Method and apparatus for the preparation of capsules
An apparatus for a continuous encapsulation process is provided. The apparatus is a vibrating tubing used alone, in series, or in combination with an encapsulation apparatus, which is used alone or in series. The vibrating tubing is a flat coil, a standing spiral, or a flume. The encapsulation apparatus includes a winding having coils disposed in an aqueous gelling solution. The winding is rotatable about its longitudinal center axis. The winding has adjacently spaced coils forming a plurality of chambers. Objects to be encapsulated are added to the apparatus such that when the winding is rotated, the chambers transport a volume of objects through the length winding in the aqueous gelling solution in a predetermined time.
1. A non-spherical seamless capsule comprising oil, wherein the oil is surrounded by a gelled gel-forming polymer comprising alginate, the capsule has a length of 16 mm to 35 mm and a diameter of 5 mm to 12 mm, the capsule is delayed release, and said capsule is made by a process comprising the steps of:
(a) continuously adding a material to be encapsulated to a tubing containing an aqueous gelling solution comprising a water soluble alginate, the tubing having an input end and an output end, wherein the material is an emulsion comprising oil, water, an emulsifier, and a gelling agent comprising a polyvalent cation and wherein the oil is present in an amount of at least 50% by weight of said emulsion;
(b) vibrating the tubing to a sufficient degree such that the material passes through the tubing from the input end to the output end in a controlled, agitated manner and with controlled residence time so as to form said seamless capsule;
(c) washing the capsule for at least three hours in (i) water or (ii) an aqueous solution that does not contain a sequestrant;
(d) plasticizing the capsule by adding the capsule to a plasticizer bath; and
(e) drying said capsule.
2. The capsule of claim 1 in which the capsule has a length of 20 mm to 35 mm and a diameter of 7 mm to 12 mm.
3. The capsule of claim 1 in which the capsule has a length of 25 mm to 35 mm and a diameter of 7 mm to 12 mm.
4. The capsule of claim 1 in which the fill weight of the capsule is 500 to 2500 mg.
5. The capsule of claim 1 in which the fill weight of the capsule is 1000 to 1500 mg.
6. The capsule of claim 1 in which the capsule additionally comprises a material selected from the group consisting of pharmaceuticals, nutraceuticals, confectionary ingredients, foods, and mixtures thereof.
7. The capsule of claim 1 in which the water content of the capsules is less than 10% by the total weight of the dried capsules.
8. The capsule of claim 1 , wherein said capsule is washed from three to eight hours.
9. The capsule of claim 8 , wherein said capsule is washed in water and said capsule to water weight ratio is 1:1-1:8, respectively.