How to find and maintain your next Industrial Spray Dryer? Six Important Factors

1

• HOW TO FIND AND MAINTAIN YOUR NEXT INDUSTRIAL
• SPRAY DRYER? SIX

IMPORTANT FACTORS An Academic presentation by Dr.
Nancy Agnes, Head, Technical Operations,
FoodResearchLab Group www.foodresearchlab.com Em
ail info_at_foodresearchlab.com
2
Today's Discussion
Introduction Optimization Improving the
ability The retractable design of CIP nozzle
valve Improved run time Cleaning in place
Ambient conditions
OUTLINE
3
Figure 1 - Industrial spray drier and its
applications
4
Introduction
We have seen the importance encapsulation in our
previous blog.
of spray dryer in
The importance of spray drying is well received
in the food industry and their demand is
increasing proportionally. The food industry
equipment market claims a growth of USD 450
Million during 2020-2024 progressing at a CAGR
of 5 during this forecast period.
5
As a manufacturer how would you choose your spray
dryer which would suit your food 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) has distinct functions in food
application (e.g., milk products, plant products
fish and meat proteins, algae, ß-carotene,
chelates, cultures, emulsifiers, enzymes, fibers
(e.g. inulin, fructooligosaccharides
(FOS), Galactooliogosachharide, flavors and encap
sulated flavors, glucose, herb extract, non-dair
y creamer, probiotics, proteins
gelatin, protein
hydrolysates, tomatoes, starch and maltodextrins,
whole blood and haemoglobin, yeast and yeast
extracts, fruit and vegetable products,
carbohydrate product, others).
6
For instance, extensively used to preserve fruit
and vegetable juices in powder form,
there are distinct varieties of dryers offering v
arious features to complete the
manufacturers needs as any improper usage would
affect physiochemical and
microstructural attributes of the product.
7
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 the ease 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 be
preferred. The main functions the instrument
should allow you to control are Control the
airflow, temperature, and pump speed.
8
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 amount
of encapsulant. The solvent used for making up t
he emulsion will dictate the type of drying gas
required, which could be either air or nitrogen.
9
(No Transcript)
10
Optimization
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 feed
temperature. Secondly, optimization is required
to reduce losses in productivity, such as from
Clean in Place (CIP). Thirdly, for seasonal
fluctuations, spray dryers run better in winter
as the amount of moisture in ambient air is
higher. According to the Study published in
Trends in Food Science Technology, Response
surface methodology was demonstrated as the most
suitable tool for optimization of spray drying
condition.
11
Improving the ability
The capability of the spray dryer is measured by
the amount of water it evaporates and is
measured at the time of wet product at
loading. The difference in inlet and outlet
temperature needs to be raised for optimal
evaporation.
12
The retractable design of CIP
nozzle valve
Although higher inlet temperatures result in
better energy efficiency, they do not operate
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 of nutrients or desired characteristics.
13
Improved run time
A good optimal production should have a
operation and very limited or unplanned downtime.
well-scheduled
A feed system should be washed regularly that shou
ld be often switched between Products and
batches. However, spray drying should be
carefully monitored for allergens and cleaning
between allergen production batches. Recently, th
ere are spray dryers with two feeds that operate a
t 100 capacity which works better for automized
nozzle systems.
14
Rotary or nozzle can be built to an atomizer and
when one feed system is turned off, another
nozzle can be utilized.
15
Cleaning in place
Planned cleaning definitely should be performed
daily or between batches for the following
reasons. To avoid fire or explosion caused by
excessive build-up. The excessive build-up will a
lso result in quality issue and cross-
contamination. To avoid microbial growth in the
chamber. To eliminate unnecessary maintenance
issues.
16
(No Transcript)
17
Ambient conditions
Seasonal variation plays a major role in the spray
dryers performance as explained
earlier. Therefore, it is important to
standardize the incoming air for optimal
productivity year-round. The capacity of the
dryer is limited by the overall moisture in the
air while leaving the chamber. The air leaving
the chamber should not be very moist for or while
producing a stable product and might lead to a
clumsy result.
18
Moreover, to deliver at maximum efficacy the
chamber should be operated at the total moisture
content possible. As said in the introduction,
parameters such as inlet and outlet temperature
along with other parameters should be optimized
for theoretical maximum productivity even during
seasonal changes. We can control this using a
few components. Primarily, it is important to
measure the ambient air moisture content with
the help of a hygrometer and the air volume is
measured. Spray dryer has fitted with a
direct-fired gas burner that runs on natural gas
or propane, moisture contribution can be
accounted for up to 10.
19
In sum, the overall volume of water contribution
which has evaporated should be measured. Using
a flowmeter, the mechanical inefficiency and
slippage should be accounted for improved
accuracy. Finally, all the operational data must
be collected to understand the machine, if it is
operating at its optimum level and if the product
yield is similar to the theoretical values. To
make use of the best industrial spray dryer, food
research lab guides you with food consulting
services.
20
CONTACT US
UNITED KINGDOM 44- 74248 10299 INDIA 91
9566299022 EMAIL info_at_foodresearchlab.com