Optimization of Unit Operations for Microencapsulating Ferrous Fumarate During Scale-up of Double Fortification of Salt with Iron and Iodine
Abstract This study evaluates factors responsible for the floating of iron premix in Double Fortified Salt (DFS) and provides solutions to scale-up of the DFS technology. The hydrophobic 10% soy stearin coating that created a barrier between iron and iodine in the Double Fortified Salt caused the iron premix to float in water. This problem initially affected the large-scale implementation of the salt fortification program in India. To mitigate this time-sensitive scale-up challenge: First, the iron premix samples were obtained from the industrial scale-up pilot studies in India, evaluated for the impact of the amount of coating material, type of formulation, amount of titanium dioxide used for color masking. Second, we studied the effect of change in the composition of the coating, from 10% soy stearin to a double coat with 5% hydroxypropyl methylcellulose and 5% soy stearin or 10% soy stearin and 1% lecithin mixture, on particle density, floating or sinking property of the iron premix, and on the stability of iodine in the Double Fortified Salt (DFS). Finally, the extruded iron premix was color masked with 25-35% of titanium dioxide. It was observed that the hydrophobic nature and the amount of soy stearin used for coating caused the floating issue. The double coating with 5% hydroxypropyl methylcellulose and 5% soy stearin was preferred because lecithin in soy stearin enhanced the moisture-aided adverse interaction between iron and iodine. Shelf-life storage studies proved over 80% iodine retention after 1-year of storage in the Double Fortified Salt formulated with iron premix double-coated with hydroxypropyl methylcellulose and soy stearin. This proffered solution enabled the full implementation of the double fortification program in India.