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.     

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.     

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.     

Releasing Fat in Whole Milk Powder during Fluidized Bed Drying

Spray-dried whole milk powders have been produced to a high bulk-to-surface-free-fat ratio due to the susceptibility to oxidation of surface free fat. Processing spray-dried whole milk powders in a fluidized-bed crystallizer by hot and high humidity air can cause the release of bulk fat and increase both inner free and surface free fat. This research investigates the fat release and its migration to particle surfaces by two different mechanisms: a) fat melting due to high temperature processing in a fluidized -bed crystallizer so that liquid fat can diffuse outwards to the particle surfaces; b) fat release from the matrix due to lactose crystallization, causing component segregation and releasing molecular bonds.

More free fat is preferable in some dairy-based processing, such as chocolate making, where cocoa butter could be substituted by milk fat to adjust the viscosity of chocolate paste and formulate good chocolate taste. This research shows the possibility of releasing more than 90% of the bulk fat to increase free fat (inner and surface) in 15 minutes processing time. Different temperatures and humidities (45°C and 78% RH) have been found to provide suitable conditions to release the bulk fat by crystallizing lactose in higher amount, as a form of inner free fat (preferentially) which is ready for further use, such as in chocolate industries. Meanwhile the released fat, as inner free fat, has less contact with oxygen than surface free fat and maintains the powder quality better. The changes in particle structure and fat release processes have also been studied during fluidized-bed drying of spray-dried whole milk powders that could improve the control and design of the drying process for milk powders.     

Staubarme Pulver durch Sprühtrocknen – Erfahrungen mit neueren Techniken

Dustless powders by spray drying – Experience with new techniques . Old drying plant with rotary- or nozzle-atomizer of conventional construction produce more or less fine, dusty powder. Increasingly, there is a demand for dustless powders. A knowledge of the parameters which influence the size of the particles and the experience gained in the drying of various products was the basis for the evolution of a new spray dryer capable of producing even dustless powder. Many trials in this new spray dryer, called the FSD (Fluidized Spray Dryer) show that the powder meets all requirements. Moreover, this spray dryer will save energy and is more gently to the product by working at lower outlet temperatures.     

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.     

Comparative efficiency of maltodextrin and protein in the production of spray-dried tamarind pulp powder

The potential of maltodextrin (DE 20) and soya protein isolate (SPI) in spray drying of tamarind pulp was compared. Powder recovery was zero when the tamarind pulp was spray dried alone. A greater amount of maltodextrin (MD; 55%) was required for successful spray drying of tamarind pulp, whereas a small amount of SPI (20%) was needed for the same purpose. The study revealed that the mechanism for the increase in product recovery with the addition of MD is due to the increase in overall glass transition temperature of tamarind pulp powder. However, using SPI, preferential migration of the protein to the surface of droplets/particles resulting in the formation of a glassy skin was responsible for a reduction in stickiness between the particles and dryer wall and hence increased the powder recovery. The potential of SPI in reducing powder hygroscopicity was almost comparable to that of MD, confirming its efficiency as a drying aid. Tamarind pulp powders produced with SPI had a larger particle size with a wrinkled particle surface morphology and high flowability compared to powders produced with MD. The study showed the excellent potential of SPI as a drying aid in production of quality tamarind pulp powder.     

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.     

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.     

Hygienic Design Requirements for Spray Drying Operations

Spray drying is used extensively in the food and food-related industries for the manufacture of a wide range of products in dry particulate form both as powders and agglomerates. Spray drying produces these products by atomizing a liquid formulation within a suspended particle drying system. Therefore, the spray-drying process features moist particles existing both in an airborne state and as a semi-dried product present at the walls of the drying chamber, ducts, and associated powder handling components. The presence of any partially dried product within the warm components of the drying system over an extended period of time can result in microbial growth. This presents a possible hygienic risk in such cases where products are sensitive to this form of contamination. With the increasing use of spray drying in the above-mentioned industries, there is greater focus on hygienic spray dryer design and the operating considerations that need to be taken into account, so that hygienic processing can be economically achieved. This is irrespective of whether a hygienic evaluation involves an existing spray dryer or the engineering phase of a new plant.

This article addresses industrial personnel associated with a hygienic manufacturing operation involving spray drying and offers guidelines for assessing whether an existing or planned new spray dryer meets hygienic engineering/design criteria for economic operation without risks of powder quality degradation through contamination.     

Hygienic Design Requirements for Spray Drying Operations

Spray drying is used extensively in the food and food-related industries for the manufacture of a wide range of products in dry particulate form both as powders and agglomerates. Spray drying produces these products by atomizing a liquid formulation within a suspended particle drying system. Therefore, the spray-drying process features moist particles existing both in an airborne state and as a semi-dried product present at the walls of the drying chamber, ducts, and associated powder handling components. The presence of any partially dried product within the warm components of the drying system over an extended period of time can result in microbial growth. This presents a possible hygienic risk in such cases where products are sensitive to this form of contamination. With the increasing use of spray drying in the above-mentioned industries, there is greater focus on hygienic spray dryer design and the operating considerations that need to be taken into account, so that hygienic processing can be economically achieved. This is irrespective of whether a hygienic evaluation involves an existing spray dryer or the engineering phase of a new plant.

This article addresses industrial personnel associated with a hygienic manufacturing operation involving spray drying and offers guidelines for assessing whether an existing or planned new spray dryer meets hygienic engineering/design criteria for economic operation without risks of powder quality degradation through contamination.     

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.     

Spray Drying of Tomato Pulp: Effect of Feed Concentration

The effect of feed concentration on spray drying of tomato pulp preconcentrated to 78, 82, and 86% wet basis is investigated in two spray drying systems: a pilot scale spray dryer (Buchi, B-191) with cocurrent regime and a two-fluid nozzle atomizer, and the same connected with an absorption air dryer (Ultrapac 2000). Data for the residue on the chamber and cyclone walls were gathered and two types of efficiencies were calculated as an indication of the spray dryer performance. Tomato powders were analyzed for moisture, particle size, and bulk density. In both spray drying systems, with increases in tomato pulp concentration overall thermal efficiency, evaporative efficiency, material loss in the cyclone, powder moisture content, and bulk density decreased, whereas powder particle size increased. On the contrary, the effect of feed solids content on residue formation and product recovery was dependent on the drying medium. In the standard dryer, the higher the feed concentration, the higher was the residue accumulation, and the lower the product recovery, whereas in the modified system increases in pulp concentration resulted in lower residue formations and higher product yields.     

Combined Crystallization and Drying in a Pilot-Scale Spray Dryer

Combined crystallization and drying of lactose solutions was performed in a pilot-scale spray dryer over a wide range of operating conditions. The effect of different parameters, including temperature, moisture content, atomizing air flow rate, liquid feed rate, main drying air flow rate, and particle size, on the degree of crystallinity of the spray-dried powders was analyzed. Water-induced crystallization (WIC) and modulated differential scanning calorimetry (MDSC) were used to assess the effect of these parameters on the degree of crystallinity of the spray-dried powders. The particles were characterized in terms of the final moisture content using WIC and distinctive differences in the peak heights, which are indicative of the particle crystallinity, were found for spray-dried particles using different drying conditions, supporting the results from MDSC. MDSC showed that decreasing the inlet air temperature by 40°C increased the degree of crystallinity in the particles threefold from 22 to 72%. A decrease in the inlet air temperature may decrease the particle temperature, resulting in wetter particles, and a lower temperature meant a longer particle drying time and allowed the particles to rearrange themselves into a more crystalline form. Up to 72% crystallinity is achievable in a pilot-scale spray dryer by suitable adjustment of the operating conditions. The results suggest differences in the rate of crystallization and particle size between small and pilot-scale spray dryers.     

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.     

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.     

THE STICKY ISSUES OF DRYING

ABSTRACT

Unconrolled agglomeration of particles and adhesion of the particulate mass to wall surfaces are common severe problems in many drying operations. This paper reviews the mechanisms of interparticle and particle‐surface attraction as well as the theory and the existing tests for characterising powders in terms of internal strength, wall friction and adhesion. The usefulness of the information obtained from these tests in dryer design and operation is critically reviewed. The importance of powder stickiness in various types of dryers is discussed and established methods of combating the problem are presented Recommendations an made for further research in the area of powder cohesion and adhesion.     

Final Drying of Whole Milk Powder in Vibrated-Fluidized Beds

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.     

To What Extent Do Whey and Casein Micelle Proteins Influence the Morphology and Properties of the Resulting Powder?

How the type of protein influences particle morphology remains a hot topic of debate. In this study we focused on the drying behavior of two major milk protein types; that is, whey protein and native micellar caseins. To improve understanding of the role of each protein in the particle-forming mechanisms, seven mixtures containing different whey proteins to caseins ratios were investigated. A monodisperse spray dryer (MDSD) was used to produce uniform particles by drying monodispersed droplets in a hot, dry air flow. Single particles were also obtained from the same material using single droplet drying in a pendant configuration. Powders were characterized according to their physical characteristics and their rehydration properties. It was demonstrated that particle morphology was mainly governed by the type of protein matrix, almost regardless of the drying kinetics, which differed considerably between MDSD and single droplet drying. Controlling product formulation thus represents a potential means by which to tune particle morphology and therefore the functional properties of powder.     

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.