Aseptic/cGMP designs for production are available.
Micropore's processes are designed to be scalable - from laboratory formulation testing to production tonnages. This enables meaningful laboratory data to be used to scale a process to production volumes.
The low shear and gentle conditions used during membrane emulsification are ideal to prevent damage to sensitive active ingredients.
We have expertise in working with companies seeking to replace some less attractive emulsifying agents, e.g. polyglycerol polyricinoleate (PGPR), with more environmentally desirable ones, that need lower shear, provide greater stability and good control during processing.
We provide a service to develop the best release profile for your ingredients and products; using our expertise in encapsulation and formulation technology based on our membrane emulsification processes.
The Micropore patented manufacturing techniques provide uniform droplets and particles and lead to 100% production success in the desired size range. There is no waste compared to conventional manufacturing techniques. Using Micropore technology results in significantly lower energy and waste disposal costs.
Reliability and Reproducibility:
Micropore’s technology enables highly reliable and reproducible production of batches of materials. Our techniques lead to no 'bad batches’ to be disposed of.
The Micropore systems are easy to control and do not require time consuming and costly specialist operator training.
Materials of construction:
Micropore production equipment is constructed from a minimum number of broad compatibility materials, to simplify validation. For example the standard AXF-1 is made from dual certified316/316L stainless steel with Virgin PTFE seals. Electropolished parts and industry standard hygienic fittings tailor the AXF for cosmetic industry use.
The system is easy to control and has a lower factory space requirement than conventional stirred tank technology.
Traditional homogenisation techniques provide a wide particle size distribution. This can affect the mechanical properties of the finished microcapsules, causing larger capsules to break too easily and smaller capsules not to break at all. This has cost and performance implications, so has to be constantly measured during production.
The Solution and Benefits
Instead of traditional homogenisation equipment, Micropore’s patented membrane emulsification technology was used to produce complex coacervate microcapsules for encapsulating essential fragrance oils.
The customer needed complete control of the resulting particle size in order to achieve 100% product within the desired size range. For each application, the microcapsule specifications had target mean diameters ranging from 10µm to 1mm. By changing process parameters to meet the various target size requirements, the membrane emulsification approach greatly improved the particle size distributions for each product in the range.
Whilst this process was initially used to manufacture fragrances, it has since been successfully used in food and flavouring production.
One of the business challenges was to lower the operating costs associated with the constant need for measurement and analysis during production. This was achieved due to the unique Micropore metal membrane which has a very regular array of fine pores with a tightly specified diameter and no internal channels, which results in zero fouling.
How we can help you
Micropore excels at evaluating complex challenges and finding creative, sustainable and scalable solutions.
Although initially sceptical due to inconclusive results using membrane technology in the past, the Micropore results quickly surpassed our expectations and delivered a viable alternative to our previous production methods’’
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