The aim of this work was to develop prediction models for shape and size of ca-alginate macrobeads produced through extrusion-dripping method. The relationship between the process variables on the shape and size of the alginate drops before and after gelation was established with the aid of image analysis. The results show that a critical Ohnersorge number (Oh)>0.24 was required to form spherical beads. The shape transition of ca-alginate beads could be typically distinguished into three phases along the collecting distance and it was affected by the combined influence of the solution properties, the collecting distance and the drop size. Mathematical equations and a master shape diagram were developed to reveal a clear operating region and the overall process limits within which spherical ca-alginate beads could be formed. In terms of bead size, the overall size correction factor (K) which accounted for the liquid loss factor (k(LF)) and the shrinkage factor (k(SF)), varied between 0.73 and 0.85 under the experimental conditions. The size prediction model correlated well with the experimental data. The approach and the outcome could be used as a model to develop prediction tools for similar bead production systems.

Alginate hydrogel beads are widely used as an encapsulation medium for biomedical, bioprocessing, and pharmaceutical applications. The size and shape of the beads are often critically controlled since in many usages the beads are monodisperse in size and spherical in shape. Extrusion dripping is a well‐known method to produce alginate beads. Nevertheless, the production of beads of desired size and spherical shape is often achieved based on one's experience or trial and error. An overview is provided on alginate properties, formulation and preparation of alginate and gelling solutions, production conditions, and post‐production treatment that may influence the bead size and shape. Various methods of bead size and shape measurement are also discussed.

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Effect of formulation of alginate beads on their mechanical behavior and stiffness. AbstractThe aim of this work was to determine the effect of formulation of alginate beads on their mechanical behavior and stiffness when compressed at high speed. The alginate beads were formulated using different types and concentrations of alginate and gelling cations and were produced using an extrusion-dripping method. Single wet beads were compressed at a speed of 40 mm/min, and their elastic limits were investigated, and the corresponding force versus displacement data were obtained. The Young's moduli of the beads were determined from the force versus displacement data using the Hertz's contact mechanics theory. The alginate beads were found to exhibit plastic behavior when they were compressed beyond 50% with the exception of copper-alginate beads for which yield occured at lower deformation. Alginate beads made of higher guluronic acid contents and gelling cations of higher chemical affinity were found to have greater stiffness. Increasing the concentration of alginate and gelling ions also generated a similar effect. At such a compression speed, the values of Young's modulus of the beads were found to be in the range between 250 and 900 kPa depending on the bead formulation.