The method for manufacturing Calcium Gluconate involves the production of Gluconic Acid as a Raw Material that is subsequently processed to Calcium Gluconate.
 
There are three processes for the production of Gluconic Acid.  First, glucose is converted to Gluconic Acid by standard Aerobic Fermentation. Secondly, glucose is converted to Gluconic Acid by use of Glucose Oxidase and Catalase (to degrade Hydrogen Peroxide). In the third process, the starting material is Sodium Gluconate or Glucono-delta-lactone, rather than Glucose. Sodium Gluconate is converted to Gluconic Acid by the use of a cat-ion exchange resin and Glucono-delta-lactone is converted to Gluconic Acid by Hydrolysis.

Calcium Gluconate is prepared from the Gluconic Acid by the addition of Calcium Carbonate or Calcium Hydroxide. The Calcium Gluconate solution may be crystallized and dried to yield Calcium Gluconate (Monohydrate) or dried without crystallization to yield Calcium Gluconate (Anhydrous). It may be prepared by Fermentation method or Electrolysis method.


Fermentation Method

The production of Calcium Gluconate by Aspergillus Niger is investigated in Rolling Shaker, Shake Flask, Air-Lift Reactor and Stirred Reactor. Growth pattern of fermentation conditions determine the yield of the product. High Calcium Gluconate production is achieved in an Air-Lift Reactor with pellet form of cell growth at moderate specific growth rate and Biomass concentration.     

In another variation of Air-Lift Reactor, when Calcium Carbonate is confined to a Cellulose Membrane, Calcium Gluconate production is Maximum. At higher specific growth rate, obtained in Shake Flask, despite the formation of Cell Pellets, product formation is low. Physical separation of particulate Calcium Carbonate and growing cells favour Product Formation. In Stirred Reactor Pulpy Mycelial growth is obtained and Calcium Gluconate production is poor.

The patent process is Eco-Friendly, low energy consuming and highly Competitive. This is a good process for converting Glucose to Gluconates in terms of capacity. Gluconates have several established pharmaceutical and other industrial applications. Calcium salts are used for oral or injectable supplement for humans as well as animals.

Electrolysis Method

Calcium Gluconate is produced by the Electrolytic Oxidation of Glucose dissolved in Sodium Bromide Solution used as Electrolyte in a Cell having Graphite Electrodes. Gluconic Acid formed is then Neutralised by the suspended Calcium Carbonate present in the Electrolyte. Formed Calcium Gluconate in the Electrolyte is recovered by cooling the mother liquor obtained after recovery of the product is continuously reused in further batches.

The method for manufacturing Calcium Gluconate involves the production of Gluconic Acid as a Raw Material that is subsequently processed to Calcium Gluconate.
 
There are three processes for the production of Gluconic Acid.  First, glucose is converted to Gluconic Acid by standard Aerobic Fermentation. Secondly, glucose is converted to Gluconic Acid by use of Glucose Oxidase and Catalase (to degrade Hydrogen Peroxide). In the third process, the starting material is Sodium Gluconate or Glucono-delta-lactone, rather than Glucose. Sodium Gluconate is converted to Gluconic Acid by the use of a cat-ion exchange resin and Glucono-delta-lactone is converted to Gluconic Acid by Hydrolysis.

Calcium Gluconate is prepared from the Gluconic Acid by the addition of Calcium Carbonate or Calcium Hydroxide. The Calcium Gluconate solution may be crystallized and dried to yield Calcium Gluconate (Monohydrate) or dried without crystallization to yield Calcium Gluconate (Anhydrous). It may be prepared by Fermentation method or Electrolysis method.


Fermentation Method

The production of Calcium Gluconate by Aspergillus Niger is investigated in Rolling Shaker, Shake Flask, Air-Lift Reactor and Stirred Reactor. Growth pattern of fermentation conditions determine the yield of the product. High Calcium Gluconate production is achieved in an Air-Lift Reactor with pellet form of cell growth at moderate specific growth rate and Biomass concentration.     

In another variation of Air-Lift Reactor, when Calcium Carbonate is confined to a Cellulose Membrane, Calcium Gluconate production is Maximum. At higher specific growth rate, obtained in Shake Flask, despite the formation of Cell Pellets, product formation is low. Physical separation of particulate Calcium Carbonate and growing cells favour Product Formation. In Stirred Reactor Pulpy Mycelial growth is obtained and Calcium Gluconate production is poor.

The patent process is Eco-Friendly, low energy consuming and highly Competitive. This is a good process for converting Glucose to Gluconates in terms of capacity. Gluconates have several established pharmaceutical and other industrial applications. Calcium salts are used for oral or injectable supplement for humans as well as animals.

Electrolysis Method

Calcium Gluconate is produced by the Electrolytic Oxidation of Glucose dissolved in Sodium Bromide Solution used as Electrolyte in a Cell having Graphite Electrodes. Gluconic Acid formed is then Neutralised by the suspended Calcium Carbonate present in the Electrolyte. Formed Calcium Gluconate in the Electrolyte is recovered by cooling the mother liquor obtained after recovery of the product is continuously reused in further batches.