| Date post: | 28-Jun-2021 |
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HOW TO FIND AND MAINTAINYOUR NEXT INDUSTRIALSPRAY DRYER? SIXIMPORTANT FACTORSAn Academic presentation byDr. Nancy Agnes, Head, Technical Operations, FoodResearchLabGroup: www.foodresearchlab.comEmail: [email protected]
Introduction
Optimization
Improving the ability
The retractable design of CIP nozzle valve
Improved run time
Cleaning in place
Ambient conditions
Today's Discussion
OUTLINE
Figure 1 - Industrial spray drier and its applications
We have seen the importance of spray dryer inencapsulation in our previous blog.
The importance of spray drying is well received in the foodindustry and their demand is increasing proportionally.
The food industry equipment market claims a growth ofUSD 450 Million during 2020-2024 progressing at a CAGRof 5% during this forecast period.
Introduction
https://www.foodresearchlab.com/blog/industries/impact-of-microencapsulation-technology-in-the-food-and-beverage-industry/https://www.foodresearchlab.com/blog/industries/impact-of-microencapsulation-technology-in-the-food-and-beverage-industry/
As a manufacturer how would you choose your spray dryer which would suit yourfood type? As different type of dryer (e.g., pressure single-fluid nozzle atomizer,rotary wheel atomizer, pneumatic two-fluid nozzle atomizer) with drying stage (e.g.,two stage spray dryer, multi-stage spray dryer, single -stage spray dryer) hasdistinct functions in food application
(e.g., milk products, plant products fish and meat proteins, algae, β-carotene,chelates, cultures, emulsifiers, enzymes, fibers (e.g. inulin, fructooligosaccharides(FOS), Galactooliogosachharide, flavors and encapsulated flavors, gelatin,glucose, herb extract, non-dairy creamer, probiotics, proteins & proteinhydrolysates, tomatoes, starch and maltodextrins, whole blood and haemoglobin,yeast and yeast extracts, fruit and vegetable products, carbohydrate product,others).
For instance, extensively used to preserve fruit and vegetable juices in powder form, there are distinct varieties of dryers offering various features to complete themanufacturer’s needs as any improper usage would affect physiochemical andmicrostructural attributes of the product.
The selection of a spray dryer needs to account for several factors.
One of the important aspects to understand before investing in a spray dryer is theease of use (if it is easy to regulate the particle size), setup and cleaning requirements.
After the basics are accounted for, then the functional factor should be looked into.Equipment that is easy to operate, adjust and develop optimum conditions should bepreferred.
The main functions the instrument should allow you to control are:
Control the airflow, temperature, and pump speed.
The volume should equate to the pressure from an air compressor.
The amount of Active Pharmaceutical Ingredient (API) required for development
The strength and behaviour of the API
The quantity of dry mix formulation required
The overall batch size will be dictated by the solid content of the active and the amountof encapsulant.
The solvent used for making up the emulsion will dictate the type of drying gasrequired, which could be either air or nitrogen.
Optimization of the spray dryer is usually done in three ways.Firstly, it is done to maximize the production quality and yield.
This can be achieved by modifying the inlet, outlet and feedtemperature. Secondly, optimization is required to reducelosses in productivity, such as from Clean in Place (CIP).
Thirdly, for seasonal fluctuations, spray dryers run better inwinter as the amount of moisture in ambient air is higher.
According to the Study published in Trends in Food Science &Technology, Response surface methodology wasdemonstrated as the most suitable tool for optimization ofspray drying condition.
Optimization
The capability of the spray dryer is measured by the amount ofwater it evaporates and is measured at the time of wetproduct at loading.
The difference in inlet and outlet temperature needs to beraised for optimal evaporation.
Improving the ability
Although higher inlet temperatures result in better energy efficiency, they do notoperate with extremely high inlet temperatures.
As build-up can occur in spray dryer vessels at a certain outlet temperature.Moreover, the product should not become denatured, burned or deprived ofnutrients or desired characteristics.
The retractable design of CIPnozzle valve
A good optimal production should have a well-scheduledoperation and very limited or unplanned downtime.
A feed system should be washed regularly that should be oftenswitched between Products and batches.
However, spray drying should be carefully monitored for allergensand cleaning between allergen production batches.
Recently, there are spray dryers with two feeds that operate at100% capacity which works better for automized nozzle systems.
Improved run time
Rotary or nozzle can be built to an atomizer and when one feed system is turnedoff, another nozzle can be utilized.
Planned cleaning definitely should be performed daily or betweenbatches for the following reasons.
To avoid fire or explosion caused by excessive build-up.
The excessive build-up will also result in quality issue and cross-contamination.
To avoid microbial growth in the chamber.
To eliminate unnecessary maintenance issues.
Cleaning in place
Seasonal variation plays a major role in the spray dryer’sperformance as explained earlier.
Therefore, it is important to standardize the incoming air for optimalproductivity year-round.
The capacity of the dryer is limited by the overall moisture in the airwhile leaving the chamber.
The air leaving the chamber should not be very moist for or whileproducing a stable product and might lead to a clumsy result.
Ambient conditions
Moreover, to deliver at maximum efficacy the chamber should be operated at thetotal moisture content possible.
As said in the introduction, parameters such as inlet and outlet temperature alongwith other parameters should be optimized for theoretical maximum productivity evenduring seasonal changes.
We can control this using a few components. Primarily, it is important to measure theambient air moisture content with the help of a hygrometer and the air volume ismeasured.
Spray dryer has fitted with a direct-fired gas burner that runs on natural gas orpropane, moisture contribution can be accounted for up to 10%.
https://www.foodresearchlab.com/blog/industries/impact-of-microencapsulation-technology-in-the-food-and-beverage-industry/
In sum, the overall volume of water contribution which has evaporated should bemeasured.
Using a flowmeter, the mechanical inefficiency and slippage should be accountedfor improved accuracy.
Finally, all the operational data must be collected to understand the machine, if it isoperating at its optimum level and if the product yield is similar to the theoreticalvalues.
To make use of the best industrial spray dryer, food research lab guides you withfood consulting services.
https://www.foodresearchlab.com/
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