Spray Drying of Skim Milk Mixed with Milk Permeate: Effect on Drying Behavior, Physicochemical Properties, and Storage Stability of Powder

The possibility of using milk permeate (MP) to lower the protein level of skim milk powder (SMP) in producing powders of 34% and lower protein is explored. Skim milk suspensions with various levels of MP were prepared by mixing SMP and MP powder (MPP) at the ratios of 1:0, 7:3, 3:7, and 0:1: from 34 to 5.3% protein. The suspensions were dried in a spray dryer with inlet and outlet temperatures of 180 and 80°C, respectively. Increasing permeate concentration in the mixture showed a greater tendency to stickiness manifested by lowered the cyclone recovery of the powder as more powder stuck on the wall of the dryer. Increasing permeate concentration in the resultant powder did not significantly affect the bulk density but led to a reduction in the particle size and also made the powder slight green and yellowish in color. It also found to lower the glass transition temperature (T_g) of the skim milk powder (SMP) and induce crystallization of lactose at lower water activity (a_w ≥ 0.328 for SMP:MPP of 3:7 and 0:1 compared to a_w ≥ 0.0.432 for SMP:MPP of 1:0 and 3:7). Addition of MP in SMP lowered the T_g values of the resulting powders. The permeate fraction in spray-dried SMP/MPP mixtures found to lower the critical a_w and moisture content, suggesting the SMP mixed with MPP is more likely to become sticky than SMP alone (at 34% protein) when stored at a similar water activity and moisture content.     

A Study of the Limitations to Spray Dryer Outlet Performance

Abstract

The concept of the product moisture locus was tested in this work using a pilot-scale modified Niro spray dryer (diameter 0.8 m, height 2 m), where the residence time of the particles inside this spray dryer is lower compared with larger industrial spray dryers. The moisture contents of skim milk powder produced from spray drying skim milk (solids content 8.8% w/v) at different operating conditions, namely different swirl vane angles (0°, 25°, 30°), inlet air temperatures (170°C, 200°C, 230°C) and process fluid flowrates (1.4 kg h^?1, 1.6 kg h^?1, 1.8 kg h^?1), were compared with the predicted equilibrium moisture contents. In addition, the residence time of the particles was also increased in the spray dryer by decreasing the inlet air mass flowrate from 0.016 to 0.013 kg s^?1. The outlet moisture contents of the skim milk powder for all the 23 runs carried out in this work were within 0.4% of the equilibrium values. Thus, the skim milk powder particles were in close equilibrium with the gas inside the drying chamber. These equilibrium limitations are confirmed by other literature data (Boonyai, P. Comparative Evaluation of Soymilk Drying in a Spray Dryer and Spouted Bed of Inert Particles. M.Sc. Thesis. Asian Institute of Technology: Bangkok, Thailand, 2000; 90 pp; Harvie, D.J.E.; Langrish, T.A.G.; Fletcher, D.F. A computational fluid dynamics study of a tall-form spray dryer. Trans IChemE 2002, in press). The use of this finding to predict spray dryer performance is demonstrated by mass and energy balance calculations.     

Water Sorption,Glass Transition,and Microstructures of Refractance Window– and Freeze-Dried Mango (Philippine “Carabao” Var.) Powder

Water sorption isotherms, glass transition, and microstructures of Refractance Window (RW)– and freeze-dried Philippine “Carabao” mango powders were investigated. Water sorption isotherms were developed by the isopiestic method, while thermal transition of the powders, at various water activities (a _w  = 0.11–0.86), was determined using differential scanning calorimetry (DSC). The sorption isotherms of RW- and freeze-dried (FD) mango powders exhibited a type III sigmoidal curve, showing higher and lower adsorption capacities above and below 0.5 a _w , respectively. A significant difference (p < 0.05) in water content of RW- and freeze-dried mango powders for equivalent water activities was obtained above 0.5 a _w . The onset glass transition temperature (T _gi ) of RW- and freeze-dried mango powder solids decreased as the water content increased. There were no significant differences (p ≥ 0.05) in T _gi of RW- and freeze-dried mango powder solids at constant water activities, except for a _w  = 0.86. Microscopic examination of mango powders indicated that freeze-dried mango powders exhibited greater surface area and porosity in comparison to RW-dried mango powders.     

Crystallization and Drying of Milk Powder in a Multiple-Stage Fluidized Bed Dryer

The rationale of this study has been to use fluidized beds to crystallize amorphous spray-dried skim milk powders with multiple stages of processing at different temperatures and humidities with the aim of rapidly making mostly crystalline powders. This paper discusses the performance of a multiple-stage fluidized bed dryer, and a combination of crystallization of lactose in spray drying at high humidity (lactose nuclei formation) and subsequent fluidized bed drying. Two different combinations of spray dryer and multi-stage fluidized-bed dryer have been suggested to crystallize lactose in skim milk powder. The results show significant improvements in the crystallinity of the powders. Moisture sorption test and X-ray diffraction analysis were used to assess the crystallinity of the powders. The processed powders that were crystallized in a humid-loop spray drying combined with a two-stage fluidized-bed dryer/crystallizer showed 92% improvement in lower amorphicity by processing at different stages of 70°C, 50% RH and 80°C, 50% RH for 15 minutes. The conventionally spray-dried powders that were crystallized in a three-stage fluidized-bed dryer/crystallizer showed 87% improvement in lower amorphicity (less moisture sorption) by processing at different stages of 60°C, 50% RH; 70°C, 40% RH; and 80°C, 40% RH for 20 minutes. The multiple-stage fluidized bed system showed distinctive potential to crystallize lactose significantly in skim milk powder using an industrial-feasible process.     

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.     

Contact-Sorption Drying of Penicillium bilaii in a Fluidized Bed Dryer

A fluidized bed dryer and drying system have been designed, constructed and operated to produce a powdered formulation of the fungus Penicillium bilaii. The dryer includes an air-shear atomizer and rotatable air vibrator to produce particles which are evenly coated with P. bilaii. The drying system included a humidifier, oven, vacuum pump and instrumentation to ensure precise control of operating conditions. Instant skim milk powder was found to be the best particle source for fixing the spores due to its solubility in water, its highly porous nature and because its moisture isotherms were similar to those of the spores. The dryer was operated at 35°C to maximize the drying rate while still preventing thermal death of the spores. The fluidizing air was best provided at an RH of 30%, thereby producing skim milk/spore particles with just the right amount of moisture to ensure long term storage viability. Storage under refrigeration conditions showed little long term decline in spore viability after 3 months of tests. Room temperature storage demonstrated a small decline rate in spore viability with little significant change if held at room temperature for a few days. © 1997 SCI.     

Drying of Skim Milk: Opportunities for Reducted Steam

ABSTRACT

Research trials were carried out over a two year period in an industrial skim milk powder production plant to examine the benefits of using an in-line viscometer rather than in-line density meter to control the degree of skim milk concentration in an evaporator prior to spray drying.

It was concluded that use of an in-line viscometer significantly reduces spray drier losses, overall steam consumption, pipeline blockages and evaporator fouling in the manufacture of skim milk powder.     

Sorption Isotherms and Drying Characteristics of Tomato Peel Isolated from Tomato Pomace

Tomato peel was separated from pomace by sedimentation and dried in cabinet and fluidized-bed dryer at 50–70°C using 4–12 kg/m²tray load. The drying of tomato peel took place under the falling rate period and the drying behavior was well described by Page's model with coefficient of determination greater than 0.99 and standard error of 0.003–0.016. A fluidized-bed dryer was much more efficient than a cabinet dryer to dry tomato peel. The moisture adsorption isotherms of tomato peel were obtained by equilibrating above saturated salt solutions of known a _w (0.113–0.92) at 20–60°C. The data were analyzed using fifteen sorption models based on coefficient of determination, standard error, and residual plots. Modified Henderson was the best model for tomato peel with coefficient of determination >0.99, standard error <0.210, and a scattered residual plot. The net isostearic heat of sorption, estimated using the Clausius-Clapeyron equation, was 0.74–23.23 kJ/mol at 2.0–2.5% moisture content (dry basis).     

Fluxes and Patterns of Wall Deposits for Skim Milk in a Pilot-Scale Spray Dryer

The pattern of wall deposits in a pilot-scale spray dryer has been studied, using skim milk, by changing the flow rate to the nozzle and measuring the resultant deposition fluxes at different positions inside the dryer. The solids concentration was maintained at 30%. The deposition was measured at three locations of the conical section and in the cylindrical section of the spray dryer. Particle deposition can be either due to the inertia of the particles or turbulent diffusion, and it is not immediately obvious which of these mechanisms is dominant. Inertial deposition appeared to be present mainly at the bottom location of the conical section and was the largest amount in quantitative terms, being at least an order of magnitude larger compared with diffusion deposition, which seemed to be dominant on the side (cylindrical) walls of the spray dryer. In addition to the above observations, the deposition patterns in the conical section have been quantified. The relative deposition flux, in m^?2, which is the ratio of the deposition flux, in g m^?2 h^?1, to the solids flow rate into the dryer, in g h^?1, was between 0.04 and 0.09 m^?2 at a solids concentration of 8.8% and between 0.15 and 0.4 m^?2 at a solids concentration of 30%. The fused appearance of the microstructure in the wall deposits of skim milk powder, as seen in the Micro-CT study, suggests that re-entrainment of the wall deposits is unlikely.     

Lactose-hydrolyzed milk powder: Physicochemical and technofunctional characterization

The objective of this work is to demonstrate the effect of operational drying parameters on the physicochemical and techno-functional properties of lactose-hydrolyzed milk powder (LHMP). LHMP showed water content superior to the control regardless of drying conditions, which is a direct result of the difficulties encountered in drying the product. For a lab-scale spray dryer, the LHMP produced at θ_air,in?=?145°C and m_CM?=?1.0?kg?·?h^?1 was the only sample that met all stipulated quality parameters: water content <5% (w/w), a_w?93, particle sizes similar to control, and complete rehydration.     

Experimental Results Contributed to Early Detection of Smouldering Milk Powder as an Integrated Part of Maintaining Spray Drying Plant Safety

Smoldering milk powder lumps deposited on dryer walls or falling through the hot air could potentially start a fire or even an explosion in milk powder dryers. Explosive behavior is more frequently experienced in the modern industry, where high production throughputs are desired. It has been known that powder at such a state emits carbon monoxide (CO). The work reported in this article is the study of the characteristics of CO generation during the incomplete combustion of milk powders. The powders used in the study were whole milk and skim milk. Samples placed in a reactor were heated using air at 300°C. The exhaust air of the reactor was continuously measured for CO concentration using a highly sensitive CO analyzer. Temperatures were monitored, and the smoke produced during the combustion of whole milk powder was collected and analyzed using gas-chromatography mass-spectroscopy (GC-MS). Whole milk powder was found to produce significantly higher amounts of CO than skim milk powder. Hydrocarbons, alcohols, and carboxylic acids were tentatively identified during the GC-MS analyses. Results from the study are definitely useful in optimizing the use of an early fire detection system in milk powder plants.     

Temperature Changes during Microwave-Vacuum Drying of Sliced Carrots

Abstract

The temperature changes during microwave-vacuum drying of sliced carrots were investigated. Sliced samples were dried to 7–10% moisture content (wet basis) at a wide range of microwave power and vacuum pressure levels. The experiments showed that for sample thickness less than 8 mm, the core temperature of the sample was the same as its surface temperature, with uniform temperature distribution within the sample. However, for sample thickness more than 8 mm, temperature gradient developed along the thickness of the sample. The experiments also showed that, with the decrease of moisture content X _w (dry basis), for samples with thickness ≤ 8 mm, the drying process of sliced carrots experienced three distinct periods: a warming-up period (X _w  = 7.68) without removal of moisture when the product temperature increased linearly with drying time until it reached the corresponding saturation temperature of water in the food at the vacuum pressure; a constant temperature period (2 ≤ X _w  < 7.68) in which most of moisture evaporated and flowed out of the sample efficiently with little resistance; and a heating-up period (X _w  < 2) in which the drying rate decreased and sample temperature increased rapidly. The mathematical models for predicting sliced sample temperature were also developed based on the energy conservation and regression of the experimental date.     

Experimental Results Contributed to Early Detection of Smouldering Milk Powder as an Integrated Part of Maintaining Spray Drying Plant Safety

Smoldering milk powder lumps deposited on dryer walls or falling through the hot air could potentially start a fire or even an explosion in milk powder dryers. Explosive behavior is more frequently experienced in the modern industry, where high production throughputs are desired. It has been known that powder at such a state emits carbon monoxide (CO). The work reported in this article is the study of the characteristics of CO generation during the incomplete combustion of milk powders. The powders used in the study were whole milk and skim milk. Samples placed in a reactor were heated using air at 300°C. The exhaust air of the reactor was continuously measured for CO concentration using a highly sensitive CO analyzer. Temperatures were monitored, and the smoke produced during the combustion of whole milk powder was collected and analyzed using gas-chromatography mass-spectroscopy (GC-MS). Whole milk powder was found to produce significantly higher amounts of CO than skim milk powder. Hydrocarbons, alcohols, and carboxylic acids were tentatively identified during the GC-MS analyses. Results from the study are definitely useful in optimizing the use of an early fire detection system in milk powder plants.     

Development of Insolubility in Dehydration of Dairy Milk Powders

The insolubility of milk powder is affected by the degree of heating in the drying process. This phenomenon was studied with milk products of different moisture content that were subjected to treatments of defined temperature (5−55°C) and time. Skim milk powder (SMP, protein content 36%) was most sensitive over a range of moistures from 15% to 40%. Milk protein concentrate (MPC) powder (73% protein) was most sensitive at higher moisture contents than SMP. At the fastest reaction rates, and for both SMP and MPC, the ratio of moisture to protein (calculated on a dry basis) was approximately one part moisture to one part protein. The rates of development of insolubility in the moist products were fitted to the Arrhenius relationship; this allows extrapolation of the rate of reaction to conditions in a spray dryer. The factors that affect the insolubility reaction are discussed, in particular the effects of the concentrations of lactose and minerals. The results explain certain features of the current design of milk powder driers and will facilitate overcoming problems with the insolubility in high protein powders.     

Effect of Maltodextrin Addition during Spray Drying of Tomato Pulp in Dehumidified Air: II. Powder Properties

This work investigates the effect of maltodextrin addition on the main powder properties during spray drying of tomato pulp in dehumidified air. A pilot-scale spray dryer was employed for the spray-drying process. The modification made to the original design consisted in connecting the spray dryer inlet air intake to an absorption air dryer. 21 DE, 12 DE, and 6 DE maltodextrins were used as drying agents. Tomato pulp was spray dried at inlet air temperatures of 130, 140, and 150°C and (tomato pulp solids)/(maltodextrin solids) ratios of 4.00, 1.00, and 0.25. The tomato powders were analyzed for rheological properties, moisture content, bulk density, solubility, hygroscopicity, and degree of caking. It was found that maltodextrin addition improved powder hygroscopicity, caking, and solubility, whereas it deteriorated slightly its moisture content and density. In addition, analysis of experimental data yielded correlations between powder properties and the above-mentioned variable operating conditions. Regression analysis was used to fit a full second-order polynomial, reduced second-order polynomials, and linear models to the data of each of the properties evaluated. F values for all reduced and linear models with an R ² ≥ 0.70 were calculated to determine if the models could be used in place of full second-order polynomials.     

An Investigation and Quantitative Assessment of Particle Shape in Milk Powders from a Laboratory-Scale Spray Dryer

Seven samples of spray-dried milk were prepared using a miniature-scale Buchi Mini Spray Dryer B-290 (diameter 0.5 m, height 1.1 m). For each run, all inlet conditions were held constant except for feed type, inlet solids concentration, and inlet temperature. Skim milk at a solids concentration of 8.8% and whole milk at a solids concentration of 11% were dried at two inlet temperatures, 120 and 200°C. Lactose-free skim milk (8.8% solids concentration) and skim milk at a solids concentration of 41.2% were also dried at an inlet temperature of 200°C to assess the effects of milk feed type and inlet concentration, respectively. Equilibrium between the outlet product moisture content and the outlet gas conditions in the miniature spray dryer was not reached, unlike previous results for pilot-scale and larger dryers, so it appears that, in small (miniature-scale) dryers, the outlet moisture content is limited by kinetics and not by equilibrium. Calculated yields ranged from 10.4 to 82.7%, with whole milk giving significantly lower yields than skim milk, due to the sticky nature of fat found in whole milk. Lactose-free skim milk produced lower yields than skim milk dried at the same conditions, indicating that the lower glass-transition temperatures of the converted lactose sugars make these powders stickier. This sugar effect was not as large as that of the fat content. Comparisons between the SEM images, fractal dimensions, particle size distributions, and bulk densities showed that lower inlet temperatures produced particles of a more collapsed nature with a higher bulk density and lower fractal dimension than milk particles dried at higher temperatures. Also, feed solids concentration heavily influenced the shape of the particles, with high concentrations producing more spherical, less broken or shriveled particles with higher fractal dimensions, as the shell walls are thicker under these conditions. The fractal dimensions appeared to give generally consistent results for quantifying the average particle shapes.     

Lactose hydrolyzed milk powder: Thermodynamic characterization of the drying process

Industrial production of lactose hydrolyzed milk powder (LHMP) remains challenging. Due to the presence of the monosaccharides glucose and galactose, lactose-free powders tend to suffer stickiness, caking, and browning during drying and storage. We sought to find ideal conditions spray dryer inlet air temperature (θ_air,in) and concentrated milk flow rate (m_CM) for LHMP production. We tested θ_air,in settings of 115–160°C and m_CM of 0.3–1.5?kg?·?h^?1, and also applied mass and energetic balances. LHMP generally exhibited higher mass and energetic losses than the control (milk powder containing lactose), as a consequence of the relatively low dryability of LHMP. For a lab scale spray dryer, the ideal conditions settings for LHMP production were θ_air,in?=?145?±?2°C and m_CM?=?1.0?kg?·?h^?1, taking into account the mass yield and energetic cost (kJ?·?kg^?1 of powder) of the process. These ideal conditions are a potential tool for the industrial development of lactose-free dairy powders.     

Final Drying of Whole Milk Powder in Vibrated-Fluidized Beds

Abstract

Vibro-fluidized beds are widely used in drying sticky powders and agglomerated materials as milk powder. Using a vibro-fluidized laboratory scale dryer, this work is aiming at analyzing preliminarily the effect of its operational variables on the drying kinetics and characteristics of whole milk powder. The full-factorial design technique with three replications at the central point has been employed to generate data and correlations to quantify the effect of inlet air temperature, air flow rate, and vibration bed amplitude on the drying curves and the milk powder properties related to its faster reconstitution in water (as tapped density, Hausner cohesion ratio, agglomerate size distribution, and internal pore concentration). Results obtained are analyzed and discussed to identify the adequate operation condition for final drying whole milk powder in vibro-fluidized beds, assuring a high product quality.     

Drying of Skim Milk: Opportunities for Reducted Steam

Research trials were carried out over a two year period in an industrial skim milk powder production plant to examine the benefits of using an in-line viscometer rather than in-line density meter to control the degree of skim milk concentration in an evaporator prior to spray drying.

It was concluded that use of an in-line viscometer significantly reduces spray drier losses, overall steam consumption, pipeline blockages and evaporator fouling in the manufacture of skim milk powder.     

Moisture Sorption Isotherms,Thermodynamic Properties,and Glass Transition of Pears and Apples

Moisture sorption isotherms of apples and pears were determined at 30, 45, and 60°C and water activity (a _w ) range of 0.04–0.83 using a standard static gravimetric method. The sorption isotherms of both fruits decreased with increasing temperature and exhibited type III behavior according to Brunauer–Emmett–Teller (BET) classification. The moisture desorption data fitted well with the Peleg model (0.997 ≤ r ≤ 0.999, 0.009 ≤ SE ≤ 0.071, and 4.840 ≤ p ≤ 13.779).

The glass transition temperature (T _g ) of both fruits decreased linearly with the increase in water activity (a _w ). The variation in glass transition temperature versus water activity (T _g  ～ a _w ) and glass transition temperature versus solid fraction of pears and apples (T _g  ～ W _s ) were adequately predicted by Khalloufi et al.'s model (0.998 ≤ r ≤ 0.999 and 0.007 ≤ SE ≤ 4.088) and the Gordon and Taylor model (0.879 ≤ r ≤ 0.979 and 9.798 ≤ SE ≤ 18.507). The thermal transition and desorption isotherms data were used to establish state diagrams of pear and apple and evaluate suitable fruits storage conditions.