Atomizer – new technology for production of micro- and nanoparticles

Challenge

Spray drying is a widely used method of producing a dry powder of a substance or mixture from a liquid by rapidly drying. The technology is used for manufacturing of sensitive materials such as foods and pharmaceuticals. However, state of the art technology suffers from many problems including an increase in temperature or other unfavorable physical conditions which prevent the technology to be used for drying of sensitive materials such as enzymes, vaccines, bacterial cultures, amino acids, vitamins or other food and pharmaceutical products, which need more gentle manufacturing. The new type of equipment developed by our researchers provides a much gentler approach, which enable us to produce high quality material and is not harmful to the material. The spray nebulization drying technology (CASND) allows materials to be produced in its native state with a maximum conservation of its biological activities or other original material properties.

Technology

The presented technology combines a micro/nanoparticle production by centrifugal micro/nanomaterial technology with technologies using supercritical CO₂. The spray nebulization drying technology (CASND) allows materials to be produced in its native state with a maximum conservation of its original biological activities or other primarily material properties.The technology is beneficial for:

• Drying of components or materials in the food, pharmaceutical or cosmetic industry, e.g. different types of extracts of plant proteins for the food industry
• Drying and encapsulation of microorganisms
• Production of special composite of nanomaterials, such as sustained release carriers and targeted delivery of biologically active substances (nutraceuticals, nutritional supplements, or drugs)

Other features and benefits of CASND include:

• Smaller particle sizes than e.g. spray drying (higher and faster solubility or dispersibility)
• Potentially new characteristics of micronized materials (e.g. micronized proteins have improved functional properties such as foaming and emulsifying activity)
• Drying takes place continuously and with less energy consumption compared to freeze drying and conventional spray drying
• The technology is modular, applicable to different types of industries
• Low drying temperatures (25 - 65°C) allow for gentle and cost-effective processing of thermolabile materials

Commercial Opportunity

The technology is available for co-development of specific applications and collaborative R&D projects including development of new products with Atomizer utilization. The technology is available for out-licensing, or co-investment into the prototype finalization and marketing.

Development Status

A prototype of the equipment is under technical optimization. The potential of a novel spray drying technology was demonstrated and tested by using various materials and matrices. Phys-chemical and biological properties of various processed materials (in scale up to several Kg) have been tested and verified.

Patent Situation

Patent pending in US, and a utility model has been approved in Czech Republic. Further patenting is expected for final technical solution.

Further Reading

n/a