"Technology...From The Space Shuttle...To The World" (Tm)
Welcome to RMANNCO, INC.
Coplanar Annular Microencapsulating Process
(Patent Pending/Patent Allowed)
Dr. Joseph A. Resnick, Ph.D., MPH, Professor Emeritus, Inventor
Comparison of RMANNCO's Process To Conventional Encapsulation Methods
I Introduction
Encapsulating substances to enable unique delivery systems and to protect ‘one substance from contacting another substance’ has presented as problematic since time immemorial. Man has constantly sought means and methods to encapsulate substances for purposes of advanced or time-released (drug) delivery, conservation of energy, preservation (foods/flavors/probiotics) or due to lack of refrigeration.
Microencapsulation methods are separated into two categories: Chemical processes and physical processes. Examples of chemical microencapsulation are centrifugal force, complex coacervation, in situ polymerization, interfacial polymerization and polymer-polymer incompatibility.
Physical processes used in microencapsulation are spray-drying and spray-cooling, fluidized-bed coating, extrusion/centrifugal extrusion, liophylization, and co-crystallization. Modifications of these methods include coascervative spray, polymeric phased-separation, laser-pulsed-drop column, etc.
A. Typical microencapsulation processes with their relative particle size
ranges are presented below:
Microencapsulation process Particle sizes in μm
Processes
Extrusion 250–2500
Spray-drying 5–5000
Fluid bed coating 20–1500
Rotating disk 5–1500
Coacervation 2–1200
Solvent evaporation 0.5–1000
Phase separation 0.5–1000
In-situ polymerization 0.5–1100
Interfacial polymerization 0.5–1000
Mini-emulsion 0.1–0.5
Sol-gel encapsulation 2–20
Layer-by-layer (LBL) assembly 0.02–20
(Resnick) Coplanar Annular Encapsulation .01-10,000
B Discussion
The Coplanar Annular Microencapsulating Process invented and advanced by Dr. Joseph A. Resnick has its foundations in work initially undertaken in the early 1980’s and early 1990’s by NASA Scientists, Dr. Taylor G. Wang (NASA JPL), Dr. John Vanderhoff (Lehigh Univ.) and Dr. Dale M. Kornfeld (MSF, Huntsville, AL). Wang, et al, were tasked with developing a means of producing monodisperse polystyrene beads, leading to the ability to encapsulate foods and liquids for consumption in space by Astronauts during spaceflight missions.
Work enabled through a Research Grant resulted in the development of a bio-reactor system wherein a tubular housing contains an internal circularly disposed set of blade members and a central tubular filter all mounted for rotation about a common horizontal axis and each having independent rotational support and rotational drive mechanisms. The housing, blade members and filter preferably are driven at a constant slow speed for placing a fluid culture medium with discrete microbeads and cell cultures in a discrete spatial suspension in the housing. Replacement fluid medium is symmetrically input and fluid medium is symmetrically output from the housing where the input and the output are apart of a loop providing a constant or intermittent flow of fluid medium in a closed loop. See: http://ntrs.nasa.gov/archive/nasa/casi.ntrs.nasa.gov/19850012877_1985012877.pdf
By 1985 The Kornfeld Monodisperse Latex Reactor experiment had flown five times on the space shuttle, with a total of eight mission flights over an eight-year period (1985-1993). The objective of the project was to manufacture, in the microgravity environment of space, large particle-size monodisperse polystyrene latexes in particle sizes larger and more uniform than can be manufactured on Earth. Historically it has been extremely difficult, if not impossible, to manufacture in quantity very high quality monodisperse
latexes on Earth in particle sizes much above several micrometers in diameter due to buoyancy and sedimentation problems during the polymerization reaction. However, the MLR project succeeded in manufacturing, in microgravity, monodisperse latex particles as large as 30 micrometers in diameter with a standard deviation of 1.4 percent. Subsequent experiments on STS 43 resulted in production of particles with a standardized manufacture aspect ratio of 100 micrometers. These tiny, highly uniform microspheres have become the "FIRST SPACE PRODUCT," that is, the first material ever to be commercially marketed that was manufactured in space. The U.S. National Bureau of Standards has certified the first batch of "space latex," which was transferred to NBS by NASA in July 1984, and marketing was begun in mid-1985 as the U.S. National 10-micrometer Standard Reference Nater id. which remains the US National Standard to this day.
The process and instrumentation developed by Dr. Resnick moves the science and art of microencapsulating most substances to the ‘next-level’ based on 30+ years of research by NASA scientists.
Realizing the significance of what NASA researchers had accomplished (culminating in the production of microspheres in Space aboard STS 41 and STS 43) and the shortfalls of the requisite manufacture methods in gravity environments, Resnick determined that the reason that Wang, et al, were unable to produce microspheres (successfully) on earth was due to the Coriolis Effect which is diminished, considerably, in the microgravity conditions encountered in shallow earth orbit.
Further, Resnick determined that conventional methods of producing microspheres on earth (e.g., coascervative spray, phase-separation, pulsed-drop column, etc.) were reliant upon gravity and were severely impacted by the Coriolis Effect, a factor apparently overlooked by artisans and scientists alike. For information regarding the Coriolis Effect see: http://www.youtube.com/watch?v=mcPs_OdQOYU
Consequently, Dr. Resnick designed an instrument that enables dispersion of both an encapsulate and an encapsulant via a dual-dispersion apparatus which enables countermeasure or offset of the Coriolis Effect through emission of substances on coplanar/annular elliptical axes which exploits astrophysics phenomena (Gravity, Inertia, Motion, Torsion, and counter-rotation) to support the actual manufacturing process in a gravity environment. The result is the production of consistently-shaped, uniform manufactures (microcapsules) ranging in exact sizes from .25um to 500um which are perfectly round-shaped and not ovoid-shaped satellites. For additional information see US Patent Number 5,807,724 which is referenced in the US (and Foreign) patents issuing to Dr. Resnick concerning this new process/method. All other microencapsulation processes mentioned above, with the exception of Dr. Resnick's process, are subject to this phenomenon resulting in production of 'spheroids' or 'satellites' which require tedious, cost consuming sieving.
The Resnick Encapsulation process is a mature technology, with its first use being in the form of environmental cleanup products, WAPED, PRP, Bio-Boom, Bio-Sok, deployed as the first bioremediation product used to mitigate environmental impact at the crash of the Exxon Valdez in Prince William Sound Alaska, in March of 1989. In this scenario Resnick used the encapsulation process/device to encapsulate a live-cell culture media comprised of C. lipolytica (Str. 10) inside microcapsules made with 100% Natural Beeswax. See a demonstration of environmental (oil spill cleanup products) at: http://www.youtube.com/watch?v=vG_vCokrdt4&feature=related and see: http://www.prlog.org/11673684-pitt-alum-nominated-for-the-tyler-prize-in-environmental-achievement.html and see: http://www.techbriefs.com/component/content/article/17737
The Resnick encapsulation process is a patent-pending process, which patent application has been ‘allowed’ by the US Patent and Trademark Office (US Patent Application SN 929), is in the process of being issued and will soon be in the Public Domain. The Resnick process is unique and capable of being used to encapsulate a variety of aqueous and biological substances.
C Operability
The Resnick Coplanar Annular Encapsulation process utilizes a unique, patent-allowed instrument and process enabling production of uniformly-shaped microspheres which can be made of various substances (polymers, monomers, isomers, waxes, etc.) and used to produce manufactures ranging from .25 micrometers to 500 micrometers in size. There are <at least> two (2) (patentably-new) fundamental differences between Dr. Resnick’s process compared to all other microencapsulation processes with these based upon those two distinctly fundamental differences and instant capabilities. The first capability is enabled by the unique design of the instrument’s ’emission module’ comprising a single orifice (which can range in size from .25um to 500um) with a second internal component comprising a secondary hollow flow tube (needle) which enables delivery of the encapsulant (substance sought to be encapsulated) into a unique ‘formation field’, atypical in comparison to a conventional ‘drop column', upon which most other microencapsulation processes are dependent (phase-pulsed, vertical deposition/drop, sol-gel, etc.), eliminating several processes in microencapsulation, e.g., sieving (which is labor-intensive and production/product cost-prohibitive).
The second significant advancement enabled by the Resnick encapsulator is due to its ability to overcome problems encountered by all prior microencapsulation processes, i.e., to produce a nearly perfect ‘round’ sphere in the gravity conditions actually encountered on the face of the planet, Earth. Conventional encapsulation/microsphere production methods do not produce ‘perfect spheres’, as such. Rather, these old processes (listed above) produce manufactures called, ‘spheroids’. Spheroids appear to be spherical-shaped to the naked eye, but when examined under light microscope and confirmed via SEM (scanning electron microscope), the manufactures are actually ‘oval-shaped‘. This is a direct result of influences encountered in the gravity environment during microencapsulation production on Earth caused by the astrophysical phenomena known as the Coriolis Effect which Dr. Resnick's process now overcomes.
Dr. Resnick’s invention compensates for this phenomenon during the manufacturing process and thus microspheres of exact size and succinct uniformity can be produced. Elimination of drying and sieving processes is a cost effective advantage.
To see Dr. Resnick's presentation at NASA's ISDC Conference regarding this technology see: http://www.facebook.com/video/video.php?v=1406952086883 . Additional information may be viewed at: http://www.cnbc.com/id/37593652/17_Ways_To_Clean_Up_The_Gulf_Oil_Spill?slide=17
.
Below are some typical questions regarding the technology presented in an effort to conserve time and help in pointing to advantages of the Coplanar Encapsulating Process over the prior art.
Q.
Could you please start by explaining how this technology is different from others in terms of the beneficial properties, other than size, that have to be considered when choosing the ingredients to be encapsulated?
A. (Short Version)
The Coplanar/Annular Microencapsulating Process and Instrumentation invented and advanced by Dr. Joseph A. Resnick differs from conventional methods of producing microspheres, nanospheres, microcapsules and nanocapsules in the gravity environment found on earth (e.g., coacervative spray, phase-separation, pulsed-drop column, etc.). Conventional methods of encapsulating substances are complex, costly, labor-intensive (sieving, for example) and sometimes very (very) dangerous (as is the case in the fleuro-chemical phase separation process used to produce pharmaceuticals and cosmetics).
In terms of consideration of properties of the substances selected for encapsulation, fluidity, viscosity, temperature, van der Waals interaction with alcohols, furans, lactones, ketones, aldehydes, small organic acids, mercaptans, thiols, sulfides, pyrazines, terpenes, phenols, and esters have been considered and examined. These have all been successfully incorporated within the various bonding matrixes depending upon project initiatives, desired product goals or specified deliverables. Further, the release mechanism (for volatile/hydrophobic) species can be selectively controlled during the manufacturing process to control incidents (van der Waals reactions, for example) and interactions between entrapped volatile flavor compounds, fatty acid (esters) and paraffinic hydrocarbons below the melting point of beeswax, or other polyolefins for example. Through precise temperature/pressure control minimal impact to organoleptic properties are made negligible and strictly controlled as well.
A.(Long Version)
The Coplanar/Annular Microencapsulating Process and Instrumentation invented and advanced by Dr. Joseph A. Resnick differs from conventional methods of producing microspheres, nanospheres, microcapsules and nanocapsules in the gravity environment found on earth (e.g., coacervative spray, phase-separation, pulsed-drop column, etc.). Conventional methods of encapsulating substances are complex, costly, labor-intensive and sometimes dangerous (as is the case in the fluero-chemical phase separation process used to produce pharmaceuticals and cosmetics).
In terms of consideration of properties of the substances selected for encapsulation, fluidity, viscosity, temperature, van der Walls interaction with alcohols, furans, lactones, ketones, aldehydes, small organic acids, mercaptans, thiols, sulfides, pyrazines, terpenes, phenols, esters, and esthers have been considered and examined. These have all been successfully incorporated within the various bonding matrixes. Further, the release mechanism (for volatile/hydrophobic) species can be selectively controlled during the manufacturing process to control incidents (van der Waals reactions, for example) and interactions between entrapped volatile flavor compounds, fatty acids (esters) and paraffinic hydrocarbons below the melting point of beeswax, for example. Through precise temperature/pressure control minimal impact to organoleptic properties are note.
Resnick's encapsulation technology has its foundations in work initially undertaken in the early 1980’s and early 1990’s by NASA Scientists, Dr. Taylor G. Wang (NASA JPL), Dr. John Vanderhoff (Lehigh Univ.) and Dr. Dale M. Kornfeld (MSF, Huntsville, AL). Wang, et al, were tasked with developing a means of producing monodisperse polystyrene beads leading to the ability to encapsulate live cells for medical purposes, cosmetics, animal adjuvants, for use in foods and liquids for consumption in space by Astronauts during spaceflight missions, and for encapsulating substances for human and animal consumption. Work enabled through NASA-funded research grants resulted in the development of a bio-reactor system wherein a tubular housing contains an internal circularly disposed set of blade members and a central tubular filter all mounted for rotation about a common horizontal axis and each having independent rotational support and rotational drive mechanisms. The housing, blade members and filter preferably were driven at a constant slow speed for placing a fluid culture medium with discrete microbeads and cell cultures in a discrete spatial suspension in the housing. Replacement fluid medium is symmetrically input and fluid medium is symmetrically output from the housing where the input and the output are apart of a loop providing a constant or intermittent flow of fluid medium in a closed loop. See ‘The Kornfeld Rotary Reactor’ at http://ntrs.nasa.gov/archive/nasa/casi.ntrs.nasa.gov/19850012877_1985012877.pdf .
Encapsulating substances has presented as problematic since time immemorial. Man has constantly sought means and methods to encapsulate substances for purposes of advanced or time-released delivery, conservation of energy and preservation due to lack of refrigeration, etc. Realizing the significance of what NASA researchers had accomplished (culminating in the production of microspheres in Space aboard STS 43) and the shortfalls of the requisite manufacture methods in gravity environments, Resnick determined that the reason that Wang, et al, were unable to produce microspheres (successfully) on earth was due to the Coriolis Effect, a phenomenon which is diminished, considerably, in the microgravity conditions encountered in shallow earth orbit. Consequently, the instrumentation and process developed by Dr. Resnick advanced the science and art of microencapsulating any substances to the ‘next-level’ based on 30+ years of research by NASA scientists. Resnick's technology was highlighted on the History Channel's 'Modern Marvels', see: http://www.youtube.com/watch?v=zmSaNqMpfCs . Products in commerce since 1992 based on Dr. Resnick's work may be viewed at NASA ISDC Conference Archve: http://tinyurl.com/5ujkx3p or http://isdc2.xisp.net/~kmiller/isdc_archive/isdc.php?link=personSelect&person_id=498
When Dr. Resnick determined that conventional methods of producing microspheres on earth (e.g., coacervative spray, phase-separation, <laser> pulsed-drop column, etc.) were reliant upon gravity and were severely <negatively> impacted by the Coriolis Effect, gravity, the earth's celestial motion, all factors apparently overlooked by artisans and food scientists and specialty chemical manufacturers alike, he designed an instrument that overcame those factors. Resnick's device enables dispersion of both an encapsulate and an encapsulant via a dual-dispersion apparatus (called an 'Emission Platform') which enables countermeasure or offset of the Coriolis Effect through emission of substances on coplanar/annular axis and elliptical axes which exploits astrophysics phenomena (Gravity, Inertia, Motion, Torsion, and counter-rotation) to support the actual manufacturing process in a gravity environment. The result is the production of consistently-shaped, uniform manufactures (microcapsules) ranging in exact sizes from .769 Angstrom Units to 5000um which are as close to a perfectly round-shaped ball one can achieve in manufacturing in a gravity environment on Earth. The drying process is eliminated with substitution of PCM's. The Sieving process is also eliminated due to the consistent round shape of the microspheres and control of the aspect ratio during formation. For additional information see US Patent Number 5,807,724.
The Resnick Encapsulation process is a mature technology, with its first use being in the form of environmental cleanup products, WAPED, PRP, Bio-Boom, Bio-Sok, deployed as the first bioremediation product used to mitigate environmental impact at the crash of the Exxon Valdez in Prince William Sound Alaska, on Wolfe Island in March of 1989. In this scenario Resnick used the encapsulation process/device to encapsulate a live-cell culture media comprised of C. lipolytica (Str. 10) inside microcapsules made with 100% Natural Beeswax. The Resnick encapsulation process is a patent-pending process (as of this publication) which patent application has been ‘allowed’ by the US Patent and Trademark Office (US Patent Application SN ) and which is in the process of issuing to the Public Domain. The Resnick process is unique and capable of being used to encapsulate any aqueous substance.
Q.
Can the process be used to encapsulate probiotics (living microorganisms), for example, in yogurts or cheeses?
A.(Short Version)
Yes.
A.(Long Version)
The process/device has been (and continues to be successfully) used to encapsulate probiotics. The first use of the device was to produce environmental cleanup products, WAPED, PRP, Bio-Boom, Bio-Sok, deployed as the first bioremediation product used to mitigate environmental impact at the crash of the Exxon Valdez in Prince William Sound Alaska, in March of 1989. In this scenario Resnick used the encapsulation process/device to encapsulate a live-cell culture media comprised of distilled water, agar, sucrose and C. lipolytica (Str. 10) as the encapsulate-media placed inside microcapsules made with 100% Natural Beeswax as the excipient (encapsulant). Dr. Resnick’s work pre-dates that of Tanock/Smith, et al, (See http://www.horizonpress.com/ciim/v/v3/05.pdf ;) and Oda, et al (See: http://www.springerlink.com/content/48q1r6088427w778/) by nearly a decade.
Q.
What about mixed raw materials, or is the technology directed at single ingredients?
A.(Short Version)
Mixtures of raw materials have been accomplished successfully resulting in production of desired manufactures (’charged/loaded‘ microcapsules).
A.(Long Version)
In the recent past, there has been an explosion of probiotic-based health products mostly in the form of fermented dairy products as well as dietary supplements. The markets for probiotic products and supplements are increasing worldwide (Playne, 1997). Today there are more than 70 “Bifidus”- and “Acidophilus”-containing products worldwide, including several fermented dairy products (Shah, 2001). Viability of probiotic bacteria in a product at the point of consumption is an important consideration for their efficacy, as they have to survive during the processing and shelf life of food and supplements, transit through high acidic conditions of the stomach and enzymes and bile salts in the small intestine. The consumption of probiotics at a level of 108-109 cfu/g per day is a commonly quoted figure for adequate probiotic consumption, equating to 100 g of a food product with 106-107 cfu/g (Kebary, 1996; Lee and Salminen, 1996; Dave and Shah, 1997c). Analysis of probiotic products in many different countries has confirmed that probiotic strains exhibit poor survival in traditional fermented dairy products (Shah, 2000, Lourens-Hattingh and Viljoen, 2001). The probiotic preparations such as tablets, powders etc. may contain lower viable counts. Of the 15 feed supplements examined, viable probiotic counts varied greatly, with 3 products containing no lactobacilli at all (Gilliland, 1981), although the supplements were supposed to contain L. acidophilus. Probiotic survival in products is affected by a range of factors including pH, post-acidification (during storage) in fermented products, hydrogen peroxide production, oxygen toxicity (oxygen permeation through packaging), storage temperatures, stability in dried or frozen form, poor growth in milk, lack of proteases to break down milk protein to simpler nitrogenous substances and compatibility with traditional starter culture during fermentation (Dave and Shah, 1997a, b, c; Kailasapathy and Rybka, 1997; Shah, 2000). Oxygen plays a major role in the poor survival of probiotic bacteria (Brunner et al., 1993).
Providing probiotic living cells with a physical barrier against adverse external conditions is an approach currently receiving considerable interest. In the past, microorganisms were immobilized or entrapped in polymer matrices for use in bio-technological applications. Please see:
http://www.horizonpress.com/ciim/v/v3/05.pdf .
Q.
Would you have samples of encapsulated ingredients, even a simple vitamin/mineral, for our evaluation?
A.
Yes. A small sample of a biological product used in oil spill cleanup scenarios is available (free of charge) subject to signing an NDA. We would be pleased to discuss undertaking a short production run for potential clients wherein simple vitamin/mineral solutions would be encapsulated using the process. A short production run can be accommodated under terms of a Master Service Agreement or a Contract-for-Services (Product-testing) Workscope Agreement with terms to be negotiated per Client’s needs.
Q.
The natural beeswax matrix is intriguing. What are the properties of that matrix in terms of stability, delivery?
A.
The properties of beeswax are varied. Beeswax has been used as a food supplement, is valued for its medicinal properties, is noted for healing properties, is used in cosmetics, adjuvants, dental applications, for making candles and used in the lining of Bagpipes. Beeswax is a highly stable molecule. Delivery of products encapsulated in beeswax are highly stable and deliverable due to the homogeneous composition of the molecule. Just about every organism can be benefited by or utilize this molecule (fatty acid ester) as a food source. Products can be enhanced through encapsulation of flavors, colors, etc., with this molecule comprising an excellent delivery system that protects deliverables from breakdown due to its resistance to hydrolysis and natural oxidation. See: http://www.insectscience.org/4.29/Kameda_JIS_4_29_2004.pdf
Q.
What is the ingredient load in relation to the coating?
A.
The ingredient load varies as a function of the specification of the desired particles size comprising (a) the specified capsule size <for example...specification of uniform capsule size is set at 150um, + or - a 2% deviation, where X= (4/3) pi r 3>; (b) the aspect ratio of the shell during manufacture <where the thickness shell-wall is specified at .025um, for example, where Y=(D) and where D = m/V>; (c) and the resultant quantity of substance to be encapsulated is specified at .000023223 ug/mL, for example, and V=(r2=0.978) <based on Korsmeyer-Peppas equation of linearity>. Dr. Resnick's design of the coplanar emission module enables exact control of the aspect ratio of the capsules being produced.
Other information in the public domain:
http://www.prlog.org/11673684-pitt-alum-nominated-for-the-tyler-prize-in-environmental-achievement.html
http://www.cnbc.com/id/37593652/17_Ways_To_Clean_Up_The_Gulf_Oil_Spill?slide=17
http://www.youtube.com/watch?v=vs2J3Uz4c8g
Q.
What is the technology?
A.
A new delivery system with ability to encapsulate substances from within microcapsules which can range in sizes from .25 to 500 micrometers.
Q.
How does it work?
A.
The microcapsules can be made of 100% Beeswax, and also can be produced using polymers, monomers, etc.
Q.
There are lots of microencapulation techniques out there - how is this different and superior?
A.
The microcapsules are manufactured using a dual-dispensing nozzle. The encapsulation process differs from various conventional encapsulation methods, e.g., coacervative-spray technique(s) and phase-separation processes. Drying and sieving processes are eliminated due to the consistent round shape of the microspheres thus greatly adding to cost effectiveness. The advantage of using this process is both ease of operation and product cost reduction (and the opportunity to create capsules made entirely from all-natural materials).
Q .
What are the areas where this new process could offer value-added?
A.
Obviously, the food, medical, aerospace and manufacturing are are targeted for deployment of this technology. Other areas would include those in which a client is currently involved or would consider employing microencapsulation technology to improve or enhance product performance, reduce product and production costs, and to achieve 'value-added' features to current product lines.
Q.
What's the IP status?
A.
Notice of Allowance has been received from US Patent Office. Patent is being brought to issue from USPTO.
Q.
What types of business models are possible for potential Clients?
A.
Possibilities include, Private Label Manufacturing, and/or licensing. The process is fully scaled and has been commercialized (e.g. oil spill remediation booms) since 1992. JV's or exclusive manufacturing scenarios are of interest.
Discussion
The major factors in producing microcapsules, or encapsulating anything for that matter, are the cost of processing, the cost of raw materials, the manufacturing standards employed, regulatory/compliance costs, etc. These are the market issues that drive production of fragrances, flavors, cosmetics, etc. Our 'breakthrough' is the 'elegance in the simplicity of the manufacturing method', which negates costly (and very dangerous) processes, e.g., phase separation, coacervative and atomization techniques, and eliminates instrumentation costs which are 'astronomical'. For example, to gear up to manufacture a specific formula for a product that relies upon the phase-separation process to produce the final product (microcapsules containing a particular substance), about 30 'steps' are involved just in the 'process', and about 2-3 million dollars required to build the pilot plant to assure safe manufacturing methods can be achieved...prior to roll-out to full production.
Our instrument/process eliminates all of those issues and, by design, has eliminated aspects of the manufacturing process (re waxes and flavorings), such as molecular damage to raw materials due to exposure to temperature extremes, high pressures, etc., that tend to degrade overall product integrity during the manufacturing process. Simply put, the process does not impact the molecular stasis of waxes or flavors during the manufacturing process.
Below are some typical questions regarding the technology presented in an effort to conserve time and help in pointing to advantages of the Coplanar Encapsulating Process over the prior art.
Q.
Could you please start by explaining how this technology is different from others in terms of the beneficial properties, other than size, that have to be considered when choosing the ingredients to be encapsulated?
A. (Short Version)
The Coplanar/Annular Microencapsulating Process and Instrumentation invented and advanced by Dr. Joseph A. Resnick differs from conventional methods of producing microspheres, nanospheres, microcapsules and nanocapsules in the gravity environment found on earth (e.g., coacervative spray, phase-separation, pulsed-drop column, etc.). Conventional methods of encapsulating substances are complex, costly, labor-intensive (sieving, for example) and sometimes very (very) dangerous (as is the case in the fleuro-chemical phase separation process used to produce pharmaceuticals and cosmetics).
In terms of consideration of properties of the substances selected for encapsulation, fluidity, viscosity, temperature, van der Waals interaction with alcohols, furans, lactones, ketones, aldehydes, small organic acids, mercaptans, thiols, sulfides, pyrazines, terpenes, phenols, and esters have been considered and examined. These have all been successfully incorporated within the various bonding matrixes depending upon project initiatives, desired product goals or specified deliverables. Further, the release mechanism (for volatile/hydrophobic) species can be selectively controlled during the manufacturing process to control incidents (van der Waals reactions, for example) and interactions between entrapped volatile flavor compounds, fatty acid (esters) and paraffinic hydrocarbons below the melting point of beeswax, or other polyolefins for example. Through precise temperature/pressure control minimal impact to organoleptic properties are made negligible and strictly controlled as well.
A.(Long Version)
The Coplanar/Annular Microencapsulating Process and Instrumentation invented and advanced by Dr. Joseph A. Resnick differs from conventional methods of producing microspheres, nanospheres, microcapsules and nanocapsules in the gravity environment found on earth (e.g., coacervative spray, phase-separation, pulsed-drop column, etc.). Conventional methods of encapsulating substances are complex, costly, labor-intensive and sometimes dangerous (as is the case in the fluero-chemical phase separation process used to produce pharmaceuticals and cosmetics).
In terms of consideration of properties of the substances selected for encapsulation, fluidity, viscosity, temperature, van der Walls interaction with alcohols, furans, lactones, ketones, aldehydes, small organic acids, mercaptans, thiols, sulfides, pyrazines, terpenes, phenols, esters, and esthers have been considered and examined. These have all been successfully incorporated within the various bonding matrixes. Further, the release mechanism (for volatile/hydrophobic) species can be selectively controlled during the manufacturing process to control incidents (van der Waals reactions, for example) and interactions between entrapped volatile flavor compounds, fatty acids (esters) and paraffinic hydrocarbons below the melting point of beeswax, for example. Through precise temperature/pressure control minimal impact to organoleptic properties are note.
Resnick's encapsulation technology has its foundations in work initially undertaken in the early 1980’s and early 1990’s by NASA Scientists, Dr. Taylor G. Wang (NASA JPL), Dr. John Vanderhoff (Lehigh Univ.) and Dr. Dale M. Kornfeld (MSF, Huntsville, AL). Wang, et al, were tasked with developing a means of producing monodisperse polystyrene beads leading to the ability to encapsulate live cells for medical purposes, cosmetics, animal adjuvants, for use in foods and liquids for consumption in space by Astronauts during spaceflight missions, and for encapsulating substances for human and animal consumption. Work enabled through NASA-funded research grants resulted in the development of a bio-reactor system wherein a tubular housing contains an internal circularly disposed set of blade members and a central tubular filter all mounted for rotation about a common horizontal axis and each having independent rotational support and rotational drive mechanisms. The housing, blade members and filter preferably were driven at a constant slow speed for placing a fluid culture medium with discrete microbeads and cell cultures in a discrete spatial suspension in the housing. Replacement fluid medium is symmetrically input and fluid medium is symmetrically output from the housing where the input and the output are apart of a loop providing a constant or intermittent flow of fluid medium in a closed loop. See ‘The Kornfeld Rotary Reactor’ at http://ntrs.nasa.gov/archive/nasa/casi.ntrs.nasa.gov/19850012877_1985012877.pdf .
Encapsulating substances has presented as problematic since time immemorial. Man has constantly sought means and methods to encapsulate substances for purposes of advanced or time-released delivery, conservation of energy and preservation due to lack of refrigeration, etc. Realizing the significance of what NASA researchers had accomplished (culminating in the production of microspheres in Space aboard STS 43) and the shortfalls of the requisite manufacture methods in gravity environments, Resnick determined that the reason that Wang, et al, were unable to produce microspheres (successfully) on earth was due to the Coriolis Effect, a phenomenon which is diminished, considerably, in the microgravity conditions encountered in shallow earth orbit. Consequently, the instrumentation and process developed by Dr. Resnick advanced the science and art of microencapsulating any substances to the ‘next-level’ based on 30+ years of research by NASA scientists. Resnick's technology was highlighted on the History Channel's 'Modern Marvels', see: http://www.youtube.com/watch?v=zmSaNqMpfCs . Products in commerce since 1992 based on Dr. Resnick's work may be viewed at NASA ISDC Conference Archve: http://tinyurl.com/5ujkx3p or http://isdc2.xisp.net/~kmiller/isdc_archive/isdc.php?link=personSelect&person_id=498
When Dr. Resnick determined that conventional methods of producing microspheres on earth (e.g., coacervative spray, phase-separation, <laser> pulsed-drop column, etc.) were reliant upon gravity and were severely <negatively> impacted by the Coriolis Effect, gravity, the earth's celestial motion, all factors apparently overlooked by artisans and food scientists and specialty chemical manufacturers alike, he designed an instrument that overcame those factors. Resnick's device enables dispersion of both an encapsulate and an encapsulant via a dual-dispersion apparatus (called an 'Emission Platform') which enables countermeasure or offset of the Coriolis Effect through emission of substances on coplanar/annular axis and elliptical axes which exploits astrophysics phenomena (Gravity, Inertia, Motion, Torsion, and counter-rotation) to support the actual manufacturing process in a gravity environment. The result is the production of consistently-shaped, uniform manufactures (microcapsules) ranging in exact sizes from .769 Angstrom Units to 5000um which are as close to a perfectly round-shaped ball one can achieve in manufacturing in a gravity environment on Earth. The drying process is eliminated with substitution of PCM's. The Sieving process is also eliminated due to the consistent round shape of the microspheres and control of the aspect ratio during formation. For additional information see US Patent Number 5,807,724.
The Resnick Encapsulation process is a mature technology, with its first use being in the form of environmental cleanup products, WAPED, PRP, Bio-Boom, Bio-Sok, deployed as the first bioremediation product used to mitigate environmental impact at the crash of the Exxon Valdez in Prince William Sound Alaska, on Wolfe Island in March of 1989. In this scenario Resnick used the encapsulation process/device to encapsulate a live-cell culture media comprised of C. lipolytica (Str. 10) inside microcapsules made with 100% Natural Beeswax. The Resnick encapsulation process is a patent-pending process (as of this publication) which patent application has been ‘allowed’ by the US Patent and Trademark Office (US Patent Application SN ) and which is in the process of issuing to the Public Domain. The Resnick process is unique and capable of being used to encapsulate any aqueous substance.
Q.
Can the process be used to encapsulate probiotics (living microorganisms), for example, in yogurts or cheeses?
A.(Short Version)
Yes.
A.(Long Version)
The process/device has been (and continues to be successfully) used to encapsulate probiotics. The first use of the device was to produce environmental cleanup products, WAPED, PRP, Bio-Boom, Bio-Sok, deployed as the first bioremediation product used to mitigate environmental impact at the crash of the Exxon Valdez in Prince William Sound Alaska, in March of 1989. In this scenario Resnick used the encapsulation process/device to encapsulate a live-cell culture media comprised of distilled water, agar, sucrose and C. lipolytica (Str. 10) as the encapsulate-media placed inside microcapsules made with 100% Natural Beeswax as the excipient (encapsulant). Dr. Resnick’s work pre-dates that of Tanock/Smith, et al, (See http://www.horizonpress.com/ciim/v/v3/05.pdf ;) and Oda, et al (See: http://www.springerlink.com/content/48q1r6088427w778/) by nearly a decade.
Q.
What about mixed raw materials, or is the technology directed at single ingredients?
A.(Short Version)
Mixtures of raw materials have been accomplished successfully resulting in production of desired manufactures (’charged/loaded‘ microcapsules).
A.(Long Version)
In the recent past, there has been an explosion of probiotic-based health products mostly in the form of fermented dairy products as well as dietary supplements. The markets for probiotic products and supplements are increasing worldwide (Playne, 1997). Today there are more than 70 “Bifidus”- and “Acidophilus”-containing products worldwide, including several fermented dairy products (Shah, 2001). Viability of probiotic bacteria in a product at the point of consumption is an important consideration for their efficacy, as they have to survive during the processing and shelf life of food and supplements, transit through high acidic conditions of the stomach and enzymes and bile salts in the small intestine. The consumption of probiotics at a level of 108-109 cfu/g per day is a commonly quoted figure for adequate probiotic consumption, equating to 100 g of a food product with 106-107 cfu/g (Kebary, 1996; Lee and Salminen, 1996; Dave and Shah, 1997c). Analysis of probiotic products in many different countries has confirmed that probiotic strains exhibit poor survival in traditional fermented dairy products (Shah, 2000, Lourens-Hattingh and Viljoen, 2001). The probiotic preparations such as tablets, powders etc. may contain lower viable counts. Of the 15 feed supplements examined, viable probiotic counts varied greatly, with 3 products containing no lactobacilli at all (Gilliland, 1981), although the supplements were supposed to contain L. acidophilus. Probiotic survival in products is affected by a range of factors including pH, post-acidification (during storage) in fermented products, hydrogen peroxide production, oxygen toxicity (oxygen permeation through packaging), storage temperatures, stability in dried or frozen form, poor growth in milk, lack of proteases to break down milk protein to simpler nitrogenous substances and compatibility with traditional starter culture during fermentation (Dave and Shah, 1997a, b, c; Kailasapathy and Rybka, 1997; Shah, 2000). Oxygen plays a major role in the poor survival of probiotic bacteria (Brunner et al., 1993).
Providing probiotic living cells with a physical barrier against adverse external conditions is an approach currently receiving considerable interest. In the past, microorganisms were immobilized or entrapped in polymer matrices for use in bio-technological applications. Please see:
http://www.horizonpress.com/ciim/v/v3/05.pdf .
Q.
Would you have samples of encapsulated ingredients, even a simple vitamin/mineral, for our evaluation?
A.
Yes. A small sample of a biological product used in oil spill cleanup scenarios is available (free of charge) subject to signing an NDA. We would be pleased to discuss undertaking a short production run for potential clients wherein simple vitamin/mineral solutions would be encapsulated using the process. A short production run can be accommodated under terms of a Master Service Agreement or a Contract-for-Services (Product-testing) Workscope Agreement with terms to be negotiated per Client’s needs.
Q.
The natural beeswax matrix is intriguing. What are the properties of that matrix in terms of stability, delivery?
A.
The properties of beeswax are varied. Beeswax has been used as a food supplement, is valued for its medicinal properties, is noted for healing properties, is used in cosmetics, adjuvants, dental applications, for making candles and used in the lining of Bagpipes. Beeswax is a highly stable molecule. Delivery of products encapsulated in beeswax are highly stable and deliverable due to the homogeneous composition of the molecule. Just about every organism can be benefited by or utilize this molecule (fatty acid ester) as a food source. Products can be enhanced through encapsulation of flavors, colors, etc., with this molecule comprising an excellent delivery system that protects deliverables from breakdown due to its resistance to hydrolysis and natural oxidation. See: http://www.insectscience.org/4.29/Kameda_JIS_4_29_2004.pdf
Q.
What is the ingredient load in relation to the coating?
A.
The ingredient load varies as a function of the specification of the desired particles size comprising (a) the specified capsule size <for example...specification of uniform capsule size is set at 150um, + or - a 2% deviation, where X= (4/3) pi r 3>; (b) the aspect ratio of the shell during manufacture <where the thickness shell-wall is specified at .025um, for example, where Y=(D) and where D = m/V>; (c) and the resultant quantity of substance to be encapsulated is specified at .000023223 ug/mL, for example, and V=(r2=0.978) <based on Korsmeyer-Peppas equation of linearity>. Dr. Resnick's design of the coplanar emission module enables exact control of the aspect ratio of the capsules being produced.
Other information in the public domain:
http://www.prlog.org/11673684-pitt-alum-nominated-for-the-tyler-prize-in-environmental-achievement.html
http://www.cnbc.com/id/37593652/17_Ways_To_Clean_Up_The_Gulf_Oil_Spill?slide=17
http://www.youtube.com/watch?v=vs2J3Uz4c8g
Q.
What is the technology?
A.
A new delivery system with ability to encapsulate substances from within microcapsules which can range in sizes from .25 to 500 micrometers.
Q.
How does it work?
A.
The microcapsules can be made of 100% Beeswax, and also can be produced using polymers, monomers, etc.
Q.
There are lots of microencapulation techniques out there - how is this different and superior?
A.
The microcapsules are manufactured using a dual-dispensing nozzle. The encapsulation process differs from various conventional encapsulation methods, e.g., coacervative-spray technique(s) and phase-separation processes. Drying and sieving processes are eliminated due to the consistent round shape of the microspheres thus greatly adding to cost effectiveness. The advantage of using this process is both ease of operation and product cost reduction (and the opportunity to create capsules made entirely from all-natural materials).
Q .
What are the areas where this new process could offer value-added?
A.
Obviously, the food, medical, aerospace and manufacturing are are targeted for deployment of this technology. Other areas would include those in which a client is currently involved or would consider employing microencapsulation technology to improve or enhance product performance, reduce product and production costs, and to achieve 'value-added' features to current product lines.
Q.
What's the IP status?
A.
Notice of Allowance has been received from US Patent Office. Patent is being brought to issue from USPTO.
Q.
What types of business models are possible for potential Clients?
A.
Possibilities include, Private Label Manufacturing, and/or licensing. The process is fully scaled and has been commercialized (e.g. oil spill remediation booms) since 1992. JV's or exclusive manufacturing scenarios are of interest.
Discussion
The major factors in producing microcapsules, or encapsulating anything for that matter, are the cost of processing, the cost of raw materials, the manufacturing standards employed, regulatory/compliance costs, etc. These are the market issues that drive production of fragrances, flavors, cosmetics, etc. Our 'breakthrough' is the 'elegance in the simplicity of the manufacturing method', which negates costly (and very dangerous) processes, e.g., phase separation, coacervative and atomization techniques, and eliminates instrumentation costs which are 'astronomical'. For example, to gear up to manufacture a specific formula for a product that relies upon the phase-separation process to produce the final product (microcapsules containing a particular substance), about 30 'steps' are involved just in the 'process', and about 2-3 million dollars required to build the pilot plant to assure safe manufacturing methods can be achieved...prior to roll-out to full production.
Our instrument/process eliminates all of those issues and, by design, has eliminated aspects of the manufacturing process (re waxes and flavorings), such as molecular damage to raw materials due to exposure to temperature extremes, high pressures, etc., that tend to degrade overall product integrity during the manufacturing process. Simply put, the process does not impact the molecular stasis of waxes or flavors during the manufacturing process.
The technology behind the Resnick Encapsulation process is mature. The basic
technology supporting the process has its foundation in programs and early
prototype instruments developed by NASA in the late 1980’s and early 1990’s and developed by Dr. Joseph A. Resnick.
The technology is listed in the NASA Spinoff Hall of Fame and is a Certified Space
Technology.
This new method of microencapsulation is well suited for encapsulating biologicals, pharma's, flavorings, probiotics, pigments, paints, etc., and can be engaged to reduce production costs (sieving, drying, etc.) thus eliminating some processing steps resulting in increased product profitability.
RMANNCO can provide custom product testing and experimental product runs at the client's facility on a contract-for-services basis. A portable pilot plant instrument is available and Dr. Joseph A. Resnick provides services at client's site (if preferred) at reduced rates with the instrument.
To request access to a special *URL to view the device in operation please contact:
Ms. Joyce Mann, Chief Executive Officer
TELECON: 478-244-2131 EMAIL: mailto: [email protected]
or write:
RMANNCO, INC.
Microencapsulation, Future Soldier Systems and Biodefense Divisions
The Green Mountain Laboratory
1016 NC Hiway 268
Lenoir, NC 28645
TELECON: 828-572-7705 office/478-244-2131 cell
EMAIL: [email protected]
Skype: drjoeresnick
Agency/Business Contact and Government Liaison: [email protected]
*No additional information will be released in absence of an executed NDA/Non-Compete Agreement. For NDA's contact Gary Topolosky, Patent Attorney at EMAIL: [email protected]
Copyright, 1991-2014, All Rights Reserved under UCC 1-207, Globally and Universally. No portion of the information published herein may be copied, reproduced or transmitted by any means, electronic or otherwise, without the permission of Dr. Joseph A. Resnick, Inventor. 'Resnick' is the Registered Trademark of Dr. Joseph A. Resnick, under Exclusive, Worldwide License to NxGenUSA Corporation. US and other Patents Pending.