NEXT-GEN BEAD FORMING MACHINE

Abstract

ABSTRACT The present disclosure introduces next-gen bead forming machine 100 for producing uniform sodium alginate beads. The system uses a syringe 102 to hold alginate solution and a syringe holder 104 to secure it in a vertical position for consistent droplet release. Droplets are dispensed through needles 106 into a beaker 108 containing calcium chloride solution, where they undergo gelation. A magnetic stirrer 110 ensures uniform mixing of the solution to promote even bead formation. The pressure gauge 112 monitors the pressure applied to the syringes, while the vacuum pump 114 provides controlled pressure to regulate droplet formation. The flat plate 116 distributes uniform pressure across all syringes, ensuring consistent droplet release. The adjustable screws 118 allow for precise adjustment of the distance between the syringe and the beaker. Reference fig 1

Specification

Description:Next-Gen Bead Forming Machine
TECHNICAL FIELD
[0001] The present innovation relates to bead-forming machine designed for precise and scalable production of uniform beads for applications in pharmaceuticals, food technology, and biotechnology.

BACKGROUND

[0002] The production of uniform sodium alginate beads is essential for various industries, including pharmaceuticals, food encapsulation, and biotechnology, where bead consistency directly affects product efficacy. Traditional methods of droplet formation, such as manual pipetting or basic nozzle systems, result in inconsistent droplet sizes, leading to variability in the shape and size of the beads. This inconsistency presents a major problem in applications where precision is critical, such as in drug delivery systems where uneven bead sizes can affect dosage and release rates. Current alternatives like microfluidic devices, customized nozzle designs, and automation systems have been explored to address this issue. However, these options come with their own challenges, such as complex operational setups, high costs, scalability limitations, and technical difficulties in maintaining uniformity across large-scale production.

[0003] The next-gen bead forming machine solves these problems by offering a controlled and scalable solution for the reproducible formation of uniform sodium alginate beads. Unlike traditional methods, this invention uses a syringe-based system with adjustable pressure and speed controls to regulate droplet formation, ensuring consistency in bead size and shape. Additionally, the system includes adjustable components to fine-tune the distance between the droplet release point and the calcium chloride solution, which further enhances the uniformity of bead gelation.
[0004] What differentiates this invention from existing systems is its ability to maintain precision control while being scalable for industrial applications. The machine integrates automation, pressure control, and customizable settings, making it both efficient and versatile for different production needs. The novelty of this invention lies in its systematic approach to optimizing droplet formation parameters while ensuring scalability, uniformity, and minimized cross-contamination. This combination of features enables the reliable, large-scale production of sodium alginate beads with consistent quality, addressing the limitations of existing technologies.

OBJECTS OF THE INVENTION

[0005] The primary object of the invention is to provide a bead-forming machine that ensures precise control over droplet formation for consistent bead size and shape.

[0006] Another object of the invention is to enhance the scalability of bead production, allowing for industrial-level manufacturing without compromising quality.

[0007] Another object of the invention is to minimize cross-contamination between droplets during the bead formation process, ensuring uniform gelation.

[0008] Another object of the invention is to automate the droplet formation process, reducing the need for manual labor and improving production efficiency.

[0009] Another object of the invention is to offer adjustable components that allow for customization of bead characteristics to meet specific application needs.

[00010] Another object of the invention is to provide a cost-effective system for the large-scale production of sodium alginate beads used in pharmaceuticals, food encapsulation, and biotechnology.

[00011] Another object of the invention is to integrate precise pressure and speed controls to regulate droplet size for optimal bead formation.

[00012] Another object of the invention is to improve production throughput while maintaining consistent bead quality across various production volumes.

[00013] Another object of the invention is to offer a flexible system that can be adapted for use with different types of solutions and bead-forming materials.

[00014] Another object of the invention is to address the limitations of existing bead-forming technologies by providing a machine that is both user-friendly and capable of maintaining high-quality, reproducible results.

SUMMARY OF THE INVENTION

[00015] In accordance with the different aspects of the present invention, next-gen bead forming machine is presented. It is designed to produce uniform beads through precise droplet formation control. It integrates adjustable pressure and speed controls to ensure consistent bead size and shape, minimizing cross-contamination and enabling uniform gelation. The machine is scalable for industrial applications while maintaining high-quality output. Its automation and customization features enhance production efficiency and allow for tailored bead characteristics for different applications. This innovation addresses the limitations of existing technologies, providing a reliable, cost-effective solution for large-scale bead production.

[00016] Additional aspects, advantages, features and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments constructed in conjunction with the appended claims that follow.

[00017] It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.

BRIEF DESCRIPTION OF DRAWINGS
[00018] The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.

[00019] Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:

[00020] FIG. 1 is component wise drawing for next-gen bead forming machine.

[00021] FIG 2 is working methodology of next-gen bead forming machine.

DETAILED DESCRIPTION

[00022] The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognise that other embodiments for carrying out or practising the present disclosure are also possible.

[00023] The description set forth below in connection with the appended drawings is intended as a description of certain embodiments of next-gen bead forming machine and is not intended to represent the only forms that may be developed or utilised. The description sets forth the various structures and/or functions in connection with the illustrated embodiments; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimised to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

[00024] While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.

[00025] The terms "comprises", "comprising", "include(s)", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, or system that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or system. In other words, one or more elements in a system or apparatus preceded by "comprises... a" does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.

[00026] In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings and which are shown by way of illustration-specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.

[00027] The present disclosure will be described herein below with reference to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail since they would obscure the description with unnecessary detail.

[00028] Referring to Fig. 1, next-gen bead forming machine 100 is disclosed, in accordance with one embodiment of the present invention. It comprises of syringe 102, syringe holder 104, needles 106, beaker 108, magnetic stirrer 110, pressure gauge 112, vacuum pump 114, flat plate 116 and adjustable screws 118.

[00029] Referring to Fig. 1, the present disclosure provides details of the next-gen bead forming machine 100 for uniform bead production. It is a system designed to ensure precise control over droplet formation, enabling consistent bead size and shape. The system comprises of syringe 102, which holds the sodium alginate solution, and syringe holder 104, which secures the syringes in place for controlled dispensing. The machine is equipped with adjustable screw 118 to regulate the height between beaker 110 and needles 106, ensuring optimal droplet release into the calcium chloride solution. It also features pressure gauge 112 and vacuum pump 114 for precise pressure application, enhancing production efficiency and consistency. The system's magnetic stirrer 110 maintains even mixing, while the flat plate 116 ensures uniform pressure across all syringes.

[00030] Referring to Fig.1, the next-gen bead forming machine 100 is provided with syringe 102, which holds the solution necessary for forming the beads. In different embodiments, different solutions may be used. In one of the embodiments, sodium alginate solution is used. The syringe 102 is mounted vertically in the syringe holder 104, ensuring stability during the droplet formation process. The role of the syringe 102 is to dispense precise amounts of the solution into the beaker below, controlling the bead size and shape. It works in coordination with the pressure gauge 112 to regulate the release of the solution, ensuring uniformity. The syringe 102 is critical for achieving consistent droplet formation required for uniform bead production.

[00031] Referring to Fig.1, the next-gen bead forming machine 100 is provided with syringe holder 104, which secures the syringe 102 in a vertical position to enable controlled droplet release. The syringe holder 104 is adjustable and allows for precise positioning of the syringe, ensuring that the height between the syringe 102 and the beaker 108 can be regulated. This component 104 plays a vital role in maintaining the stability of the system, preventing disturbances during the bead formation process. The syringe holder 104 works together with the adjustable screw 118 to fine-tune the positioning, ensuring that bead production remains consistent.

[00032] Referring to Fig.1, the next-gen bead forming machine 100 is provided with needles 106, which guide the sodium alginate droplets from the syringe 102 into the beaker 108 containing calcium chloride solution. The needles 106 are crucial for ensuring that the droplets are released at a consistent size and shape, directly influencing the final bead characteristics. These needles 106 work in tandem with the syringe 102 to ensure a smooth flow of the solution, without blockages or inconsistencies. Their precise placement and design contribute to the uniformity of the beads produced by the machine.

[00033] Referring to Fig.1, the next-gen bead forming machine 100 is provided with beaker 108, which contains the calcium chloride solution necessary for cross-linking the sodium alginate to form beads. The beaker 108 is positioned under the needles 106 to collect the alginate droplets and initiate the bead formation process. This component is placed on a magnetic stirrer 110 to ensure that the calcium chloride solution remains evenly mixed, preventing cross-contamination between droplets. The beaker 108 plays a crucial role in facilitating the gelation of the droplets into solid beads, working alongside other components to ensure the desired bead characteristics are achieved.

[00034] Referring to Fig.1, the next-gen bead forming machine 100 is provided with magnetic stirrer 110, which maintains the uniformity of the calcium chloride solution within the beaker 108. The magnetic stirrer 110 ensures even mixing of the solution, preventing any inconsistency during bead gelation. This component works closely with the beaker 108 to maintain the correct environment for bead formation, ensuring that each droplet cross-links evenly. The stirring action also helps to prevent any build-up of unreacted material, allowing for a continuous and efficient production process.

[00035] Referring to Fig.1, the next-gen bead forming machine 100 is provided with pressure gauge 112, which monitors the pressure applied to the syringe 102. The pressure gauge 112 ensures that the correct amount of force is exerted on the syringes to release consistent droplets of sodium alginate into the calcium chloride solution. This component is crucial for maintaining uniform droplet size, directly influencing bead consistency. The pressure gauge 112 works in coordination with the vacuum pump 114 to regulate the pressure applied, ensuring precision in the droplet formation process.

[00036] Referring to Fig.1, the next-gen bead forming machine 100 is provided with vacuum pump 114, which applies the necessary pressure to the syringe 102 via the flat plate 116. The vacuum pump 114 ensures consistent pressure control, allowing the solution to be dispensed in a uniform manner. This component works in tandem with the pressure gauge 112 to adjust and maintain the required pressure for droplet formation. By providing precise pressure control, the vacuum pump 114 helps to achieve the consistent size and shape of the sodium alginate beads.

[00037] Referring to Fig.1, the next-gen bead forming machine 100 is provided with flat plate 116, which is attached to the back of the machine and applies uniform pressure across all the syringe 102 units. The flat plate 116 helps distribute pressure evenly, ensuring that all syringes release droplets at the same rate. This component works in conjunction with the vacuum pump 114 and pressure gauge 112 to maintain uniformity during bead production. It can be removed or attached as required, offering flexibility in the machine's operation depending on the production needs.

[00038] Referring to Fig.1, the next-gen bead forming machine 100 is provided with adjustable screws 118, which allow for fine-tuned adjustments of syringe holder 104. These adjustable screws 118 ensure that the syringes are properly positioned and locked into place, preventing any unwanted movement during the bead formation process. This component 118 plays a critical role in maintaining the overall stability of the machine, enabling consistent droplet release and precise control over the bead size and shape. The adjustable screws 118 facilitate smooth operation and easy adjustments when needed

[00039] Referring to Fig 2, there is illustrated method 200 for next-gen bead forming machine 100. The method comprises:

At step 202, method 200 includes filling the syringe 102 with alginate solution and positioning it vertically in the syringe holder 104;

At step 204, method 200 includes filling the beaker 108 with calcium chloride solution and placing it under the syringes on the magnetic stirrer, with speed and temperature regulated;

At step 206, method 200 includes adjusting the height between the syringe 102 and the beaker 108 using the adjustable screws 118 and locking the syringes in place;

At step 208, method 200 includes attaching the flat plate 116 to apply uniform pressure to the syringes, with the option to remove the plate when not needed;

At step 210, method 200 includes measuring the pressure using the pressure gauge 112 and applying the required pressure through the vacuum pump 114;

At step 212, method 200 includes releasing sodium alginate droplets from the syringe 102 into the beaker 108 as pressure is applied through the flat plate 116;

At step 214, method 200 includes cross-linking of sodium alginate in the calcium chloride solution to form beads of desired shape and size.


[00040] In the description of the present invention, it is also to be noted that, unless otherwise explicitly specified or limited, the terms "fixed" "attached" "disposed," "mounted," and "connected" are to be construed broadly, and may for example be fixedly connected, detachably connected, or integrally connected, either mechanically or electrically. They may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood in specific cases to those skilled in the art.

[00041] Modifications to embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as "including", "comprising", "incorporating", "have", "is" used to describe and claim the present disclosure are intended to be construed in a non- exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural where appropriate.

[00042] Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the present disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.

, Claims:WE CLAIM:
1. A next-gen bead forming machine 100 comprising of
syringe 102 to hold the alginate solution for droplet formation;
syringe holder 104 to secure the syringe in a vertical position for consistent droplet release;
needles 106 to guide the alginate droplets into the beaker for gelation;
beaker 108 to contain the calcium chloride solution for cross-linking the alginate droplets;
magnetic stirrer 110 to ensure uniform mixing of the calcium chloride solution;
pressure gauge 112 to monitor the applied pressure for controlled droplet formation;
vacuum pump 114 to apply the required pressure to the syringes for droplet release;
flat plate 116 to distribute uniform pressure across the syringes; and
adjustable screws 118 to adjust and lock the height between the syringe and beaker.

2. The next-gen bead forming machine 100 as claimed in claim 1, wherein syringe 102 is configured to hold and dispense solution vertically, allowing precise droplet formation for consistent bead size and shape and syringe holder 104 is configured to secure the syringe in a stable vertical position, preventing disturbances during the droplet release process.

3. The next-gen bead forming machine 100 as claimed in claim 1, wherein needles 106 are configured to guide sodium alginate droplets into the beaker 108 containing calcium chloride solution, facilitating accurate droplet deposition for gelation.

4. The next-gen bead forming machine 100 as claimed in claim 1, wherein beaker 108 is configured to contain calcium chloride solution, providing the medium for cross-linking alginate droplets into solid beads.

5. The next-gen bead forming machine 100 as claimed in claim 1, wherein magnetic stirrer 110 is configured to maintain uniform mixing of the calcium chloride solution, ensuring even bead gelation and preventing droplet clumping.

6. The next-gen bead forming machine 100 as claimed in claim 1, wherein pressure gauge 112 is configured to measure and monitor the pressure applied to the syringes, ensuring precise control of droplet size during the bead formation process.

7. The next-gen bead forming machine 100 as claimed in claim 1, wherein vacuum pump 114 is configured to apply regulated pressure to the syringes, enabling uniform droplet release across multiple syringes for consistent bead production.

8. The next-gen bead forming machine 100 as claimed in claim 1, wherein flat plate 116 is configured to distribute uniform pressure across all syringes, ensuring consistent droplet formation and preventing variations in bead size and shape.

9. The next-gen bead forming machine 100 as claimed in claim 1, wherein adjustable screws 118 are configured to adjust and lock the height between the syringe 102 and the beaker 108, ensuring precise positioning for optimal droplet formation and consistent bead production.

10. The next-gen bead forming machine 100 as claimed in claim 1, wherein method comprises of

filling the syringe 102 with alginate solution and positioning it vertically in the syringe holder 104;
filling the beaker 108 with calcium chloride solution and placing it under the syringes on the magnetic stirrer, with speed and temperature regulated;
adjusting the height between the syringe 102 and the beaker 108 using the adjustable screws 118 and locking the syringes in place;
attaching the flat plate 116 to apply uniform pressure to the syringes, with the option to remove the plate when not needed;
measuring the pressure using the pressure gauge 112 and applying the required pressure through the vacuum pump 114;
releasing sodium alginate droplets from the syringe 102 into the beaker 108 as pressure is applied through the flat plate 116; and
cross-linking of sodium alginate in the calcium chloride solution to form beads of desired shape and size.

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