CN101549273A - 纳米分散的高全反式类胡萝卜素微胶囊的制备方法 - Google Patents
纳米分散的高全反式类胡萝卜素微胶囊的制备方法 Download PDFInfo
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Abstract
本发明公开了一种纳米分散的高全反式类胡萝卜素微胶囊的制备方法。将高全反式类胡萝卜素结晶与二氯甲烷一起研磨至结晶粒径2~5μm,制成10~20%类胡萝卜素悬浮液,将该悬浮液与另一路经预热的二氯甲烷一起打入溶解釜溶解后成为0.5~2%的溶液;将上述溶液与乙醇或异丙醇同时连续送至超重力旋转填充床析晶装置中,然后进刮膜式蒸发器脱溶至固含率10~20%,得到透明的类胡萝卜素醇分散液;将该醇分散液与含有抗氧化剂、保护胶体的水溶液一起打浆,再喷雾干燥,得到纳米分散的高全反式类胡萝卜素微胶囊。由于本发明所得类胡萝卜素微胶囊中其晶体是纳米级分散的,且反式异构体含量可达90%以上,因而生物利用度高。
Description
技术领域
本发明涉及类胡萝卜素微胶囊的制备,具体地说是一种纳米分散的高全反式类胡萝卜素微胶囊的制备方法。
背景技术
类胡萝卜素广泛存在于自然界中,其最重要的代表是β-胡萝卜素、虾青素、斑蝥黄、番茄红素。对于食品、化妆品、饲料、制药工业来说,这些物质是重要的着色剂。此外,它们中的一些还是维生素A的前体。类胡萝卜素不溶于水,在油中溶解度也很小,且大多数类胡萝卜素对热、氧敏感,因此直接用粗粒状的晶体很难被动物吸收。无论是在食品还是在其他领域中使用,一般均需将类胡萝卜素以细颗粒形式存在,并需用保护性胶体进行保护,以抵抗氧化。而对于以着色为目的用途来说,希望类胡萝卜素经制剂化后能提高生物利用率,以提高着色效果,降低用量,减少使用过程中的损失。
在使用过程中,经常需将类胡萝卜素制成水可分散的制剂。为此目的,已有一些文献报导了这类制剂的制备方法。
WO91/06292和WO94/19411介绍了使用胶体磨将β-胡萝卜素研磨成2~10μm的微粒,然后经干燥制成水分散的类胡萝卜素粉。但研磨法效率低、能耗大,且类胡萝卜素粒径很难达到1μm以下。
US3998753记载了一种水可分散的类胡萝卜素制备方法,其中类胡萝卜素的粒度小于1μm,该方法是先将类胡萝卜素与其他添加剂配成有机溶剂的溶液,然后加入到含明胶、分散剂、稳定剂的水溶液中,经高速剪切使体系形成乳液;除去有机溶剂,喷雾干燥得到所需粉末。
EP-0065193(或US4522743)所记载的制备水分散的类胡萝卜素粉的方法,是将类胡萝卜素于50~200℃于10秒内溶解在挥发性水可混溶的溶剂中,然后于0~50℃下与含保护胶体的水溶液快速混合,类胡萝卜素即以<0.5μm的尺寸分散于保护胶体中,脱除溶剂,干燥可得类胡萝卜素粉。该工艺需要在高压(压力在3.0~6.0MPa)、高温(170~200℃)进行,对设备要求高,操作、控制难度大。
以上溶剂法或高温溶剂法均需在保护胶体中脱除体系中所含的大量溶剂,所需时间长,不易脱除干净,且在保护胶体存在下加热脱溶,体系极易起泡,脱溶时的效率很低,不易控制所需类胡萝卜素粉的粒径和反式异构体含量。
基于上述专利中存在的各种问题,我们于2005年申请了一种水分散性类胡萝卜素粉的制备方法(专利公开号CN1836652A),该法是将类胡萝卜素粗结晶溶于含有抗氧化剂、乳化剂的卤代烃或酯类溶剂中,所得的溶液以喷雾形式加入到高速搅拌的乙醇或异丙醇中,使类胡萝卜素以<2μm的无定形粉末形态析出;然后用滤膜或烧结滤棒过滤析出的类胡萝卜素,滤饼以乙醇或异丙醇洗涤,滤干;再将滤饼加入含有保护胶体的水溶液中,先搅拌打浆,后经均质乳化,接着脱除残余溶剂,制成水分散液;最后将所述的分散液用喷雾法造粒,再经流态化干燥得到水分散性类胡萝卜素的制剂。该方法的优点是溶剂残留量少,脱除快,效率高,但所得类胡萝卜素粉中晶体粒径在0.7~0.9μm,全反式异构体含量小于85%。
为提高类胡萝卜素粉中全反式异构体的含量,我们又提出添加组合抗氧剂来改善上述双溶剂法所存在的问题(专利公开号CN101016259A),但类胡萝卜素粉中晶体粒径仍在0.7~0.9μm,生物利用度仍有待提高。
US2005/0037115记载了一种类胡萝卜素纳米分散液的制备方法,是以脂肪酸酯为溶剂溶解类胡萝卜素,然后加入到含分散剂的水相中,蒸发溶剂得到纳米级分散的类胡萝卜素分散液。由于类胡萝卜素在酯中溶解度很低,因而仅能制得含量小于0.5%的产品。
Henelyta S.Ribeitro等(Food Hydrocolloids 22(2008)12-17)以丙酮为溶剂,PLA、PLGA为聚合物,先将聚合物、β-胡萝卜素溶解在丙酮中,然后将该溶液加入到含明胶、Tween-20的水溶液中,用溶剂置换法制得纳米级β-胡萝卜素分散液。由于β-胡萝卜素在丙酮中溶解度很小,因此所得β-胡萝卜素分散液的含量很低。
Xiaoyun Pan等(Journal of Colloid and Interface Science 315(2007)456-463)以无水乙醇为溶剂,将β-胡萝卜素溶解或分散于无水乙醇中,然后加入到含接枝改性酪蛋白的水溶液中,用溶剂置换制法得纳米级β-胡萝卜素分散液。同样,由于β-胡萝卜素在乙醇中溶解度极低,因此所得β-胡萝卜素分散液的含量很低。
C.P.Tan,M.Nakajima(Food Chemistry 92(2005)661-671)报导了一种方法,他们先将β-胡萝卜素溶于正己烷中,然后加入到含Tween 20的水中,先预乳化、再均质后在流化床中脱溶,得到β-胡萝卜素的纳米分散体。
以上报导的纳米化方法均采用对β-胡萝卜素溶解度很低的溶剂,因而难以得到具有工业化价值的纳米分散的β-胡萝卜素微胶囊。
发明内容
本发明的目的是克服上述现有技术存在的缺陷,提供一种既能保持高全反式异构体含量,又能使晶体达到纳米级分散的纳米分散的高全反式类胡萝卜素微胶囊的制备方法。
纳米分散的高全反式类胡萝卜素微胶囊的制备方法包括以下步骤:
1)将全反式含量大于98%的类胡萝卜素结晶与溶剂二氯甲烷一起研磨至结晶粒径2~5μm,制成10~20%的类胡萝卜素悬浮液;
2)将类胡萝卜素悬浮液连续送至溶解釜中,同时二氯甲烷经换热器加热至45~50℃,送至溶解釜中,溶解釜内保持压力0.2~0.3MPa,温度35~40℃,物料停留时间4~12分钟,使类胡萝卜素晶体完全溶解,得到类胡萝卜素含量为0.5~2.0%的二氯甲烷溶液;
3)将类胡萝卜素含量为0.5~2.0%的二氯甲烷溶液连续送入带有液体分布器的超重力旋转填充床析晶装置中,同时将5~10倍二氯甲烷溶液重量的乙醇或异丙醇送入超重力旋转填充床析晶装置中,使类胡萝卜素以纳米级晶体形式析出,得到透明的类胡萝卜素分散液;
4)将透明的类胡萝卜素分散液在刮膜式蒸发器中连续减压脱溶,得到类胡萝卜素含量为10~20%的纳米分散的类胡萝卜素醇分散液;
5)将纳米分散的类胡萝卜素醇分散液与含有抗氧化剂、保护胶体的水溶液一起送入另一超重力旋转填充床中打浆,然后喷雾干燥,得到纳米分散的高全反式类胡萝卜素微胶囊。
所述类胡萝卜素是指虾青素、斑蝥黄、β-胡萝卜素或番茄红素。溶解釜为高径比3~4,共分为3~4段,且段内均有搅拌的多层搅拌釜,物料从釜下部进入,釜上部流出。超重力旋转填充床内有金属丝网填料、液体分布器,其转速为1000~3000转/分钟。抗氧化剂为维生素C、维生素C钠盐、异维生素C或异维生素C钠盐。保护胶体为明胶、鱼明胶或改性淀粉。
本发明的核心是将类胡萝卜素结晶研磨后使其快速溶解于溶剂中,然后在超重力旋转填充床析晶器中通过超重力作用形成纳米级类胡萝卜素的分散液,经刮膜快速脱溶,再经超重力旋转填充床打浆后立即喷雾干燥,得到纳米分散的类胡萝卜素微胶囊。这样类胡萝卜素在制剂化过程中受热的时间很短,从而能保持很高的全反式异构体含量。
本发明最终得到的纳米分散的高全反式类胡萝卜素微胶囊中类胡萝卜素晶体的D95<300nm,全反式异构体含量大于90%。
本发明的有益效果是:无需高压设备,操作、控制相对简单,可连续化生产,产品中溶剂残留少,生物利用度高。
具体实施方式
以下结合实施例对本发明予以详细说明。
实施例1
将10kg虾青素结晶(全反式含量98.6%)与40kg二氯甲烷在砂磨机中研磨,得到粒径5μm的20%虾青素悬浮液。将1kg异维生素C、85kg明胶溶于200kg水中,冷却至40℃备用。
将上述20%虾青素悬浮液以5kg/小时的流量用浆料泵送入5L容积、具有3层搅拌的高径比为3的三段溶解釜的底部;同时,以95kg/小时的流量将二氯甲烷经盘管预热器预热至50℃后也送入溶解釜的底部,控制溶解釜内温度在40℃,压力0.3MPa,停留时间约4分钟后取样分析已完全溶解,成为浓度为1%的虾青素二氯甲烷溶液。将该溶液通入带液体分布器、金属丝网填料的超重力旋转填充床析晶器中,同时以500kg/小时的流量将乙醇送入上述超重力旋转填充床析晶器中,控制转速为1500转/分钟,从超重力旋转填充床析晶器出口得到流量为600kg/小时的纳米分散的虾青素分散液。将该分散液在降膜蒸发器中减压脱除大部分溶剂,得到流量为10kg/小时的虾青素乙醇分散液(固含量约10%)。将上述虾青素乙醇分散液用泵以10kg/小时送入另一台超重力旋转填充床打浆器中,同时将已配好的明胶水溶液以28kg/小时流量送入上述超重力旋转填充床打浆器中,得到流量约38kg/小时的打浆液。将上述打浆液送入喷雾干燥器干燥,得到约9.5kg/小时的虾青素微胶囊,10小时共得虾青素微胶囊95kg。经检测,微胶囊中虾青素含量为10.3%,全反式异构体含量为91.7%,粒径分析表明产品中虾青素晶体的D95为220nm。
实施例2
将10kg斑蝥黄结晶(全反式含量98.8%)与90kg二氯甲烷在砂磨机中研磨,得到粒径2μm的10%斑蝥黄悬浮液。将1kg异维生素C钠盐、85kg鱼明胶溶于200kg水中,冷却至40℃备用。
将上述10%斑蝥黄悬浮液以10kg/小时的流量用浆料泵送入4L容积、具有4层搅拌的高径比为4的四段溶解釜的底部;同时,以40kg/小时的流量将二氯甲烷经盘管预热器预热至45℃后也送入溶解釜的底部,控制溶解釜内温度在35℃,压力0.2MPa,停留时间约12分钟后取样分析已完全溶解,成为浓度为2%的斑蝥黄二氯甲烷溶液。将该溶液通入带液体分布器、金属丝网填料的超重力旋转填充床析晶器中,同时以500kg/小时的流量将乙醇送入上述超重力旋转床析晶器中,控制转速为1000转/分钟,从超重力旋转填充床析晶器出口得到流量为550kg/小时的纳米分散的斑蝥黄分散液。将该分散液在降膜蒸发器中减压脱除大部分溶剂,得到流量为5kg/小时的斑蝥黄乙醇分散液(固含量约20%)。将上述斑蝥黄乙醇分散液用泵以5kg/小时送入另一台超重力旋转填充床打浆器中,同时将已配好的明胶水溶液以28kg/小时流量送入上述超重力旋转床打浆器中,得到流量约33kg/小时的打浆液。将上述打浆液送入喷雾干燥器干燥,得到约9.6kg/小时的斑蝥黄微胶囊,10小时共得斑蝥黄微胶囊96kg。经检测,微胶囊斑蝥黄含量为10.2%,全反式异构体含量为92.8%,粒径分析表明产品中斑蝥黄晶体的D95为230nm。
实施例3
将10kgβ-胡萝卜素结晶(全反式含量98.4%)与70kg二氯甲烷在砂磨机中研磨,得到粒径3μm的12.5%β-胡萝卜素悬浮液。将0.5kg维生素C、0.5kg维生素C钠盐、85kg改性淀粉溶于200kg水中,冷却至40℃备用。
将上述12.5%β-胡萝卜素悬浮液以8kg/小时的流量用浆料泵送入4L容积、具有4层搅拌的高径比为4的四段溶解釜的底部;同时,以192kg/小时的流量将二氯甲烷经盘管预热器预热至47℃后也送入溶解釜的底部,控制溶解釜内温度在38℃,压力0.25MPa,停留时间约5.4分钟后取样分析已完全溶解,成为浓度为0.5%的β-胡萝卜素二氯甲烷溶液。将该溶液通入带液体分布器、金属丝网填料的超重力旋转填充床析晶器中,同时以1000kg/小时的流量将异丙醇送入上述超重力旋转填充床析晶器中,控制转速为3000转/分钟,从超重力旋转填充床析晶器出口得到流量为1200kg/小时的纳米分散的β-胡萝卜素分散液。将该分散液在降膜蒸发器中减压脱除大部分溶剂,得到流量为7kg/小时的β-胡萝卜素异丙醇分散液(固含量约14.3%)。将上述β-胡萝卜素异丙醇分散液用泵以7kg/小时送入另一台超重力旋转填充床打浆器中,同时将已配好的明胶水溶液以28kg/小时流量送入上述超重力旋转床打浆器中,得到流量约35kg/小时的打浆液。将上述打浆液送入喷雾干燥器干燥,得到约9.4kg/小时的β-胡萝卜素微胶囊,10小时共得β-胡萝卜素微胶囊94kg。经检测,微胶囊中β-胡萝卜素含量为10.4%,全反式异构体含量为93.2%,粒径分析表明产品中β-胡萝卜素晶体的D95为205nm。
实施例4
将10kg番茄红素结晶(全反式含量98.6%)与70kg二氯甲烷在砂磨机中研磨,得到粒径4μm的12.5%番茄红素悬浮液。将0.5kg维生素C、0.5kg维生素C钠盐、85kg改性淀粉溶于200kg水中,冷却至40℃备用。
将上述12.5%番茄红素悬浮液以8kg/小时的流量用浆料泵送入4L容积、具有4层搅拌的高径比为4的四段溶解釜的底部;同时,以192kg/小时的流量将二氯甲烷经盘管预热器预热至48℃后也送入溶解釜的底部,控制溶解釜内温度在37℃,压力0.28MPa,停留时间约5.4分钟后取样分析已完全溶解,成为浓度为0.5%的番茄红素二氯甲烷溶液。将该溶液通入带液体分布器、金属丝网填料的超重力旋转填充床析晶器中,同时以1000kg/小时的流量将异丙醇送入上述超重力旋转床析晶器中,控制旋转床转速为2000转/分钟,从超重力旋转填充床析晶器出口得到流量为1200kg/小时的纳米分散的番茄红素分散液。将该分散液在降膜蒸发器中减压脱除大部分溶剂,得到流量为7kg/小时的番茄红素异丙醇分散液(固含量约14.3%)。将上述番茄红素异丙醇分散液用泵以7kg/小时送入另一台超重力旋转填充床打浆器中,同时将已配好的明胶水溶液以28kg/小时流量送入上述超重力旋转床打浆器中,得到流量约35kg/小时的打浆液。将上述打浆液送入喷雾干燥器干燥,得到约9.4kg/小时的番茄红素微胶囊,10小时共得番茄红素微胶囊94kg。经检测,微胶囊中番茄红素含量为10.3%,全反式异构体含量为92.5%,粒径分析表明产品中番茄红素晶体的D95为210nm。
Claims (6)
1、一种纳米分散的高全反式类胡萝卜素微胶囊的制备方法,其特征在于包括以下步骤:
1)将全反式含量大于98%的类胡萝卜素结晶与溶剂二氯甲烷一起研磨至结晶粒径2~5μm,制成10~20%的类胡萝卜素悬浮液;
2)将类胡萝卜素悬浮液连续送至溶解釜中,同时二氯甲烷经换热器加热至45~50℃,送至溶解釜中,溶解釜内保持压力0.2~0.3MPa,温度35~40℃,物料停留时间4~12分钟,使类胡萝卜素晶体完全溶解,得到类胡萝卜素含量为0.5~2.0%的二氯甲烷溶液;
3)将类胡萝卜素含量为0.5~2.0%的二氯甲烷溶液连续送入带有液体分布器的超重力旋转填充床析晶装置中,同时将5~10倍二氯甲烷溶液重量的乙醇或异丙醇送入超重力旋转填充床析晶装置中,使类胡萝卜素以纳米级晶体形式析出,得到透明的类胡萝卜素分散液;
4)将透明的类胡萝卜素分散液在刮膜式蒸发器中连续减压脱溶,得到类胡萝卜素含量为10~20%的纳米分散的类胡萝卜素醇分散液;
5)将纳米分散的类胡萝卜素醇分散液与含有抗氧化剂、保护胶体的水溶液一起送入另一超重力旋转填充床中打浆,然后喷雾干燥,得到纳米分散的高全反式类胡萝卜素微胶囊。
2、根据权利要求1所述的纳米分散的高全反式类胡萝卜素微胶囊的制备方法,其特征在于所述类胡萝卜素是指虾青素、斑蝥黄、β-胡萝卜素或番茄红素。
3、根据权利要求1所述的纳米分散的高全反式类胡萝卜素微胶囊的制备方法,其特征在于所述溶解釜为高径比3~4,共分为3~4段,且段内均有搅拌的多层搅拌釜,物料从釜下部进入,釜上部流出。
4、根据权利要求1所述的纳米分散的高全反式类胡萝卜素微胶囊的制备方法,其特征在于所述超重力旋转填充床内有金属丝网填料、液体分布器,其转速为1000~3000转/分钟。
5、根据权利要求1所述的纳米分散的高全反式类胡萝卜素微胶囊的制备方法,其特征在于所述抗氧化剂为维生素C、维生素C钠盐、异维生素C或异维生素C钠盐。
6、根据权利要求1所述的纳米分散的高全反式类胡萝卜素微胶囊的制备方法,其特征在于所述保护胶体为明胶、鱼明胶或改性淀粉。
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