2:
The patent introduces propylene glycol as an intermediary substance to dissolve zilpaterol. This mediator allows the active ingredient to be uniformly distributed throughout the feed premix without requiring particle size control, solving the contradiction between achieving uniform distribution and avoiding complex particle size management
2Loss of time
If conventional drying steps are used in the manufacturing process, then moisture content is controlled, but the process becomes time-consuming and costly
Solution Approach 1:
The patent extracts and eliminates the drying step from the conventional manufacturing process. By using propylene glycol as a solvent that does not require removal, the process removes the time-consuming and costly drying operation while maintaining ease of manufacture, directly addressing the contradiction between manufacturing cycle time and process simplicity
Solution Approach 2:
The patent employs propylene glycol as a disposable solvent that remains in the final product. This approach eliminates the need for energy-intensive drying steps, reducing both manufacturing time and costs while maintaining process simplicity, thereby resolving the contradiction between loss of time and ease of manufacture
3Object-affected harmful factors
If solid zilpaterol is used in the premix, then the active ingredient can be incorporated into feed, but dust is generated creating safety concerns
Solution Approach 1:
The patent changes zilpaterol from a solid powder form to a liquid solution in propylene glycol. This parameter change eliminates dust generation entirely while maintaining the ability to incorporate the required quantity of active ingredient (0.5-2.0% zilpaterol or salt) into the feed premix, directly resolving the contradiction between harmful factors and quantity of substance
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 achieves uniform distribution of zilpaterol at concentrations as low as 4 ppm with improved physical properties, reduced costs, and enhanced safety by eliminating the need for drying steps and controlling particle size, resulting in a stable and effective animal feed premix.
Implementation Method 1
A supersaturated solution of zilpaterol is created by dissolving it in propylene glycol
Implementation Method 2
combining it with a solid carrier
Data Source
AI summary
A new solid dosage form formulation and manufacturing process incorporating zilpaterol HCl is presented. This formulation is an animal feed premix with improved content uniformity and is manufactured by a simple method that uses a supersaturated solution of zilpaterol that is incorporated into a solid carrier matrix.