SIMULATION OF WATER TRANSFER IN SPRAY DRYING

ABSTRACT

A drying method by desorption in a water activity meter (Aw-meter) was used to simulate the conditions of spray drying and to determine the water transfer inside the dairy concentrate to the surface (first transfer) and from the surface to the drying air (second transfer). A limitation in the first transfer decreased the second transfer. The percentage of bound or unbound water was determined as a function of the nature of concentrates (milk concentrate, high protein milk concentrate, native casein suspension, caseinate dispersion, ) before drying. The water transfer in the different dairy concentrates during drying was shown as a function of the environment of their water content and the nature of the constituents. The percentage of bound or unbound water and the drying behavior of any dairy concentrate could be determined in 4 to 6 hours and might predict spray drying behavior in an industrial tower.     

DEHYDRATION BY DESORPTION AND BY SPRAY DRYING OF DAIRY PROTEINS: INFLUENCE OF THE MINERAL ENVIRONMENT

ABSTRACT

A drying method by desorption in a water activity meter was used to simulate the conditions of spray drying and to determine the water transfer inside dairy concentrates towards the surface and from the surface to the drying air. The concentrates were also spray dried and solubility index of powders were determined during reconstitution. Whey protein concentrates (WPC) and native phosphocaseinate suspensions (NPCS) were used to study the effect of NaCl (420 mM), CaCl₂ (222 raM), sodium phosphate (173 mM) and sodium citrate (238 mM) on the water transfers. The decrease in water transfer during drying was explained by the high hygroscopicity of added mineral salts to WPC. NaCl addition to NPCS decreased the water transfer during drying, but increased the solubility index. Citrate and phosphate addition to NPCS increased the water transfer during drying and reconstitution. CaCl₂ increased the water transfer during drying but the solubility index was always low. Results are discussed as a function of the aqueous environment, of the nature of mineral salts, of the structure of dairy proteins and of protein solvation.     

DEHYDRATION BY DESORPTION AND BY SPRAY DRYING OF DAIRY PROTEINS: INFLUENCE OF THE MINERAL ENVIRONMENT

A drying method by desorption in a water activity meter was used to simulate the conditions of spray drying and to determine the water transfer inside dairy concentrates towards the surface and from the surface to the drying air. The concentrates were also spray dried and solubility index of powders were determined during reconstitution. Whey protein concentrates (WPC) and native phosphocaseinate suspensions (NPCS) were used to study the effect of NaCl (420 mM), CaCl₂ (222 raM), sodium phosphate (173 mM) and sodium citrate (238 mM) on the water transfers. The decrease in water transfer during drying was explained by the high hygroscopicity of added mineral salts to WPC. NaCl addition to NPCS decreased the water transfer during drying, but increased the solubility index. Citrate and phosphate addition to NPCS increased the water transfer during drying and reconstitution. CaCl₂ increased the water transfer during drying but the solubility index was always low. Results are discussed as a function of the aqueous environment, of the nature of mineral salts, of the structure of dairy proteins and of protein solvation.     

An Investigation of Milk Powders Produced by a Laboratory-Scale Spray Dryer

ABSTRACT

A mini spray dryer has been used to investigate morphological changes that occur to milk particles during the spray drying process. We have found that the mini spray dryer is ideal for such investigations, because phenomena such as skin and vacuole formation in particles can be analyzed without the added complication of particle agglomeration, which only occurs in much larger spray dryers where particle number concentrations are higher. We have confirmed observations made by various researchers that the bulk density of spray-dried milk powder is greatly affected by the drying temperature, due to the strong influence of the latter on the porosity of the particles. In addition, we have attempted to explain observations made by various workers that fat accumulates preferentially at the surface of a particle during drying by postulating that fluid fat is transported towards the surface, via a network of cracks and pores, by the development of a vacuole overpressure which is also responsible for the inflation of the particle. Finally, we have shown that milk powders can be spray dried a second time, by reconstitution with water, with no change to the thermodynamic characteristics of the resultant powder. Thus, milk concentrates for spray drying research can be prepared from already-spray-dried milk powders rather than using the more arduous evaporation method to concentrate unprocessed milk.     

An Investigation of Milk Powders Produced by a Laboratory-Scale Spray Dryer

A mini spray dryer has been used to investigate morphological changes that occur to milk particles during the spray drying process. We have found that the mini spray dryer is ideal for such investigations, because phenomena such as skin and vacuole formation in particles can be analyzed without the added complication of particle agglomeration, which only occurs in much larger spray dryers where particle number concentrations are higher. We have confirmed observations made by various researchers that the bulk density of spray-dried milk powder is greatly affected by the drying temperature, due to the strong influence of the latter on the porosity of the particles. In addition, we have attempted to explain observations made by various workers that fat accumulates preferentially at the surface of a particle during drying by postulating that fluid fat is transported towards the surface, via a network of cracks and pores, by the development of a vacuole overpressure which is also responsible for the inflation of the particle. Finally, we have shown that milk powders can be spray dried a second time, by reconstitution with water, with no change to the thermodynamic characteristics of the resultant powder. Thus, milk concentrates for spray drying research can be prepared from already-spray-dried milk powders rather than using the more arduous evaporation method to concentrate unprocessed milk.     

石灰浆滴脱硫-干燥关系的模拟研究

本文以模拟试验为基础,较详细地研究了喷雾脱硫塔内石灰浆滴的脱硫-干燥关系,表明干燥与脱硫密切相关:当浆滴干燥成的固粒含水量低于临界值时,脱硫率将急剧减小。阐明了脱硫剂表面含有非结合水分是维持脱硫的快速反应—离子反应的必要条件。同时,得出了第一阶段中浆滴的传热传质关联式,能与实验结果较好地吻合。     

Numerical Study of the Drying Process of Different Sized Particles in an Industrial-Scale Spray Dryer

Development of high-performance spray dryers that are more energy efficient and are able to produce high-quality milk powders is very important for the future of the dairy powder industry. Understanding and optimization of the exiting dryers are also of great value. Computational fluid dynamics is a powerful tool to simulate and help understanding the characteristics of spray drying and to introduce potentially improved designs. The present study has concentrated on the multiphase flow in an industrial-scale spray dryer using the CFD package FLUENT. A Eulerian-Lagrangian approach is used in the simulations. A new drying model, REA model, for milk particles has been implemented for the first time in a CFD application. The numerical results match well with the plant data. It is argued that the “reflecting wall” boundary condition produced more physically correct results for normal dryer operation than the “escaping wall” boundary condition. The second one is an oversimplification. The influences of the particle size and particle size distribution, residence time, kinetic energy, and maximum temperature have been analyzed. The initial droplet size range was set to be from 100 to 500 µm with Rosin-Rammler distribution function. One significant result of this study is that rather dense particle clouds of medium-size particles (224–285 µm) are found near the side walls. They are transported upwards along the side wall (conical wall surface) and then are dispersed. It is found the particles with initial diameters of between 225 and 270 µm have the largest residence times.     

Dairy Milk Particles Made with a Mono-Disperse Droplet Spray Dryer (MDDSD) Investigated for the Effect of Fat

Mono-disperse droplet generation and subsequent drying in a spray-drying chamber, i.e., mono-disperse droplet spray dryer (MDDSD), provides a better-defined “flight experience” for liquid droplets. The related particle formation can be investigated more easily than that in the usual poly-disperse droplet spray dryer (PDDSD). Previously, skim milk, which is of high protein and high lactose content and is one of the two main dairy fluids that are processed into powder form for consumer markets, was subjected to this kind of investigation in Australia. Here, whole milk, which is the other main dairy fluid, has been spray-dried in a MDDSD set-up at Xiamen University (China). Because the initial droplet size is uniform, measurable, and the particle morphology after drying is consistent, it was possible to investigate the initial solids content effect upon shrinkage and inlet air temperature effect upon shrinkage. In contrast to what had been found for skim milk particles, the formation of the fat-containing (whole milk) particles does not follow the perfect shrinkage model as the skim milk does. This work has improved our quantitative understanding of the whole milk drying process. A fundamental analysis invoked with a modified one-dimensional modeling of spray drying has been given that has shown some further insight about the process.     

Model parameters for single-droplet drying of skim milk and its constituents at moderate and elevated temperatures

Single-droplet drying experiments were conducted with solutions of dairy materials in water (skim milk and its constituents, namely lactose, whey protein, and a lactose–whey mixture) at both moderate and elevated temperatures, at which inflation/deflation phenomena are observed. The experimental data were used to obtain parameters of a spatially resolving single-droplet drying model, which was extended to empirically account for inflation/deflation. Inflation/deflation parameters and conditions for crust formation at the transition from the first to the second drying stage were clearly solute dependent, and respective correlations with drying conditions were developed for the investigated dairy materials. The parametrized model was shown to satisfactorily describe measured data in respect to drying curve, drying time, and the diameter of product particles.     

Nanofiltration and reverse osmosis of model process waters fromthe dairy industry to produce water for reuse

In dairy plants the process waters generated during the starting, equilibrating, interrupting and rinsing steps contribute to the production of effluents. They correspond to milk products (milk, whey, cream) diluted with water without chemicals. The treatment of these dairy process waters by nanofiltration (NF) or reverse osmosis (RO) operations was proposed to concentrate dairy matter and to produce purified water for reuse in the dairy plant. The study reports one-stage and two-stage (NF + RO and RO + RO) spiral-wound membrane treatments with five model process waters representative of the main composition variations observed in dairies. Performances (permeate flux, milk components rejection, purified water characteristics) of the different operations were compared. Discussion was focused on the comparison between quality of produced waters and vapour condensates (from product drying and evaporation processes) reused in dairy plants. Accordingly, both total organic carbon (TOC) and conductivity of water treated by a single RO or NF + RO operations were convenient for reuse as heating, cooling, cleaning and boiler feed water. With the two-stage RO + RO process, a more purified water complying with the TOC drinking water limit was achieved.     

Comparative Analysis of Explosion Vent Areas for Milk Spray Dryers According to the EN-14491 (2006) and NFPA-68 (2007) Standards

Venting systems are commonly employed to minimize damage and/or losses caused by dust explosions in spray dryers. At present, the two most commonly used vent-sizing standards are the American standard NFPA-68 (2007) and the European standard EN-14491 (2006). The work described in this paper has two main aims. The first aim is to compare the results of the venting area as required by the two aforementioned standards for conventional milk drying when dealing with three products commonly treated in the dairy industry: buttermilk, powdered milk, and full-fat milk. The vent area was calculated by taking into account the reduced pressure (P_red) and the geometry of the spray dryer (aspect ratio of the vessel length/diameter). In addition, the results obtained as per NFPA-68 were also corrected on the basis of turbulence intensity and partial volume. The second aim is to apply the two standards to the real case of a spray dryer in a dairy processing plant located in the south of the province of Lugo (NW Spain). The results showed significant differences between the two standards in that the vent areas obtained following the criteria of EN-14491 were always higher than those obtained with the American standard (except for the cases in which L/D = 1).     

Effect of outlet drying temperature and milk fat content on the physicochemical characteristics of spray-dried camel milk powder

Abstract

A composite face-centered experimental design was used to investigate the influence of spray drying conditions on the physicochemical characteristics of camel and cow milk powders. Response surface methodology (RSM) was deployed to appraise the effects of these processing parameters (the outlet drying temperature and the milk fat content) on water activity (a_w), glass transition temperature (T_g), bulk density, and free fat quantity. According to RSM analysis, it was noticed that the a_w and the T_g were primarily influenced by the outlet drying temperature instead of by milk fat content. Our results highlighted the negative effects of milk fat content and of the outlet drying temperature on the bulk density as well as on the free fat quantity of camel milk powder. Likewise, our findings underlined the negative effect of the outlet drying temperature on the bulk density of cow milk powder. However, the increase of fat content has led to the overexposure of fat at the free surface of the cow milk powder. Our results suggested a marked similarity of the overall thermodynamic behavior of both milks, during drying. Nevertheless, some differences were highlighted regarding the structuring of the particles of camel milk powder.     

Recent advances in spray drying relevant to the dairy industry: A comprehensive critical review

Milk is extremely perishable, and yet it has to be preserved for later consumption. In this view, membrane filtration, vacuum concentration lactose crystallization, homogenization, and spray-drying dehydration are valuable techniques to stabilize most dairy ingredients. Considering the increasing development of dairy trade, there is a need for the dairy industry to improve its understanding of how these concentration and spray-drying processes affect the quality of the resulting dairy powders, so to control it. However, the residence time of the droplet and the powder in the spray dryer is so short that it is very difficult to implement studies on the mechanisms of the structural changes in the protein without fundamental research into the process/product interactions. Moreover, several authors have reported the crucial and specific role of dairy components in the mechanisms of water transfer during drying and rehydration. The aim of this paper is to review the present and recent advances in knowledge and innovations, on the properties of spray-dried dairy products, on the modeling and simulation of water transfer processes (drying and rehydration), and on spray-drying equipment and energy consumption.     

DRYING KINETICS AND PARTICLE RESIDENCE TIME IN SPRAY DRYING

A unique experimental equipment for extensive trials on the spray drying kinetics and particles residence time involving “in situ” analysis of the properties of continuous and dispersed phases was designed, built, and tested. Advanced experimental techniques (including laser techniques) to determine current parameters of spray drying process (temperature, humidity, moisture content) and current structure of spray (particle size distribution, particle velocities, etc.) were employed. Full scale spray drying tests of baker's yeast and maltodextrin enabled identification of the effect of process parameters on drying kinetics and spray residence time in the tower. Quantitative relationship describing spray drying kinetics as a function of atomization ratio and drying agent temperature were determined. The experimental results proved that spray residence time was controlled by atomization ratio and airflow rate. Drying kinetics in spray drying process is presented for the first time in the literature.     

DRYING KINETICS AND PARTICLE RESIDENCE TIME IN SPRAY DRYING

ABSTRACT

A unique experimental equipment for extensive trials on the spray drying kinetics and particles residence time involving “in situ” analysis of the properties of continuous and dispersed phases was designed, built, and tested. Advanced experimental techniques (including laser techniques) to determine current parameters of spray drying process (temperature, humidity, moisture content) and current structure of spray (particle size distribution, particle velocities, etc.) were employed. Full scale spray drying tests of baker's yeast and maltodextrin enabled identification of the effect of process parameters on drying kinetics and spray residence time in the tower. Quantitative relationship describing spray drying kinetics as a function of atomization ratio and drying agent temperature were determined. The experimental results proved that spray residence time was controlled by atomization ratio and airflow rate. Drying kinetics in spray drying process is presented for the first time in the literature.     

明胶软胶囊干燥特性的研究

在对流干燥实验台上进行了明胶软胶囊干燥特性的实验,研究了加热空气温度、风速、湿度对干燥过程的影响规律。实验结果表明,提高加热空气的温度,虽然提高了传热速率,但在第2降速阶段干燥速率下降,导致最终含水质量分数反而偏高;随着加热空气风速的提高,传热速率增加,干燥速率在第1降速阶段呈现加快趋势,软胶囊的最终含水质量分数稍有降低;而加热空气湿度的变化,对传热过程影响很小,但随着加热空气湿度的降低,干燥速率提高,使得最终含水质量分数明显降低。通过研究软胶囊的干燥特性,为制药工业中软胶囊的生产提供合理指导,对优化干燥过程、降低能耗、提高产品质量和经济效益具有重要意义。     

Comparison of the Efficiency of Five Different Drying Carriers on the Spray Drying of Persimmon Pulp Powders

The aim of this work was to compare the efficiency of different carrier agents (maltodextrin, gum arabic, starch sodium octenyl succinate, whey protein concentrate, and egg albumin) on the powder recovery and physicochemical properties of persimmon powders produced by spray drying. Moisture content, water activity, hygroscopicity, solubility index, total phenol retention, color parameters, particle size, morphology, crystalline state, and sorption isotherms of persimmon powders were determined. No powder was recovered when the persimmon pulp was spray dried alone. The amount of maltodextrin, gum arabic, starch sodium octenyl succinate, whey protein concentrate, and egg albumin needed to obtain a powder recovery of 70% was 45, 30, 30, 25, and 10%, respectively. The use of maltodextrin, gum arabic, and starch sodium octenyl succinate resulted in higher total polyphenol retention and better reconstitution properties, but the powders were paler than those with whey protein concentrate and egg albumin. All carriers could aid the formation of persimmon irregular spherical microcapsules. However, powders produced with maltodextrin and gum arabic had a smoother surface and a more spherical shape than powders produced with other carriers. In addition, powders produced with starch sodium octenyl succinate, whey protein concentrate, and egg albumin were more agglomerated and shriveled compared to those produced with maltodextrin and gum arabic. All experimental data of water adsorption were well fitted to the Guggenheim-Anderson-de Boer (GAB) model.     

Influence of Dryer Type on Surface Characteristics of Milk Powders

Reconstituted milk powders (skim milk, whole milk, and milk protein concentrate powders) were spray dried using research-scale (laboratory- and pilot-scale) spray dryers to investigate the influence of type on the dryer on the surface composition (protein, fat, lactose) and morphological characteristics (size and surface structure) of the powder particles. Milk powders produced by these research-scale dryers were compared to commercially produced and freeze-dried powders. The powders produced by the laboratory- and pilot-scale dryers were significantly different from the commercially dried powders in both surface composition and morphology. The milk powders produced by laboratory- and pilot-scale dryers provided reproducible results with similar surface morphologies between dryer types, despite varying surface compositions. The surface composition of the freeze-dried powder was also significantly different from than that of the spray-dried powders. The freeze-dried skim milk powder (SMP) was similar in surface protein to its bulk protein composition, indicating relative homogeneity of particle composition of the freeze-dried powder.     

Theoretical probing of the phenomenon of the formation of the outermost surface layer of a multi-component particle, and the surface chemical composition after the rapid removal of water in spray drying

Spray drying is a primary process for the manufacture of powders, which satisfy a vast array of societal demands in the areas of nutrition, health and medicine. The functionality of a spray-dried product begins with its incorporation into water (wetting followed by dispersion) Therefore, as its surface chemical composition and structure determine its first contact with water (that is, its hydrophilic nature), these are of prime concern. Laboratory studies on this first layer, which is in the order of several nm in depth from the surface, have been extensive but there is still a lack of a fundamental quantitative explanation of it. This has hampered the development of any sort of approach, which would enable industries to predict what the product may be like before conducting costly trials. This current study is an attempt to describe the on-set of solid formation around the outermost layer of a single droplet during the drying process using an innovative ‘conventional’ continuum approach, i.e. diffusion–convection equations, with a few innovative derivations. Though some complexities such as multi-component equations deduced from irreversible thermodynamics, are avoided for simplicity, some comparisons with experimental/industrial results are made. The main feature of this work is that the multi-component effect is combined with the viscosity (at the surface) effect upon the diffusivities of individual components in the solution droplets or suspension droplets. The derivations allow some extended analytical procedures to proceed in order to help make sense of the experimental observations. Comparisons are made against the data published on dairy fluids. This work provides a good basis for a fruitful area of study that will have a positive impact for spray drying industries. In particular, to help this kind of industry to forge ahead into high performing functional particle production, which are becoming increasingly popular.     

Some Aspects of Freeze Drying of Dairy Biomaterials

ABSTRACT

Different theoretical and experimental aspects of freeze drying of dairy biomaterials are reported. The following dairy biomaterials were chosen for investigations: three kefir bacterial cultures and one bacterial concentrate of a dairy vaccine. Experiments were performed both at one-region conductive or radiative heating and at combined two-region conductive-radiative heating. Emphasis was put on quality interactions between physical and biological properties of the material to be dried and freeze drying process parameters. Qualitative estimations of the following properties of biomaterials: a) colour, b)suppleness to caking and c) suppleness to scraping born the hot surface in dependence with the process parameters were performed using four-step subjective scales. On the basis of this estimations a synthetic quality criterion SQC was defined whose numerical value reflects general product quality. The results of mathematical modelling, numerical solution of the model and comparison with experimental data indicated that the process was heat transfer controlled and that the main factors resulting in good product quality and high SQC are low temperature of the conductive heated surface and vacuum chamber pressure affecting sublimation temperature. The influence of the sample freezing parameters on the elimination of the foaming or puffing and on the product quality was observed and examined. Furthermore, preliminary measurements of the dauy biomaterials viability after freeze drying were presented.