Working name: Cave of Steel

TL;DR – Time-Release Protein for Bodybuilders

💡 Goal: Reduce meal frequency while maintaining stable blood protein levels for muscle growth.

🔬 How? Encapsulate protein powders (yeast, pea, BCAA, etc.) inside biodegradable agar microspheres suspended in a jelly matrix. Different sphere sizes and cross-linking control release timing.

🕒 Comparison of Protein Delivery:

• Traditional 3 Meals → Spikes & crashes in blood protein.
• Frequent Meals & Shakes → More stable, but requires constant eating.
• Time-Release Protein → Slow, sustained release from a single dose.

⚙️ Techniques for Controlled Release:
✅ Different Microsphere Sizes → Small spheres digest fast, large ones release slowly.
✅ Brine Cross-Linking (NaCl, CaCl₂) → Strengthens gel, slows digestion.
✅ Agar Jelly Matrix → Further delays breakdown, mimicking multiple meals.

📈 Expected Benefit: Fewer meals, steady protein supply, better muscle recovery & growth. 🚀

Key Blood Tests for Amino Acid Uptake

1. Plasma Amino Acid Profile (Comprehensive Amino Acid Panel)
   • Measures individual amino acid levels in the blood, showing which ones have increased after eating fish.
   • Can indicate protein metabolism efficiency and deficiencies.
2. Blood Urea Nitrogen (BUN) Test
   • Measures nitrogen waste from protein metabolism.
   • If amino acids are being metabolized, BUN may rise slightly.
3. Serum Albumin & Total Protein Test
   • Reflects protein status over time, but won’t change much immediately after a meal.
4. Insulin & Glucose Levels
   • Protein stimulates a mild insulin response, which facilitates amino acid uptake into tissues.
5. Branched-Chain Amino Acids (BCAA) Test (Leucine, Isoleucine, Valine)
   • Useful if you’re monitoring muscle metabolism or recovery.

A plasma amino acid profile is the most direct test for seeing how your body absorbs amino acids after a fast. A muscle biopsy with tracer studies could be used to calculate protein update.

Micro Sphere Science

1. Microsphere Basics

Microspheres are small, spherical particles (typically 1–1000 µm in size) that encapsulate a substance for controlled release over time. The release rate depends on factors like polymer composition, degradation rate, and diffusion properties.

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2. Biodegradable Polymers for Microspheres

For time-release protein, you’d need a biodegradable, biocompatible polymer. Vegan options are Alginate or Agar

Agar

• Origin: Extracted from red algae (seaweed). 
• Type: A reversible hydrocolloid, meaning it can transition between gel and sol (liquid) states by heating and cooling. Gelation: Gels by cooling and forms a firm, elastic gel. Solubility: Insoluble in cold water but dissolves in boiling water. 
• Applications:
  • Food Industry: Used as a stabilizer, thickener, and gelling agent in various foods, including pie fillings, icings, and desserts. 
  • Microbiology: Used as a growth medium for bacteria and other microorganisms. 
  • Dentistry: Used as a reversible hydrocolloid for dental impressions. 
• Flexibility: Agar has higher flexibility compared to alginate. 

Alginate

• Origin: Extracted from brown algae (seaweed). 
• Type: An irreversible hydrocolloid, meaning it cannot revert back to a sol state once gelled. Gelation: Gels through a chemical reaction, typically by crosslinking with calcium ions. Solubility: Slowly soluble in water, forming a viscous, colloidal solution. 
• Applications:
  • Food Industry: Used as a thickener, stabilizer, and emulsifier in various foods, including sauces, dressings, and ice cream. 
  • Pharmaceuticals: Used in drug delivery systems and wound dressings. 
  • Dentistry: Used as an irreversible hydrocolloid for dental impressions. 
  • Biomedical Applications: Used in tissue engineering and drug delivery. 
• Flexibility: Alginate has lower flexibility compared to agar. 

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3. Protein Release Mechanisms

Microspheres release their contents via:

1. Diffusion – Protein slowly leaks out from the polymer matrix.
2. Surface Erosion – The polymer breaks down over time, releasing protein.
3. Bulk Degradation – The microsphere degrades completely, releasing its load.

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4. Manufacturing Methods

To encapsulate protein, you can use:

• Ionic Gelation (for agar and alginate) – Uses calcium or tripolyphosphate for crosslinking.

Each method affects protein stability, which is critical since heat or solvents can denature proteins.

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5. Application to a Time-Release Protein Supplement

To optimize for bodybuilders:
✅ Use multi-phase release microspheres (some fast, some slow) to maintain steady blood amino acid levels.
✅ Combine fast-releasing whey peptides with slow-releasing encapsulated proteins (like casein or leucine-enriched microspheres).
✅ Consider pH-sensitive coatings so digestion occurs gradually through the GI tract.

Cave of Steel Recipe

Step 1: Prepare Protein-Filled Microspheres

Ingredients for Microspheres:

• 2g Alginate powder (low-gelling temperature for better protein preservation)
• 100mL Filtered water
• 5g Yeast protein isolate
• 5g Pea protein
• 3g BCAA (2:1:1 ratio)
• 2g Omega-3 powder
• 1g Bromelain powder (only added after cooling slightly)
• Cold oil bath (e.g., vegetable oil chilled in the freezer for 1 hour)
• Brine Solution (5–10% NaCl or 0.5–2% CaCl₂ solution)

Procedure:

1. Heat water to 85–90°C and dissolve the Alginate powder while stirring.
2. Slowly mix in protein powders, BCAAs, bromelain powder and omega-3, ensuring even distribution.
3. Let the solution cool to 40–50°C, then stir in bromelain powder (to prevent protein breakdown at high heat).
4. Using a pipette or syringe, drop the mixture into the cold oil bath—this will cause the Alginate solution to form spheres.
5. Allow spheres to set for 5–10 minutes, then rinse with cold water and store in a cool place.
6. Remove microspheres and immediately submerge in the brine solution for 10–30 minutes.
7. 5% NaCl solution → Mild cross-linking (firmer but still soft).
8. 0.5–2% CaCl₂ solution → Stronger cross-linking (slower breakdown).
9. Rinse with cold water to remove excess salts.
10. Store in the refrigerator before adding to the agar jelly matrix.

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🔹 Step 2: Prepare the Agar Jelly Matrix

Ingredients for Jelly Base:

• 3g Agar powder
• 250mL Filtered water
• 1 tbsp Coconut powder (for texture and taste)
• 1 tsp Electrolyte powder

Procedure:

1. Heat water to 85–90°C and dissolve agar powder.
2. Stir in coconut powder and electrolyte powder for added hydration benefits.
3. Let cool slightly (to about 50°C) before pouring into molds.

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🔹 Step 3: Assemble the Final Product

1. Pour half of the jelly mixture into a mold.
2. Evenly distribute the protein-filled microspheres throughout the jelly.
3. Pour the remaining agar mixture on top to fully encapsulate the microspheres.
4. Allow to set at room temperature for 30 minutes or refrigerate for a firmer texture.

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🕒 Expected Impact on Release Rate

Microsphere Type	Without Brine Cross-Linking	With Brine Cross-Linking
Small (100–300µm)	2–4 hours	4–6 hours
Medium (300–500µm)	6–8 hours	8–12 hours
Large (500–800µm)	12+ hours	18–24 hours

By tweaking the salt concentration and soaking time, you can fine-tune the release rate of amino acids into the bloodstream.

Idea 250,311 Time released Protein Jellies

Caves of Steel; Protein

Introduction

TL;DR “A plant-based, time-release protein jelly ball designed for athletes and bodybuilders. Made from yeast and plant proteins with a complete amino acid profile, it delivers a sustained release of essential nutrients for muscle growth and recovery. Encapsulated in an eco-friendly, edible, or biodegradable shell, this protein-packed snack eliminates the need for constant eating while maximizing muscle protein synthesis. Fortified with BCAAs, digestive enzymes, and key micronutrients, it provides a steady stream of fuel for peak performance.”

Table of Contents

URS
Physics
Free Body Diagram
Design
BOM
Electronics
Code
Modeling
Fabrication
How to make Yeast Protein Isolate
Guides
Notes
Contact

URS

User Requirement Specifications
A list of requirements that need to be met. Posted to GitHub

Constraints	Approach	Achieved
Size:	4g – 8g
Shape:	Mouthsize
Cost:	<$2/10g protein
Packaging	Environmentally Sustainable
Temperture Range	32F/0°C-104°F/40°C
Protein	~

Physics

Physics
A list of formulas with math that should be benifical for the objective. Posted to Reddit r/physics r/math r/engineering

FBD

Free Body Diagram
Is a simple graphical illustration used to visualize the applied forces, moments, and resulting reactions on a body in a given condition. Super simple geometric shapes, arrows, and stick figures. Post on Instagram, Pinterest, Twitter

Design

Design
A plan or drawing produced to show the look and function or workings of the object before it is built or made. All components are labeled.

BOM

Bill of Materials || BOM
Is a list of parts needed for the fabrication of the design. This will included Name, with URL to source, Quantity of need parts, total cost (qty x price), and a section for notes. If possible use a shortened URL.

Google Sheet View

Quanity Needed	Item Description	Ordering Link	Quanity (grams)	Cost	Item Cost	Total Cost
300.00	Yeast Protein Isolate		1000	$98.00	$0.10	$29.40
200.00	Pea Protein Isolate	https://a.co/d/chj2ufC	907	$22.45	$0.02	$4.95
100.00	Agarose (or Agar)	https://a.co/d/dubqFOM	500	$27.97	$0.06	$5.59
150.00	Coconut Milk Powder	https://a.co/d/cLFIGTU	907	$24.25	$0.03	$4.01
50.00	Calcium Chloride Solution (1-2%)	https://a.co/d/3wf3lOM	454	$13.49	$0.03	$1.49
100.00	Water					$0.00
30.00	BCAA Powder (Leucine, Isoleucine, Valine)	https://a.co/d/8qoTmkE	500	$22.97	$0.05	$1.38
20.00	Magnesium Citrate (for muscle support)	https://a.co/d/4zSVIkX	907	$26.05	$0.03	$0.57
20.00	Digestive Enzyme Blend (Protease, Bromelain)	https://a.co/d/f9KCQp4	100	$16.19	$0.16	$3.24
20.00	Plant-based Omega-3 (optional)	https://a.co/d/8sGKAw9	130	$26.95	$0.21	$4.15
10.00	Electrolyte Mix (Sodium, Potassium)	https://a.co/d/7reAdJY	210	$11.69	$0.06	$0.56

Directions

Steps
Ingredients (Makes ~10 balls)
Instructions

1. Prepare the Protein Gel Matrix
   1. In a mixing bowl, combine yeast protein, pea protein, BCAA powder, and digestive enzymes.
   2. In a saucepan, heat 100mL water to ~70°C (not boiling).
   3. Sprinkle in agarose (or agar) powder while stirring constantly until fully dissolved.
   4. Slowly whisk in coconut milk powder for structure.
   5. Once smooth, slowly add the protein mix, ensuring even dispersion.
2. Form the Protein Balls
   6. Allow the mixture to cool slightly until it becomes moldable (~50°C).
   7. Scoop into small spheres (about half an egg size) and shape them evenly.
3. Crosslinking for Time-Release
   8. Prepare a saltwater bath using either:
   • 1% NaCl solution (For a mild gel network)
   • 0.1M Calcium Chloride solution (For stronger gel formation)
   9. Submerge the protein balls in the bath for 5-10 minutes.
   10. The crosslinked gel network forms around the protein, controlling its release when consumed.
4. Final Processing & Storage
   11. Remove from the bath and air-dry for 1 hour to set the structure.
   12. Store in a sealed, biodegradable container at room temperature or refrigerate for up to 7 days.

How It Works

• Agarose/Agar gelation + salt crosslinking creates a slow-dissolving structure.
• Calcium/sodium ions reinforce the gel, delaying protein breakdown.
• Yeast protein & BCAAs provide a steady amino acid release for muscle growth.

This method ensures that when the ball is swallowed, it gradually releases protein over several hours instead of being digested all at once.

Would you like modifications for texture, hydration, or storage stability? 

Schematics

Wokwi

Notes

Code

Coding
Is a section holds the Sequence Diagram, link to code repos, and another other notes.

Sequence Diagram

Repo

Notes

Modeling

Modeling
This section holds 3D infomration about your project.

Parametric Model

Revisioning

Notes

Fabrication

Fabrication
This area holds a list of steps to complete the fabrication. This section is also called ‘directions’. Each number should represent roughly one hour of work.

• [ ] 1. Cut
• [ ] 2. Model
• [ ] 3. Test

Revisioning

Notes

Guides

Guides
This section is for a guide on how to assemeble, use, and operate the build. Ideally URL to google docs and Youtube Videos.

How to make Yeast Protein Isolate

The goal is to seperated the protein from other yeast components, such as fiber, carbohydrates, and nucleotides. Below is a step-by-step lab-scale protocol to extract high-purity yeast protein isolate from brewer’s yeast or nutritional yeast.

Overview of the Process

1. Yeast Cell Disruption – Break open yeast cells to release intracellular proteins.
2. Protein Extraction – Solubilize the proteins while removing unwanted components.
3. Purification – Precipitate and separate proteins from nucleotides and cell debris.
4. Drying & Storage – Convert the isolate into a powdered form for storage.

Step-by-Step Protocol

1. Materials & Equipment

Ingredients:

• Brewer’s yeast or nutritional yeast (deactivated yeast)
• Alkaline buffer (NaOH, pH 9–11) (to solubilize proteins)
• Acid solution (HCl, pH 4.5–5.5) (for isoelectric precipitation)
• Distilled water
• Ethanol (optional, for further purification)

Equipment:

• Magnetic stirrer & hot plate
• pH meter
• Centrifuge (5,000–10,000g)
• Ultrasonicator or homogenizer (for better cell disruption)
• Buchner funnel & vacuum filtration
• Freeze-dryer or spray dryer (for drying the final protein powder)

2. Yeast Cell Disruption

(Goal: Break open the yeast cells to release proteins)

1. Suspend yeast cells in 3-5x their weight in distilled water.
2. Adjust pH to ~9–11 using NaOH (alkaline conditions help break down cell walls).
3. Heat to ~50°C while stirring continuously for 30–60 minutes.
4. Use an ultrasonicator (if available) to mechanically disrupt the cells (10–15 minutes in pulses).

• Alternative: High-speed homogenization or bead beating.

1. Centrifuge at 10,000g for 10 minutes to remove cell debris.

• The supernatant contains solubilized proteins.

3. Protein Purification (Isoelectric Precipitation)

(Goal: Extract pure protein by pH-controlled precipitation)

6. Adjust the pH of the supernatant to 4.5–5.0 using diluted HCl. This is the isoelectric point of yeast protein, where it precipitates out of solution.
7. Stir for 30 minutes at room temperature, allowing protein aggregation.
8. Centrifuge at 10,000g for 10 minutes and collect the protein pellet.
9. Wash the pellet with cold ethanol or acetone to remove residual nucleotides and lipids.
10. Resuspend in neutral pH buffer (pH ~7) and dialyze overnight to remove any residual salts.

4. Drying & Storage

(Goal: Convert the isolate into powder form)
11. Freeze-dry or spray-dry the protein suspension to produce a powder.

• Alternative: Dry in an oven at 40–50°C under vacuum.

1. Store in an airtight container at room temperature.

Expected Yield & Protein Content

• Final product: Yeast protein isolate powder (~75–85% protein)
• The yield depends on the efficiency of cell lysis and precipitation.
• A successful process will remove nucleotides, cell debris, and fiber, leaving mostly soluble yeast proteins.

Final Notes

• Adjust pH carefully – Over-acidification can degrade proteins.
• Ultrafiltration (optional) – If a dialysis membrane (10 kDa MW cutoff) is available, it can further purify the protein.
• Alternative Methods – Enzymatic hydrolysis (using proteases) can improve protein release but requires optimization.

Assemebly Guide

Operating Guide

Notes

Notes

Notes
Here is a section for basic notes, questions, and research.

Recipe

Cost to Make

Affordable Bulk Ingredient Pricing and Production Cost Estimates

Key Ingredients and Bulk Pricing

For a plant-based time-release protein ball, the main cost drivers are its protein sources and binding agents. Sourcing in bulk can significantly reduce costs for each ingredient:

• Yeast Protein Isolate – In bulk, yeast-derived protein (75–80% protein) is available around $28–$35 per kg (minimum ~25 kg order) . This is a novel protein source; small-scale retail options (like specialty “single-cell” yeast protein powders) tend to be much pricier or hard to find. To keep costs low at home, some makers substitute nutritional yeast or other fermented protein, though those have lower protein content.
• Pea Protein Isolate – Pea protein is one of the most affordable plant isolates. Large food manufacturers can get low-grade pea protein (∼84% protein) for about $5.9 per kg from Chinese suppliers . Even premium pea protein made in North America/Europe costs only ~$2–3 more per kg , so roughly $8–$9/kg at the high end. In smaller quantities (e.g. 20–25 kg bulk bags) available online, prices are about $8–$10/kg . Home users buying retail (1–5 kg at a time) might pay closer to $10–15/kg, but pea protein remains one of the cheapest protein powders available.
• Agar or Agarose – Agar (food-grade seaweed gelatin alternative) can be obtained for ~$10–$12 per kg in bulk lots . Higher-quality agar or certain grades can cost $20–30/kg , but for functional food use, the lower-cost bulk options are suitable. Agarose (a purified form) is much more expensive (hundreds of dollars per kg, used mainly for labs ) and would not be cost-effective for food production. Using standard agar powder provides the gelling needed for time-release at a tiny fraction of the cost of agarose.
• Coconut Milk Powder – Bulk dried coconut milk powder (for healthy fats and flavor) typically ranges around $5–$15 per kg depending on quality and order size. Suppliers list prices as low as ~$4–$5/kg for large orders of basic coconut powder, up to ~$10–$14/kg for organic or smaller orders . For example, one bulk supplier quotes $4.23–$13.76/kg with a low minimum order . Home cooks buying retail packs (e.g. 1 kg bags) may pay a bit more (often $15–$20 per kg for name brands), but sourcing generic bulk coconut powder can significantly cut costs.
• Crosslinking Agents (e.g. Calcium Chloride) – These functional additives are very inexpensive. Calcium chloride (food grade), often used to crosslink gels (e.g. in alginate spheres or to strengthen an agar gel), costs only a few cents per kilogram at industrial scale. In pallet quantities (1+ ton) it can be as low as $0.10–$0.13 per kg . Even on a smaller scale, it’s cheap: for instance, a 5 lb (2.27 kg) food-grade CaCl₂ bag is about $23 (≈$4.60/lb, or $10/kg) , and bigger 40–50 lb sacks bring it under $7/kg . Since each protein ball uses only a fraction of a gram of CaCl₂ (if any – some recipes might not require it if using agar alone), the cost per ball from crosslinkers is practically negligible (well under $0.01). Other agents like calcium lactate or plant-based crosslinkers have similarly minor cost impact at the usage levels needed.

Minimal-Cost Sustainable Packaging Options

To keep packaging economical and eco-friendly, the strategy is to use simple, minimal material packaging that is biodegradable or recyclable:

• Bulk or Multi-Pack Packaging: Instead of individually wrapping each ball (which adds cost and waste), pack multiple protein balls together in one pouch or box. For example, a compostable stand-up pouch made of plant-based film or paper can hold a dozen balls. Such pouches purchased in bulk cost only $0.05–$0.10 each (even less for very large orders), only adding a fraction of a cent per ball. A simple recycled cardboard box or paper sleeve is similarly just a few cents per unit when ordered by the thousand.
• Biodegradable Films or Wrappers: If individual wrapping is required (for portion control or shelf life), using a biodegradable plastic film (e.g. PLA or cellophane) keeps it sustainable. These can cost slightly more than regular plastic but still on the order of a few cents per wrapper in bulk. For instance, small compostable baggies run around $0.06 each in wholesale . Edible rice paper wraps are another low-cost option for an inner lining, though usually an outer package is still needed for protection.
• Recycled or Reusable Materials: Utilizing 100% recycled paper for labels or boxes is both eco-friendly and cheap. Many sustainable packaging options (recycled paperboard, biodegradable inks, etc.) only raise packaging costs by ~25% or less compared to conventional plastics . Given the small absolute cost (a few cents), this premium is minor. Overall, a minimal, sustainable package for one protein ball can be kept under $0.03–$0.05 per ball at scale by using bulk-purchased compostable bags or recycled paper wrapping. This ensures the packaging cost doesn’t negate the affordability of the product.

Cost per Protein Ball: Home-Scale vs. Large-Scale Production

Home/Kitchen-Level Production: Making these protein balls at home or in a small test kitchen will have higher ingredient costs (due to buying smaller quantities at retail prices) and less efficiency, but it can still be affordable. An approximate cost breakdown per ball (assuming ~30g ball with ~10g protein) might be:

• Ingredients: Roughly $0.40–$0.60 per ball in raw ingredients at home. This assumes using retail protein powder (pea protein ~$10–15/kg and possibly a small supply of yeast protein or a substitute). For example, 15g of protein powder might cost $0.20–$0.30 (pea protein at $12/kg is $0.018/g, so 10g = $0.18; yeast isolate if used could add a bit more) . Add a few grams of coconut milk powder ($0.05) and a gram of agar ($0.01), plus negligible CaCl₂ (<$0.01). Any flavorings/oats or extras would add a few more cents. Overall, $0.50 each is a reasonable small-batch estimate.
• Packaging (if any): At home, one might not individually wrap the balls at all (stored in a reusable container, effectively $0 packaging cost). If you do wrap them (say in wax paper or small compostable baggies), it might add another 5–10 cents per ball in small quantities. So with packaging, perhaps ~$0.60 each total.
• Labor/Overhead: Your own labor isn’t typically “charged,” but it’s worth noting that making small batches is time-intensive. There are no real economies of scale – you still have to mix, form, and gel each batch manually. However, for a home project or recipe, the cost per protein ball well under $1.00 is far cheaper than store-bought protein snacks (which often cost $2–$3 each retail). Homemade recipes for protein bars/balls commonly report costs around $0.50–$0.70 each in ingredients , aligning with this estimate.

Large-Scale Production (Co-Packer): Outsourcing to a co-packer for mass production unlocks bulk pricing and efficient manufacturing, dramatically lowering the unit cost. In large volumes (tens of thousands of balls per run), you can expect:

• Bulk Ingredient Costs: Approximately $0.10–$0.20 per ball. With bulk rates, the protein component becomes very cheap – e.g. 10g of pea protein at ~$6/kg is only ~$0.06 , and even yeast protein at ~$30/kg contributes about $0.15 for 5g. The other ingredients (agar, coconut powder, etc.) collectively add just a few cents (e.g. 1g agar at $0.01, 3g coconut powder maybe $0.02). In total, raw ingredients per ball in mass production can be on the order of a couple of dimes or less. Maintaining nutritional quality doesn’t significantly raise costs here since these core ingredients are still relatively inexpensive protein and fiber sources.
• Manufacturing & Labor: A co-packer will charge for processing, which might add roughly $0.05–$0.10 per unit at scale. This covers automated mixing, forming the balls, gelation time, quality control, etc. High-volume equipment (like continuous mixers and formers, and batch setting of the agar gels) means the labor cost per ball is very low compared to hand-rolling at home. There may be some overhead for R&D, quality testing, and the co-packer’s margin, but these are spread over large quantities.
• Packaging: Using the minimal packaging approach described, packaging might add $0.03–$0.05 per ball in large-scale production. For instance, if 6 balls are packed in one biodegradable pouch that costs $0.10, that’s under $0.02 per ball. Even individually flow-wrapping each ball in compostable film (a few cents each) keeps it in this range. Bulk purchasing of packaging (thousands of units) drives this cost down.

Taking all these into account, each protein ball could cost on the order of $0.20–$0.30 at scale (rough estimate) to produce with a co-packer. This assumes aggressive bulk pricing and a simple packaging format. Even with some variance (say a more expensive recipe or a co-packer with higher fees), it’s likely well under $0.50 per ball. This low production cost meets the goal of affordability while delivering a high-protein, high-quality product. The combination of inexpensive plant proteins (pea, yeast) and low-cost binders allows the product to remain nutritionally rich (complete amino acid profile from yeast+pea, plus fiber from agar and healthy fats from coconut) without breaking the bank.

Summary – Affordability with Functional Nutrition

By strategically sourcing plant-based ingredients in bulk and opting for simple, sustainable packaging, a time-release protein ball can be produced very economically. Pea and yeast protein isolates provide high-quality protein at low cost per unit  , and agar-based gelation creates the desired slow-release effect with minimal expense. At a home-kitchen level, one might spend on the order of cents to a few dimes per ball in ingredients, whereas a scaled-up operation with a co-packer can drive this below a quarter per ball. Throughout scaling up, we’ve prioritized keeping costs low without sacrificing nutrition – the final product remains a nutrient-dense, plant-based snack, just made in a wallet-friendly way. By maintaining simplicity in formulation and packaging, it’s feasible to achieve an affordable cost per protein ball in both small batches and large-scale production, all while using sustainable practices and high nutritional quality ingredients.

Sources: Bulk ingredient pricing and supplier data for yeast protein, pea protein, agar, etc.    ; cost of crosslinkers like calcium chloride  ; examples of sustainable packaging costs .

Recipe

Nutrition Label

Serving Ingredient Label for Plant-Based Time-Release Protein Ball

(Per Serving – 1 Ball, Approx. 40g)

Macronutrients

• Calories: ~120 kcal
• Protein: 15g
• Total Fat: 3g
• Saturated Fat: 2g
• Carbohydrates: 5g
• Dietary Fiber: 1g
• Sugars: 0g
• Sodium: 100mg
• Magnesium: 50mg
• Electrolytes (Sodium & Potassium Blend): 50mg

Amino Acid Content

• Branched-Chain Amino Acids (BCAAs): ~3.5g
• Leucine: 1.8g
• Isoleucine: 1g
• Valine: 0.7g
• Essential Amino Acids (EAAs): 7g

Ingredients:

Yeast Protein Isolate, Pea Protein Isolate, BCAA Powder (Leucine, Isoleucine, Valine), Agarose (or Agar) Gel Matrix, Coconut Milk Powder, Magnesium Citrate, Digestive Enzyme Blend (Protease, Bromelain), Electrolyte Blend (Sodium, Potassium), Plant-Based Omega-3 Powder, Calcium Chloride Crosslinking Solution.

Suggested Use:

Consume 1-5 balls per day, spaced throughout the day to maintain a steady supply of protein and amino acids for muscle growth and recovery. Best taken post-workout or between meals to support sustained muscle protein synthesis.

Would you like a formatted nutrition facts panel or additional adjustments?

Testing Calculations

1. desired release rate would be around 6-8 hours
2. Steady state
3. I’m open to any method of encapsulation
4. Start with theoretical, so it can match it with lab-based approach. Could this be done via blood test?

Controlled Protein Release from Various Encapsulation Matrices

Achieving a steady-state protein release over 6–8 hours requires a near-constant release rate (approximately equal amounts of protein released per hour). In practical terms, if a total dose of protein is encapsulated, the system should deliver roughly one-sixth to one-eighth of the dose per hour to maintain steady levels. Below we compare three encapsulation methods – agar/agarose hydrogels, calcium-alginate beads, and lipid-based microcapsules – in terms of their diffusion-controlled release profiles and how they can be tuned for ~6–8 hour sustained release. We also discuss how each method influences protein digestion and amino acid absorption, followed by laboratory techniques for validating release dynamics.

Diffusion Rates in Different Encapsulation Methods

Agar/Agarose Gel Matrices

Agar and agarose form hydrophilic gel matrices with a mesh-like network that slows the diffusion of proteins. Release from agarose gels is primarily diffusion-controlled: water penetrates the gel, dissolves the protein, and protein molecules diffuse out. To achieve ~6–8 hours of steady release, the gel’s properties (concentration, cross-linking density, and geometry) can be adjusted to modulate the diffusion rate. In general, unmodified hydrogels tend to release their payload relatively quickly, often with an initial “burst” of protein followed by a slower phase . This burst occurs as protein near the surface diffuses out rapidly. Achieving a truly constant (zero-order) release with a simple hydrogel is challenging because as the concentration gradient decreases, diffusion slows. However, by increasing gel concentration (reducing pore size) or by adding interactions between the protein and gel (e.g. using charged or affinity groups in the agarose), one can slow and flatten the release profile . The theoretical release rate can be estimated using Fick’s law: , where D is the protein’s diffusion coefficient in the gel, A is surface area, and ΔC/Δx is the concentration gradient. For a roughly constant release over 6–8h, the system is designed so that as protein diffuses out, the concentration gradient is maintained (for example, by having excess protein in the interior or a large gel volume). In practice, agarose matrices might deliver sustained release on the order of hours; for instance, without special modifications, a significant portion of protein could be released within the first few hours. Methods to extend this include thicker gel pieces or composite gels to slow diffusion. It’s been shown that hydrogels can be engineered to release proteins over several hours or even days by tuning these parameters . Overall, agar/agarose encapsulation can approach the desired 6–8h release window, but extra measures may be needed to minimize the initial burst and maintain a steady diffusion-driven output.

Calcium-Alginate Beads

Calcium alginate beads are formed by ionic cross-linking of alginate (a polysaccharide) with Ca²⁺, creating a gel particle. Their release kinetics are influenced by pH and ionic conditions in the GI tract. In acidic gastric fluid (pH ~1–2), alginate beads remain largely intact and do not dissolve – the alginate’s carboxylate groups protonate and the gel stays solid . This means little protein is released in the stomach (often only a small fraction diffuses out during the first 1–2 hours in gastric conditions). Once the beads move into the higher pH of the small intestine (pH ~6–7.4), the alginate begins to swell and gradually dissociate (Ca²⁺ can be replaced by Na⁺, and the alginate dissolves), allowing the protein to diffuse out quickly  . Typically, standard calcium-alginate beads release most of their payload within 1–2 hours in intestinal conditions, meaning total release may be complete by ~3–4 hours post-ingestion . This is shorter than our 6–8h target. To extend the release, formulation strategies are used: for example, making beads with higher alginate concentration or adding a secondary polymer (like gum arabic or chitosan) to strengthen the matrix. Research shows that using a very high alginate concentration can triple the dissolution time of alginate beads, significantly prolonging release . Likewise, alginate-gum arabic blend beads have achieved ~100% release in about 4 hours, versus ~2 hours for regular alginate . With further optimization (larger bead size, higher polymer content, or coating the beads with an extra diffusion barrier), it’s feasible to approach a 6–8 hour release duration. The diffusion rate in alginate beads is not constant over time: there is often a lag phase in the stomach, then a faster release in the intestine. However, by staggering multiple beads or formulations (some releasing slightly faster, others slower), one could approximate a near steady-state input of protein to the body over 6–8 hours. In summary, calcium-alginate encapsulation is very useful for protecting protein from stomach digestion and targeting intestinal release, and with formulation tweaks it can be tuned for sustained release on the order of several hours.

Lipid-Based Microencapsulation

Lipid-based microencapsulation involves entrapping the protein within a fat/oil matrix or coating – for example, spray-congealed lipid microspheres or liposomes. These systems create a hydrophobic barrier to water ingress, which can markedly slow the release of a hydrophilic macromolecule like a protein. In the digestive tract, lipid capsules tend to melt or erode gradually (especially if solid at body temperature) and may require bile salts to emulsify them, so the release often begins in earnest in the small intestine. A well-formulated lipid microcapsule can achieve very prolonged release: studies have shown that a uniform lipid coating (e.g. using glyceryl behenate or other high-melting lipids) can release protein over 24 hours with minimal initial burst . In contrast, an improperly encapsulated protein (e.g. cracks or non-uniform coating) can cause a large burst release – one experiment saw ~70% of BSA protein release in 30 minutes when the lipid coat was discontinuous . To target a steady 6–8 hour release, the lipid formulation might use medium-chain triglycerides or waxes that soften at 37 °C, combined with stabilizers to avoid a burst. The diffusion rate here is governed by how quickly water can penetrate the lipid matrix and dissolve the protein, and/or how fast the lipid matrix dissolves. Because lipids don’t swell like hydrogels, release can be more zero-order (linear) if the capsule erodes uniformly. In theory, if one has (for example) 100 mg of protein encapsulated and desires ~8 hours of release, the design goal is ~12.5 mg/hour release. By controlling the surface area and thickness of the lipid coat, formulators aim for a roughly constant release rate. Lipid microencapsulation also can slow gastric emptying (since fatty particles linger longer), potentially extending the time window for release. Overall, lipid-based encapsulation is quite effective for sustained release – achieving 6–8h of continuous protein release is well within reach, provided the formulation minimizes any burst phase and that the lipids chosen allow gradual digestion. These systems offer the slowest diffusion rates of the three methods (often the rate-limiting step is lipid digestion), which makes them valuable for prolonging release.

Impact on Protein Hydrolysis and Amino Acid Absorption

Encapsulation not only affects release rate but also where and how the protein is broken down and absorbed in the GI tract. All three methods provide a degree of protection to the protein in the stomach, thereby slowing enzymatic hydrolysis:

• Protection from Gastric Enzymes: Encapsulated protein is less exposed to pepsin in the stomach. For example, alginate beads remain intact in low pH, so the protein isn’t significantly digested during the first couple of hours . Similarly, a lipid coat can prevent stomach acid and enzymes from contacting the protein immediately. This means a larger portion of the protein stays intact until it reaches the small intestine.
• Slower, Sustained Digestion: Because release is gradual, the protein is delivered to digestive enzymes in a metered fashion rather than a large bolus. Enzymatic hydrolysis (by trypsin, chymotrypsin, etc. in the intestine) occurs over an extended period. This prolonged hydrolysis mimics the effect of a “slow-digesting” protein in the diet. A real-world analogy is the difference between whey and casein proteins: whey (not encapsulated) is digested and absorbed quickly, whereas casein clots in the stomach and is digested over many hours. Studies show amino acid levels remain elevated for 4–5 hours after consuming casein, compared to only ~90 minutes for whey – the slow release from casein’s gelled state provides a steady stream of amino acids . Encapsulation systems aim to create that same effect: a steady release of amino acids into the bloodstream over 6–8 hours instead of a sharp spike. This can benefit muscle protein synthesis and overall nitrogen retention by providing a continuous supply of amino acids.
• Site of Absorption: Encapsulation can shift more protein digestion and absorption to the small intestine rather than the stomach. This is generally advantageous, since the small intestine is the primary site for amino acid absorption. For instance, alginate encapsulation is specifically used to protect bioactives through the stomach and release them at a controlled rate in the intestine, which maximizes their bioavailability . By ensuring that proteins (or derived peptides) are mostly released in the intestine, we capitalize on the efficient transport mechanisms there. Each method achieves this to a degree – alginate via pH-triggered release, lipid via delaying release until bile interaction, and agarose by simply slowing transit and diffusion so that much of the protein reaches later sections of the gut.
• Plasma Amino Acid Levels: A direct consequence of slowed release and digestion is that blood plasma amino acid levels rise more gradually and stay elevated longer. Instead of a single large peak in plasma amino acids shortly after ingestion (as would happen with a rapidly absorbed protein), encapsulation yields a flatter curve. This can be confirmed by measuring plasma amino acid concentrations over time. In concept, a well-formulated 6–8h release protein would produce a moderate increase in plasma amino acid levels that persists for the full 6–8 hours, without the steep decline after 1–2 hours seen with fast-release proteins. Such sustained amino acid availability has been demonstrated in studies – for example, volunteers given a “prolonged-release” amino acid formulation still had significantly elevated plasma amino acid levels even 7 hours post-dose . This prolonged presence in blood indicates the intestinal absorption was spread out over time, aligning with the encapsulated release profile.

It’s worth noting that extremely slow release beyond the absorption window of the small intestine could reduce total absorption (since unabsorbed protein reaching the colon may be metabolized by gut bacteria). However, a 6–8 hour timeframe is generally within the transit time of the small intestine for most of the dose. Thus, these encapsulation methods, by modulating release rate, allow more controlled protein hydrolysis and absorption, potentially improving the efficiency of protein utilization and reducing any gastrointestinal side effects (like discomfort or high osmolarity) that a large quick dose might cause.

Lab-Based Validation Techniques

To ensure the theoretical release profiles and absorption effects discussed above occur in practice, researchers use both in vitro tests and in vivo measurements. Key validation methods include:

In Vitro Dissolution Testing

Controlled lab tests can simulate the digestive environment to measure how the encapsulated protein releases over time:

• Simulated Gastric and Intestinal Fluids: The encapsulated protein is placed in simulated gastric fluid (SGF) – typically 0.1 M HCl at pH ~1.2 (often with pepsin enzyme) – for about 2 hours to mimic stomach residence . Then it is transferred to simulated intestinal fluid (SIF) – typically a pH ~6.8–7.4 phosphate or bicarbonate buffer (with pancreatic enzymes like trypsin) – for additional hours to simulate the small intestine . This sequential approach models the pH change and transit of the GI tract.
• Dissolution Apparatus: The test can be done in flasks/shaking incubators or using USP dissolution apparatus (e.g. rotating paddle or basket). The temperature is kept at 37 °C and gentle agitation is applied to simulate peristalsis . At set time intervals, samples of the fluid are taken and analyzed for protein content released. For example, one might sample every 30 minutes initially, then hourly, etc., up to 6–8 hours total.
• Measuring Released Protein: Various assays can quantify the protein in solution – UV absorbance, BCA or Lowry protein assays, or HPLC for specific amino acids/peptides. By plotting cumulative release vs. time, the profile (lag phase, release rate, completion time) can be observed. A successful steady-release formulation would show a relatively linear increase in released protein from 0 to 6–8h (with perhaps a small initial lag or burst). In the case of calcium-alginate beads, in vitro tests often confirm minimal release in SGF (acid) and then rapid release in SIF , matching the pH-responsive design. For lipid encapsulates, these tests might show slow, continuous release in the intestinal phase (and sometimes a reduced release in purely aqueous media unless bile salts are added to mimic fat digestion).
• Interpreting Results: In-vitro dissolution is a critical step to optimize formulations. If the release is too fast (e.g. 100% in 2–3 hours), formulators will adjust the matrix (increase cross-link density, add coating, etc.) to slow it. If there’s too large of an initial burst, they may add a barrier layer or change drying methods. Only once the in-vitro profile shows ~6–8h sustained release under simulated conditions would a formulation move to in vivo testing. This method is relatively low-cost and repeatable, and it provides insight into the mechanism (diffusion vs. erosion) by analyzing the shape of the release curve.

In Vivo Plasma Amino Acid Monitoring

The ultimate test for a sustained-release protein supplement or delivery system is to administer it to a living subject and track how the release translates to absorption. One practical and fairly non-invasive way to do this (especially for nutritional proteins) is by measuring blood amino acid levels over time:

• Study Design: Typically, a group of subjects (human or animal) would consume the encapsulated protein product. For comparison, the same subjects might consume an equivalent dose of unencapsulated (fast-release) protein on a different day. Blood samples are then drawn at regular intervals (for instance, every 30 minutes or hour) for several hours. For a 6–8h release formulation, samples would be taken throughout that period (and possibly a bit beyond, to see when levels return to baseline).
• Measurement: The plasma is analyzed for amino acid concentrations. This is often done with high-performance liquid chromatography (HPLC) or mass spectrometry after deproteinizing the sample. Researchers may look at total amino acids, essential amino acids (EAAs), or specific key amino acids (like leucine) as indicators of protein absorption.
• Expected Outcomes: An effective sustained-release encapsulation will produce a flatter, prolonged plasma amino acid curve compared to a rapid-release protein. For example, one would expect a lower peak concentration but a longer duration of elevated amino acids. Empirical studies support this; in trials with slow-digesting proteins or specially engineered amino acid mixtures, the plasma amino acid levels can remain significantly elevated even 7–8 hours after ingestion . In contrast, a fast protein might spike at 1–2 hours and then drop near baseline by 4–5 hours. By comparing these profiles, one confirms the in vivo “release rate.” The area under the curve (AUC) is also informative – a similar AUC between slow and fast forms indicates total absorption is the same, just the timing differs.
• Interpretation for Hydrolysis: If plasma amino acids rise slowly and stay steady, it confirms that the protein is being hydrolyzed and absorbed gradually, matching the design goal. This also indirectly confirms that the encapsulation protected the protein from immediate digestion and instead released it progressively. In some cases, instead of amino acids, researchers might measure the appearance of peptide fragments or even the intact protein (if a peptide drug intended to be absorbed whole) in the blood. However, for dietary proteins, amino acid levels are the clearest indicator of absorption dynamics.
• Feasibility and Significance: Measuring blood amino acids is quite feasible and is commonly done in nutrition science. It requires blood draws and analytical equipment but provides direct evidence of the formulation’s performance in vivo. Such tests bridge the gap between in vitro results and real physiological outcomes. If an encapsulated protein is intended to have a certain effect (e.g. muscle recovery or satiety), demonstrating sustained amino acid release in the bloodstream over 6–8 hours strongly supports its efficacy. Moreover, these tests can reveal if there are any unexpected issues in vivo (for instance, if the formulation caused delayed gastric emptying, the onset of absorption might be later than predicted, etc.). Adjustments can then be made accordingly.

In summary, a combination of in vitro dissolution studies and in vivo plasma amino acid monitoring provides a robust validation of sustained-release protein formulations. The in vitro tests ensure the encapsulation method achieves the desired 6–8 hour release profile under controlled conditions, and the in vivo tests confirm that this translates to prolonged protein digestion and absorption in a living system. Together, these techniques help refine the encapsulation approach (agarose hydrogel, alginate beads, or lipid microcapsules) to reliably deliver a steady stream of amino acids over several hours, enhancing the nutritional or therapeutic benefits of the protein.

Sources:
1. Hettiaratchi et al. (2018) – discussion of protein diffusion through hydrogels and methods to modulate release  .
2. Voo et al. (2015) – note on typical calcium-alginate bead dissolution times (1–2 h in intestinal fluid) and strategies to prolong release  .
3. Mohamed et al. (2017) – alginate/gum Arabic beads showing ~4 h release and pH-dependent swelling behavior (minimal release in pH 1.2)  .
4. Ribeiro Dos Santos et al. (2002) – lipid-coated BSA microcapsules with either burst release (70% in 30 min) or sustained 24 h release depending on coating uniformity .
5. Healthline (2019) – summary of casein vs whey absorption: casein provides ~5 h of amino acid release due to stomach gelation, vs ~90 min for whey  .
6. RSC Food & Function Review (2024) – encapsulation in food applications aims to protect actives through gastric phase and target release in intestine for better bioavailability .
7. Scheinin et al. (2020) – study showing prolonged-release amino acid formula keeps plasma levels elevated at 7 h post-ingestion (used to demonstrate sustained absorption)  .

Edible Packaging

That’s a great direction—creating a sustainable, jelly-based protein ball with eco-friendly packaging could set your product apart. Here are a few ways to achieve this:

1. Edible Packaging

If you want to eliminate waste entirely, you can explore edible packaging made from natural, food-grade materials:

• Seaweed-based films (e.g., Notpla, Evoware): These dissolve in water and can hold semi-solid jellies.
• Rice paper or starch-based casings: Similar to mochi wrappers, these would dissolve in the mouth.
• Agar or alginate membranes: Used in some molecular gastronomy techniques to create spheres of liquid (like boba).

1. Biodegradable Wrappers

If an edible shell isn’t feasible, opt for compostable wrappers:

• Beeswax wraps or plant wax coatings: These can hold the jelly without plastic.
• Cassava starch-based film: Used in Indonesia for plastic-free packaging.
• Banana leaves or bamboo paper: Common in Asian food packaging and compostable.

1. Recyclable or Reusable Containers

If the product needs a solid container:

• Molded fiber cups: Like the ones used for biodegradable coffee lids.
• Glass jars with a deposit system: Customers return them for a refill or deposit refund.
• Paper-based biodegradable cups: Lined with plant wax instead of plastic.

Practical Challenges

• Shelf life & moisture retention: If using compostable or edible packaging, ensuring freshness will be key.
• Sealing & transport: A sturdy, leak-proof design is needed if the product is liquid or soft.
• Consumer education: Many people aren’t used to edible packaging, so marketing will need to highlight its benefits.

Would you like help exploring a specific material or manufacturing process for a prototype?

Notes

This video is based on an error. He is citing a paper that measured protein intake in g/kg, but he keeps phrasing the same or similar numbers from the paper as being g/lbs. The paper ultimately recommended 1.5g/kg, not 1.3g/lbs. 1.5g/kg is closer to 0.7g/lbs…