MICROENCAPSULATION USING HIGH VOLTAGE, LOW CURRENT, HIGH FREQUENCY AC SPRAY ATOMIZATION

Abstract

A spray-drying system and a process for encapsulating a core material, such as a volatile flavoring oil, within a carrier or wall material are described. The process is achieved by atomizing a liquid emulsion comprising the core material, the wall material, and a liquid solvent, applying a high-voltage, low-current, high-frequency alternating current load or a high-voltage, low-current, low-frequency alternating current load at the atomization site, and drying the atomized emulsion into a free-flowing, encapsulated powder. The application of a high-voltage, low-current alternating current at the atomization site allows spray drying to be performed at significantly reduced temperatures, specifically inlet temperatures in the range of 25°C to 150°C and outlet temperatures in the range of 25°C to 110°C.Low drying temperatures impart improvements to the resulting encapsulated powder product, including better retention of volatile flavor components, a flavor profile comparable to that of the starting liquid formulation, and improved hydration and dissolution in water-based applications.

Description

Background of the invention [1] The present technology relates to a spray-drying system and process for encapsulating active ingredients that are volatile, or sensitive to heat or oxygen, using spray atomization that applies high-voltage, low-current, high-frequency alternating current, or high-voltage, low-current, low-frequency alternating current, at the atomization site. The present technology also relates to the encapsulated product resulting from spray atomization. [2] Spray drying systems have been widely used in the food and flavoring industries to encapsulate food ingredients or flavorings and to transform liquid ingredients into free-flowing dry powders. Encapsulation is a technique by which one material or mixture of materials is coated with another material or mixture of materials. The coating material is also known as the wall or carrier material. The wall material forms the outer layer or shell of the encapsulated product. The inner coated material is known as the core. The spray-dried product can be in core-shell form, containing Lfrzcnn / Lznz / E / YiA is a single core in the dry particle, or in matrix form, containing multiple cores within the particle. Since many food ingredients and flavorings are volatile and chemically unstable in the presence of heat, air, moisture, and / or light, encapsulating these ingredients in a wall or carrier material is a way to limit degradation or loss during processing or storage. The encapsulation process generally requires a heat source to initiate thermally induced phase separation. Phase separation results in the formation of a surface film or layer that allows water to diffuse selectively while retaining the more volatile components within the core of the encapsulated product. [3] One disadvantage of conventional spray-drying systems for encapsulating food and flavorings is the required thermal energy to induce proper carrier film formation and dehydration to obtain a desirable free-flowing encapsulated powder product. Typical processing temperatures for conventional spray-drying systems range from approximately 140°C to approximately 220°C for inlet temperatures and from 60°C to 120°C for outlet temperatures. As a result of such high temperatures, the flavor profile of the dried encapsulated food or flavor component can be significantly different from its original flavor profile, presenting a significant challenge in formulating an acceptable product from highly volatile flavor compounds and heat-sensitive food ingredients.In addition, the energy and time required to pre-condition the spray dryer to achieve the set heating conditions can be costly and time-consuming. [4] To overcome at least some of the disadvantages resulting from the high temperatures used in spray drying systems, many in the flavor and food industry have developed specific wall materials or carriers to protect against the volatilization of food or flavor components. However, such wall materials or carriers may not be suitable for all types of food or flavor components. Furthermore, the use of specific wall materials does not meet the energy requirements of conventional spray drying systems. Reducing the processing temperatures used in conventional spray drying systems is not a viable solution because, at lower inlet temperatures, such as 120°C, carrier film formation is slower, resulting in higher surface oil content and a loss of flavor retention in the resulting product. [5] A solution to the problem of the high temperatures used in conventional spray drying processes is described in Beetz et al., U.S. Patent No. 8,939,388. This approach uses a spray drying process in which an electrostatic charge is applied to a high-viscosity, high-solids emulsion prior to atomization. The electrically charged emulsion is then atomized into electrostatically charged wet particles that can be spray dried at lower temperatures. [6] An electrostatic spray drying process is also described in Sobel et al., U.S. Publication Request No. 2017 / 0312726A1. In the process of Sobel et al., a liquid emulsion having a viscosity of 150 cP to 250 cP is atomized, an electrostatic charge is applied at the atomization site, and the atomized emulsion is then dried into a free-flowing, encapsulated powder. The application of an electrostatic charge at the atomization site allows the spray drying process to be carried out at dryer inlet temperatures of approximately 25°C to approximately 110°C. [7] One disadvantage of electrostatic spray drying processes is the inability to create discrete particles of particular size distributions due to residual static charge. Control over particle size is also limited because the pulse width of the electrostatic field does not allow for complete control. Another disadvantage is that the accumulation of residual static charge can lead to product buildup on the walls of the spray dryer and product conveying systems. [8] Therefore, there remains a need for spray-drying systems that mitigate the problems associated with conventional high-temperature spray-drying systems, while providing an encapsulated product that retains its original flavor profile, and that also provide greater control over the particle size and particle morphology of the spray-dried product. There is also a need for an encapsulated product that provides improvements in properties such as encapsulation efficiency, product flowability, and particle size. Brief summary of the invention [9] One aspect of the present technology is a spray-drying process for preparing an encapsulated product, wherein the process facilitates the drying, or desolvation of water, or other suitable solvent, by the application of high-voltage, low-current, high-frequency alternating current (HVLCHFAC), or high-voltage alternating current, Low current, low frequency (HVLCLFAC) is applied to a spray atomizer or other atomizer using an electrical resonant transformer (Tesla coil). This process easily converts a liquid emulsion into a free-flowing powder without the need for heat. By applying an HVLCHFAC or HVLCLFAC field around the atomization site, it is possible to reduce the amount of thermal energy required to facilitate the conversion of a liquid flavor or food ingredient into a free-flowing powder.

[10] In one embodiment, the process comprises the steps of: forming an emulsion by emulsifying at least one core component with a solution or suspension comprising a liquid solvent and at least one wall material; atomizing the emulsion into droplets using an atomizer connected to a high-voltage, low-current, high-frequency alternating current source, or a high-voltage, low-current, low-frequency alternating current source; and drying the droplets in a drying chamber at an inlet temperature of approximately 25°C to approximately 150°C and an outlet temperature of approximately 25°C to approximately 110°C to obtain the encapsulated product. In some embodiments, higher inlet temperatures, ranging from over 100°C to approximately 150°C, may be employed.

[11] In another aspect, the present technology provides a spray drying system that includes an atomizer for atomizing the emulsion into droplets and a dryer for drying the atomized droplets. An electrical resonant transformer is connected to the atomizer and applies either high-voltage, low-current, high-frequency alternating current or high-voltage, low-current, low-frequency alternating current to the atomization site. The alternating current applies energy to the atomized emulsion, allowing for the use of lower temperatures for the drying gas in the dryer compared to conventional spray drying systems. An inert gas can be used in the spray drying system to improve the quality attributes of the finished powders. The inert gas can be used as both the atomizing fluid and the drying gas within the spray dryer's drying chamber.

[12] In a further aspect, the present technology provides an encapsulated product prepared by spray-drying a liquid emulsion comprising at least one core component and at least one wall material, wherein an electrical charge from a high-voltage, low-current alternating current source is applied to the liquid emulsion. The encapsulated product may have a core-shell structure or a matrix structure. In some embodiments, the high-voltage alternating current may act as a bactericide, thereby improving food safety.

[13] At least one aspect of the present technology provides encapsulated food and flavor products with improved quality characteristics, such as increased encapsulation efficiency (ingredient retention) and / or a flavor profile comparable to that of the starting food ingredient or flavor. By mitigating the problems associated with conventional high-temperature spray drying, the present technology produces a free-flowing encapsulated powder that retains its original flavor profile. In addition, in some embodiments, encapsulated food and flavor products may have an improved shelf life compared to conventional and electrostatically spray-dried products due to the bactericidal properties imparted by the high-voltage alternating current source.

[14] Further details and embodiments are described in the discussion of the detailed description below. Brief description of the drawings

[15] Figure 1 is a schematic of one modality of a spray drying system of the present technology;

[16] Figure 2 is a cross-sectional view of one modality of a spray nozzle used in the spray drying system of the present technology;

[17] Figure 3 is a cross-sectional view of an alternative form of a spray nozzle used in the spray drying system of the present technology;

[18] Figure 4 is a cross-sectional view of another alternative form of a spray nozzle used in the spray drying system of the present technology;

[19] Figure 5 is a schematic of an alternative modality of a spray drying system of the present technology;

[20] Figure 6 is a schematic of an alternative modality of a spray drying system of the present technology;

[21] Figure 7 is an SEM photograph showing the morphological characteristics of the encapsulated product made in Example 1;

[22] Figure 8 is an SEM photograph showing the morphological characteristics of the encapsulated product made in Example 2;

[23] Figure 9 is an SEM photograph showing the morphological characteristics of the encapsulated product made in Example 3;

[24] Figure 10 is an SEM photograph showing the morphological characteristics of the encapsulated product made in Example 4;

[25] Figure 11 is an SEM photograph showing the morphological characteristics of the encapsulated product made in Example 5;

[26] Figure 12 is an SEM photograph showing the morphological characteristics of the encapsulated product made in Example 6;

[27] Figure 13 is an SEM photograph showing the morphological characteristics of the encapsulated product made in Example 7;

[28] Figure 14 is an SEM photograph showing the morphological characteristics of the encapsulated product made in Example 8;

[29] Figure 15 is an SEM photograph showing the morphological characteristics of the encapsulated product made in Example 9. Detailed description of the invention

[30] The present technology provides an improved spray-drying system and method for preparing an encapsulated product comprising at least one core component and at least one carrier or wall material. The method comprises atomizing an emulsion formed from the core material and the carrier or wall material, and applying either high-voltage, low-current, high-frequency alternating current (HVLCHFAC) or high-voltage, low-current, low-frequency alternating current (HVLCLFAC) at the atomization site. The HVLCHFAC / HVLCLFAC field applied to the atomized emulsion facilitates film formation by the wall material without the high heat normally required to induce film formation. As a result, the emulsion can be dried with or without a gentle heat supply to the drying chamber to produce a spray-dried encapsulated powder.

[31] The encapsulated product of the present technology is prepared from a formulation comprising a solid component and a liquid solvent component. The solid component comprises 45% to 95%, alternatively 50% to 90%, alternatively 60% to 85%, or alternatively 75% to 85% by weight of at least one carrier or wall material, and 5% to 50%, alternatively 10% to 50%, alternatively 15% to 40%, or alternatively 15% to approximately 25% by weight of at least one core material. The carrier or wall material is selected from a variety of materials or mixtures thereof, including carbohydrates, proteins, gums, lipids, waxes, food-grade polymers, phospholipids, cellulosic materials, and cellular materials, including, but not limited to, yeast cells or cell wall materials.Desirable wall materials should have GRAS (generally recognized as safe) status, have film-forming ability, be able to form a stable emulsion with the core material, and not be reactive with the core material.

[32] Examples of carbohydrates suitable for use as Suitable vehicle or wall materials include maltodextrin, chitosan, sucrose, glucose, lactose, dextran, corn syrup, cyclodextrin, isomalt, amylose, modified food starch, sugar-based materials, sugar alcohol-based materials, and mixtures thereof. Examples of suitable protein materials include gelatins, soy proteins, whey proteins, zein, casein, albumin, hemoglobin, peptides, gluten, and mixtures thereof. Examples of suitable gums include gum arabic, acacia gum, agar, sodium alginate, carrageenan, xanthan gum, gelatins, and mixtures thereof. Examples of suitable cellulose materials include carboxymethylcellulose, methylcellulose, ethylcellulose, nitrocellulose, acetylcellulose, cellulose acetate-phthalate, cellulose acetate-butyrate-phthalate, and mixtures thereof. The selection of the carrier or wall material will depend on the core material and the requirements of the encapsulated product.

[33] The core material may include any naturally occurring or created flavor base oil, for example, citrus, spice, mint, berry, tropical fruit, or savory types, or essential oils. The core material may also include individual components of any of the naturally occurring or created oils or flavors, such as, for example, benzaldehyde, isoamyl acetate, ethyl butyrate, linalool, methyl salicylate, limonene, menthol, decanol, phthalate Lfrzcnn / Lznz / E / YiAi diethyl and citral. The base oil may contain various flavor / aroma compounds, depending on the type of flavor creation. The core material may also be other natural or synthetic materials that can benefit from encapsulation. Such other materials include, for example, animal and / or vegetable oils, animal and / or vegetable protein, starch and starch derivatives, coffee, tea, vegetable or fruit juices, milk protein fractions, eggs, cereals, stevia, animal feed, cocoa powder, vitamins, nutraceuticals, colorants, perfumes, fragrances, spices, flavorings, enzymes, pharmaceutical actives, agricultural actives, including fertilizers and pesticides, pharmaceutically or nutritionally acceptable salts, ceramic materials, catalyst supports, microalgae, and hemoglobin. The core material may also comprise mixtures of the above core materials.

[34] The formulation may include one or more optional additives, such as, for example, emulsifiers, antioxidants, colorants, sweeteners, animal / vegetable oil, animal / vegetable proteins, food acids, salts, diluents, flavor maskers, flavor enhancers, fillers, preservatives, fruit / vegetable extracts, stabilizers, lubricants, and the like. Such additives are known to those skilled in the art.Examples of emulsifiers that can be used include monoglycerides, mixtures of monoglycerides and diglycerides, propylene glycol monoglycerides, lecithin, modified lecithins, acetylated monoglycerides, lactylated fatty acid esters of glycerol and propylene glycol, lactylated propylene glycol monoglycerides, sorbitan polyesters

[20] monoglycerides, polyglycerol esters, diacetyl tartarate esters of monoglycerides (DATEM), succinylated esters of monoglycerides, polyoxyethylene propylene copolymers, ethylene oxide-propylene oxide copolymers, and mixtures thereof. Examples of suitable antioxidants include rosemary oil and vitamin E. Typical amounts of additives, when used, may range from approximately 0.1% to approximately 10% by weight for emulsifiers, from approximately 0.01% to approximately 5% by weight for antioxidants, and from approximately 0.01% to approximately 10% by weight for other additives.

[35] The liquid solvent component of the spray-dried formulation is generally water, but other suitable solvents, such as hexane or ethanol, or a combination of solvents, may be used. The choice of liquid solvent will depend on the solid component and the end use of the spray-dried product.

[36] The dry spray formulation is prepared by emulsifying together the liquid solvent, the material of the The wall and core material, and any optional components, are combined to form an emulsion. In some embodiments, the wall material is pre-hydrated in water before emulsification with the core material. The wall material may be supplied by the manufacturer in a pre-hydrated or water-hydrated form prior to use. Better flavor retention is achieved when the wall material is widely solubilized and / or fully saturated before emulsification. The amount of water and the hydration time required to saturate the wall material will depend on the type of wall material used in the formulation. For example, some starches may need to be hydrated overnight to avoid residual granules and fully perform the interface function between the water and the flavoring component (oil) in the emulsion.Preferably, enough water is used to form an aqueous solution or suspension of the wall material.

[37] Emulsification of the core material with the wall material and the liquid solvent can be achieved using a high-shear mixer or a homogenizer. In general, higher shear rates tend to produce better, more homogeneous emulsions with smaller micelles. Suitable devices for achieving high shear rates include, but are not limited to, the HSM-100-LSK high-shear mixer, available from Lfrzcnn / Lznz / E / YiAi Ross, operated for 5 to 20 minutes at 2,000 rpm to 10,000 rpm, or a Nano Debee homogenizer, operated at a pressure of 140.6 kg / cm² to 4,218 kg / cm² through 2 to 6 cycles. It should be appreciated that these devices are only examples, and that a person skilled in the art can determine other suitable devices. The specific equipment and operating conditions employed to obtain a liquid emulsion will depend, at least in part, on the core and wall materials selected. The resulting emulsion has a viscosity suitable for pumping and atomizing in a spray-drying system. Viscosities can vary from approximately 50 cP to approximately 10,000 cP, alternatively approximately 100 cP to approximately 7,000 cP, alternatively approximately 150 cP to approximately 4,000 cP, alternatively approximately 150 cP to approximately 1,500 cP, alternatively Lfrzcnn / Lznz / E / YiAi approximately 150 cP to approximately 600 cP, to approximately 700 cP, to approximately 800 cP, to approximately 900 cP, or to approximately 1,000 cP. The The resulting emulsion has a solids content, comprising the wall material, the core material, and any additives, ranging from approximately 15% to approximately 70% by weight of the emulsion, alternatively from approximately 15% to approximately 65% ​​to approximately 60%, to approximately 55%, to approximately 50%, or to approximately 45% by weight of the emulsion.

[38] Once the emulsion of the core material and the wall material has been prepared, it is introduced into the spray drying system, where the liquid emulsion is dried into a free-flowing powder of encapsulated core material. One embodiment of the spray drying system is shown in Figure 1. The spray drying system 10 comprises an atomizing unit 20 for atomizing the emulsion into droplets, a drying unit 30 connected to the atomizing unit for drying the droplets into a powder, and a collection unit 40 for collecting the dried powder product. The spray drying system may also include a recirculation unit 50 that allows the drying gas exiting the drying unit to be processed and reused within the drying unit. With reference to Figures 1 and 2, each of the units will now be described in more detail.

[39] The atomizing unit 20 includes an inlet port 21 for receiving the emulsion to be dried. Typically, the emulsion is mixed and / or stored in an emulsion tank 12 and pumped by a feed pump 14 to the inlet port 21 of the atomizing unit 20. Any suitable feed pump 14 may be used to pump the liquid emulsion into the atomizing unit. The feed rate for pumping the liquid emulsion will depend, at least in part, on the scale of the system. Lfrzcnn / Lznz / E / YiAi spray drying, and can vary from approximately 5 ml / min to approximately 15 ml / min for bench-scale operations, to approximately 500 ml / min to approximately 10,000 ml / min for production-scale operations. In one mode, the feed rate can range from approximately 5 ml / min to approximately 500 ml / min.

[40] The atomizing unit 20 may include several different atomizers known in the art, such as, but not limited to, a dual-fluid nozzle, a rotary atomizing nozzle, a pressurized nozzle, or another commercially available atomizing nozzle. In one embodiment, the atomizing unit comprises a dual-fluid spray nozzle 24, shown in Figure 2. The spray nozzle 24 includes an elongated body 25 having a proximal end 26 connected to the inlet port 21, and a distal or descending end 27 having a spray nozzle 28. A hollow conductive metal electrode 29 extends through the body 25, from the inlet port to the spray nozzle 28, and receives and carries the emulsion to be atomized.A high-voltage alternating current source 60 is connected to a proximal end of the conductive metal electrode 29, and imparts a charge to the emulsion as the emulsion travels through the electrode to the spray tip 28.

[41] An important aspect of the present technology is Lfrzcnn / Lznz / E / YiAi The use of a high-voltage, low-current, high-frequency alternating current source, or alternatively a high-voltage, low-current, low-frequency alternating current source, to impart an alternating current load to the emulsion. High voltage is understood to be a voltage of at least 2 kVAC, preferably at least 10 kVAC, and may vary up to 200 kVAC or more. In one embodiment, the high-voltage source supplies a voltage that varies from approximately 20 kVAC to approximately 50 kVAC. Low current is understood to be a current that is less than 1 mA. The frequency of the current source may range from 50 kHz to 30 megahertz (MHz), depending on whether the alternating current source is a high- or low-frequency current source. The low frequency may range from approximately 50 kHz to approximately 3 MHz. The high frequency may range from approximately 3 MHz to approximately 30 MHz.While not tied to any specific theory, alternating current (AC) provides a localized charge on the surface of the atomized droplet, which can lead to faster skin formation compared to the electrostatic charge provided by direct current (DC). This faster skin formation can result in improved encapsulation efficiency and reduced loss of volatile components. AC produces droplets with a neutral charge that do not exhibit static charge buildup. This can reduce the amount of product buildup on the spray dryer walls that can occur in electrostatic spray drying systems due to residual static charge accumulation. AC also allows for better control of particle size and morphology compared to conventional and electrostatic spray drying systems.

[42] The high-voltage, low-current alternating current source is an electrically resonant transformer circuit (Tesla coil). A Tesla coil is a high-frequency oscillator that drives a resonant air-core transformer tuned to convert high-voltage, high-current into low-voltage, high-current. The alternating current produces frequencies in the low radio frequency range, approximately 50 kHz to approximately 1 MHz, and depends on the capacitance frequency. Higher frequencies can be obtained by changing the capacitance and / or the spark gap within the tank circuit of a spark-type Tesla coil, or by driving high-speed switching transistors in a solid-state Tesla coil. There are three types of Tesla coils: spark-excited or spark-triggered Tesla coil, switched or solid-state Tesla coil, and continuous-wave Tesla coil.Tesla coils with spark gaps use a spark gap to switch the oscillating current between the primary and secondary circuits. Tesla coils can be stationary spark gaps. Lfrzcnn / Lznz / E / YiAi stationary triggered spark gap or rotating spark gap. Solid-state Tesla coils use semiconductor devices to switch current pulses from a DC power supply through the primary circuit. The current pulses to the primary circuit excite resonance in the tuned secondary circuit. Solid-state Tesla coils can be single-resonant or double-resonant. Continuous-wave coils generate a continuous sine wave output rather than a pulsed output. Although any of the three types of Tesla coils could be used in current technology, a switched or solid-state Tesla coil is preferred for safety reasons.

[43] The atomizing unit 20 also includes an inlet gas port 22 for introducing an atomizing gas into the spray nozzle. The atomizing gas can be supplied through the gas inlet port 22 at a pressure of approximately 0.35 kg / cm² to approximately 8.44 kg / cm², alternatively from approximately 1.41 kg / cm² to approximately 5.62 kg / cm², or alternatively from approximately 2.81 kg / cm² to approximately 4.22 kg / cm². In some embodiments, the atomizing gas supplied to the spray nozzle can be heated. The temperatures for the atomizing gas can range between the temperature Lfrzcnn / Lznz / E / YiAi ambient and approximately 130°C. In some preferred embodiments, the atomizing gas temperature is in the range of approximately 60°C to approximately 90°C. By heating the atomizing gas, the thermally induced phase separation of the liquid and solids in the emulsion occurs more rapidly than if the atomizing gas were at ambient temperature, resulting in faster film formation by the wall material on the droplet surface. In some alternative embodiments, the atomizing gas may be cooled before being supplied to the spray nozzle, such that the gas is at a temperature below ambient temperature.

[44] The atomizing gas can be air, carbon dioxide, or an inert gas, such as nitrogen, argon, helium, xenon, krypton, or neon, although nitrogen is preferred. The use of an inert gas, such as nitrogen, as the atomizing gas also offers the benefit of reducing the concentration of oxidative byproducts in the finished encapsulated powder product that might otherwise occur if air were used as the atomizing gas. As a result, the encapsulated powder product has better flavor and / or color due to lower concentrations of oxidative degradation products. An inert gas also improves a safety aspect of the spray-drying system, since the nozzle tip can emit sparks capable of igniting flammable materials and powders. Consequently, in some embodiments, the atomizing gas does not include air.

[45] The atomizing gas and emulsion flow in co-current through the hollow electrode 29 and meet at the electrode tip 28. The emulsion is charged as it passes through the conducting electrode because the high-voltage charge is supplied by the high-voltage alternating current source 60. The charged emulsion is atomized by the tangential shear forces provided by the pressurized gas at the electrode tip 28 and sprayed into the drying unit 30. Not linked to the theory, it is believed that the HVLCHFAC field, or HVLCLFAC field, applied to the emulsion at the atomization site drives the core material to the center of the atomized droplet and facilitates film formation by the wall material on the droplet surface.Since film formation is achieved through the application of an electric field, the high temperatures required for proper film formation in conventional spray drying systems can be avoided, allowing for significantly lower drying temperatures in this system. Furthermore, the atomized cloud of droplets acts as a capacitor (parasitic capacitance) and can interact with the soil, thus facilitating low-temperature drying. In some embodiments, the resonant transformer circuit that supplies the high-voltage, low-current alternating current can be tuned to resonate with the capacitance developed in the atomized cloud of droplets.Adjusting the frequency of the alternating current waveform to match the inductance and capacitance of the droplet cloud causes the system to resonate and provides the maximum amount of charge for drying, thus improving the efficiency of the drying system.

[46] In an alternative embodiment, a rotary atomizer nozzle, as shown in Figure 3 as 24a, can be used to atomize the emulsion into droplets. The rotary atomizer nozzle 24a employs a rotating disc or plate 62, instead of a spray nozzle, to atomize the emulsion into droplets. Like the dual-fluid nozzle shown in Figure 2, the rotary atomizer nozzle 24a includes a hollow metal electrode 29a connected to a high-voltage alternating current source. The high-voltage alternating current source imparts an alternating current charge to the emulsion as the emulsion travels through the electrode 29a to the plate 62.

[47] In a further embodiment, a pressure nozzle, as shown in Figure 4 as 24b, can be used to atomize the emulsion into droplets. Regardless of the atomizer employed, a high-voltage alternating current source is connected to the conductive metal electrode inside the atomizer nozzle, and imparts an alternating current charge to the emulsion as the emulsion travels through the electrode and is sprayed into the drying unit.

[48] ​​Referring again to Figure 1, the drying unit 30 comprises a drying chamber 32 for drying the atomized emulsion droplets, an inlet dryer 34 for receiving the drying gas, and a dryer outlet 36 through which the encapsulated product and drying gas exit the drying chamber. Inside the drying chamber, the dryer inlet temperature can range from 25°C to 150°C, and the dryer outlet temperature can range from 25°C to 110°C. These temperatures are significantly lower than the processing temperatures of conventional spray drying systems. The drying gas can be a mixture of inert gas and air, such that the oxygen concentration of the drying gas stream is lower than that of air. Preferably, the oxygen concentration of the drying gas is less than 5% by volume.In some configurations, nitrogen gas, used as an atomizing gas, enters the drying chamber through the atomizer and mixes with the gas in the drying chamber to maintain the oxygen concentration below 5% by volume. Alternatively, nitrogen gas could be introduced through a port into the drying chamber to maintain the oxygen concentration below 5%.

[49] The drying gas flowing inside the chamber of The gas flow in the Lfrzcnn / Lznz / E / YiAi drying unit 32 comes into contact with the atomized droplets and evaporates the water. The gas flow can be parallel or countercurrent to the flow of atomized droplets. The gas flow rate will depend on the size of the drying unit, but can vary from approximately 70 liters per second (L / s) to approximately 8496 L / s, alternatively from approximately 236 L / s to approximately 7080 L / s, or alternatively from approximately 330.4 L / s to approximately 4720 L / s.

[50] The drying gas carries the dried encapsulated product from the drying chamber to the product collection unit 40, where it is collected as a final product. The product collection unit comprises a separation cyclone 42, where the dried particles are separated from the drying gas, and a product collection chamber 44 that receives the final encapsulated product. The drying gas exits the separation cyclone as exhaust gas through an exhaust outlet 48.

[51] In a preferred embodiment, the exhaust outlet 48 is coupled to the recirculation unit 50 so that the exhaust gas can be processed and recirculated in the drying chamber. In the recirculation unit, the exhaust gas is filtered through a particle separator 52 and then conveyed by a blower 54 to a condenser 56. The condenser 56 removes excess moisture from the exhaust gas, usually by means of chilled water condenser coils. Preferably, as much moisture as possible is removed from the exhaust gas so that the moisture level in the recirculated gas is less than 10%, preferably less than 3%. The drying gas is directed by the blower 54 through a heater 58, which reheats the gas to a temperature suitable for reuse as drying gas.The recirculated drying gas is mixed with nitrogen gas introduced through the atomizer, or an alternative port in the drying chamber, to keep the oxygen content of the drying gas below 5%.

[52] The present technology could be used in a variety of commercially available spray dryer types or fluidized bed spray dryers with the modification of drying gas recycling. Spray dryer types include, but are not limited to, a conventional spray drying system that has an external particle separation configuration, as shown in Figure 1. In an alternative embodiment, the spray drying system could comprise a modified spray drying system 10a with an internal particle separation configuration, as shown in Figure 5. The system shown in Figure 5, where equal numbers represent equal parts, is similar to that shown in Figure 1. Instead of the separation cyclone Lfrzcnn / Lznz / E / YiAi As shown in Figure 1, the system shown in Figure 5 employs a separation chamber 72 within the drying chamber 32a to separate the dried particles from the drying gas. A product collection chamber 44a receives the final dry, encapsulated product. The drying gas exits the drying chamber 32a as exhaust gas and travels through a condenser 56a, where water vapor is removed from the exhaust gas, typically by means of chilled water condenser coils. The dry exhaust gas is then directed by a blower 54a through a gas heater 58a, which reheats the drying gas to a temperature suitable for reuse as drying gas. The recirculated drying gas is then mixed with nitrogen gas introduced through the atomizer, or an alternative port in the drying chamber, to maintain the oxygen content of the drying gas below 5%.

[53] As an additional alternative, the spray drying system could be a modified spray drying system 10b shown in Figure 6. This system employs a FilterMat spray dryer configuration, which equips the drying unit 30b with a drying chamber 32b, a secondary drying zone 75, and a cooling zone 76, as shown in Figure 6. It is also contemplated that the present technology could be used with other types of fluidized dryers.

[54] The present technology provides several advantages over traditional spray drying technologies. Traditional spray drying operates at elevated temperatures ranging from approximately 150°C to approximately 210°C for inlet temperatures and from approximately 60°C to approximately 120°C for outlet temperatures. These temperatures require 30 to 50 minutes of preconditioning for the spray dryer to reach the set heating conditions. During the typical spray drying process, product stuck in the drying chamber will not be collected due to prolonged exposure to the excessive heat environment, leading to product yields of only 60 to 90%. As a result of the excessive heat environment, many of the highly volatile components volatilize, reducing encapsulation efficiency by 15 to 20%.Products resulting from a conventional spray-drying process are typically in the form of a free-flowing powder, with particle sizes ranging from 80 to 350 µm. The product may have odors due to the unencapsulated surface flavoring, raising concerns about cross-contamination in the production of certain foods. Spray-dried encapsulated flavoring is widely used in a variety of food and beverage products. However, common challenges arise when using it. Lfrzcnn / Lznz / E / YiAi spray-dried flavoring presents problems of dust during food processing, flotation, and slow hydration in water-based applications.

[55] Due to the lower processing temperatures used in the present technology, the time required for spray dryer preconditioning is significantly reduced to 5 to 30 minutes, and less energy consumption is required, depending on the dryer capacity. An additional advantage of the low processing temperatures is that the dried product remaining in the drying chamber has a quality comparable to that of the product collected from the collection chamber. Consequently, the product in the drying chamber can also be collected, increasing product yield to over 90%. In terms of product quality, the process of the present technology provides superior retention of volatile flavor components, thus making the product's flavor profile closer to that of the originally created flavor formulation.The product of this technology also has less oil on its surface than conventional spray-dried products, which can lead to a more stable product in storage since surface oil oxidation is minimized. In conventional spray-dried products, the surface oil content is generally 1% to 5%. However, the product of this technology... The present technology is capable of achieving a surface oil content of less than approximately 1%, preferably less than approximately 0.5%, and most preferably approximately 0.4% or less, based on the total weight of the product. In some embodiments, the product of the present technology has a surface oil content as low as 0.01% by weight. The process of the present technology also offers a product with less aroma in the headspace due to low surface flavors, thus eliminating cross-contamination of flavors. The process also provides better control over particle size and morphology than conventional or electrostatic spray drying systems, resulting in products that can have a designed particle size range.In some embodiments, the process of the present technology can provide products with larger particle sizes than conventional spray-drying processes. These larger particle sizes can range from approximately 80 µm to approximately 600 µm, potentially resolving dust problems and offering excellent instant hydration properties in water-based applications. In some embodiments, the spray-dried products have a particle size distribution in which the median or D50 value is at least 85 µm, compared to a D50 value of less than 50 µm for conventional spray-dried products. In other embodiments, the D50 value of the spray-dried powder from the present technology is at least 75 µm.Depending on the product type, small particle sizes may be desirable, such as those in the range of less than 1 μm to approximately 300 µm, or alternatively less than 1 µm to approximately 250 µm, with a D50 value of less than 40 µm. The process of the present technology can achieve such small particle sizes using an emulsion with a solids content of less than 50% by weight. In some embodiments, the spray-dried products have an agglomerated morphology, with multiple smaller particles adhering to larger particles to form agglomerates. In other embodiments, the process can be adjusted to provide a discrete particle morphology. It is also envisaged that, in some embodiments, the high-voltage alternating current used in the present technology acts as a bactericide, killing bacteria and / or other microbes and thus improving food safety.

[56] The foregoing modalities are illustrated by the following examples, which should not be interpreted as limiting the invention or the scope of the specific procedures or formulations described herein. A person skilled in the art will recognize that modifications to the technology currently described can be made without Lfrzcnn / Lznz / E / YiAi to deviate from the spirit or scope of the invention. Example 1-2 Materials and methods:

[57] An example formulation was prepared to evaluate the effects of the low-temperature spray drying process of the present technology compared to a conventional high-temperature spray drying process. The formulation contained 80 parts by weight of OSAN starch (Hi-Cap™ 100, National Starch and Chemical Co.) as the carrier material and 20 parts by weight of orange oil (FONA, Inc. 1x160.1515 orange oil) as the core material. Water was used to hydrate the carrier at 82 parts, so that the example emulsion contained approximately 55% solids by weight. The emulsion was prepared by emulsifying the orange oil with prehydrated OSAN starch (Hi-Cap™ 100) using a high-shear mixer (Charles Ross & Son Company, model: HSM-100LSK, serial number: 205756) at 5,000 rpm for 5 minutes.After mixing under high shear, the mixture was homogenized using a homogenizer (Gaulin Corporation, Type 405M3 3TPS) with a first pass at 210.9 kg / cm2 and a second pass at 35.15 kg / cm2. Sample made by conventional spray drying (control sample 1)

[58] An emulsion made by the procedure as described above was sprayed into a pilot-sized spray dryer with an emulsion feed rate of 180 ml / minute, an air pressure of 2.81 kg / cm², and a drying gas flow rate of approximately 23.6 l / s. The dryer temperature was set at 190°C for the inlet and 90°C for the outlet. The product was collected as a free-flowing, dry powder from the product collector for further evaluation. Sample made with current technology (Examples 1 and 2)

[59] An emulsion made by the process described above was sprayed into a pilot dryer with a drying gas recycle function. The HVLCHFAC spray nozzle was charged with 20 kVAC for Example 1 and 50 kVAC for Example 2. The emulsion feed rate was set at 0.18 kg / min with an air pressure of 4.22 kg / cm² and an air flow rate of 306.8 l / s. The inlet temperature for both Example 1 and Example 2 was set at 90°C, and the outlet temperature was observed to be approximately 50°C. The final products were collected as a free-flowing, dry powder. Lfrzcnn / Lznz / E / YiAi

[60] Table 1: Processing parameters and observations Control 1 Example #1 Example #2 Processing Parameter: Spray Nozzle Standard Dual Fluid Nozzle HVLCHFAC Spray Nozzle charged with 20 kVAC HVLCHFAC Spray Nozzle charged with 50 kVAC Emulsion Solids Content (%) 55 55 55 Inlet Temperature (°C) 190 90 90 Outlet Temperature (°C) 85-90 50 50 Supply Gas Air Nitrogen Nitrogen Emulsion Feed Rate (ml / min) 180 180 180 Atomizing Gas Pressure (kg / cm2j) 2.81 4.22 4.22 Atomizing Temperature (°C) 25 90 90 Visual Appearance of Final Product Free-flowing Powder Free-flowing Powder Free-flowing Powder

[61] Product quality was assessed by total oil, surface oil, moisture content and surface morphology. Total oil analysis:

[62] The total oil content was determined using a Clevenger apparatus. Ten grams of powdered product were dissolved in 150 ml of water in a round-bottom flask of 500 ml. An appropriate amount of boiling wood chips and an antifoaming agent were added to the solution. The Clevenger apparatus was placed on top of the flask with a water-cooled condenser. The solution was distilled for 3 hours. The total oil content was calculated by the weight of the recovered oil divided by the total weight of the sample, as shown in the following equation. Each example was performed in triplicate.

[63] Total oil (%) / Weight of recovered orange oil / \ _ .nn,η / λ= 1 'Sample weight)x 100 Lfrzcnn / Lznz / E / YiAi Surface oil analysis:

[64] The surface oil was determined gravimetrically. The dry powder sample (10 g) was mixed with 150 mL of n-pentane for 4 hours. The surface oil was extracted in the solvent phase. The solvent was separated from the dry powder by filtration and dried using gaseous nitrogen in a flask. The amount of surface oil was determined by subtracting the original weight of the flask from the weight of the flask (after solvent evaporation), as shown in the following equation. Each experiment was performed in triplicate.

[65] Surface oil (%) = (Container weight after pentane evaporation — container weight / / Sample weight x100 (%) Encapsulation efficiency: Encapsulation efficiency is calculated using the following equation: Encapsulation efficiency (%) Total oil content (per g of sample) - Surface oil content (per g of sample) Original oil weight / carrier weight Particle size analysis:

[66] The sample particle size was measured using a laser diffraction particle size analyzer (Beckman Coulter, LS 13 320). The D50 value was calculated and used to compare particle size between each sample. The D50 value, or median value, is defined as the value at which half of the population lies above this point and half below it. For a particle size distribution, the D50 value is the size in millimeters that divides the distribution, with half above and half below it. Lfrzcnn / Lznz / E / YiA of this diameter. Moisture content analysis:

[67] Moisture content was measured using the thermogravimetric (heat loss) method with a moisture analyzer (METTLER TOLEDO, MJ33). The sample (5 g) was added to the aluminum tray for moisture content measurement. The moisture content was determined when the sample was completely dried to the precision scale using heat.

[68] The structure and morphology of the product particles were inspected using a scanning electron microscope (SEM). Results: Total oil / encapsulation efficiency

[69] The products produced by the HVLCHFAC nozzle at 60°C (Example 1) and 90°C (Example 2) were both presented as free-flowing dry powder and provided better total oil and encapsulation performance than the conventional spray-drying control example. Although different voltage loads were used on the samples, Example 1 (20 kVAC) and Example 2 (50 kVAC), there was no significant difference in total oil content or encapsulation efficiency due to the load voltage. Lfrzcnn / Lznz / E / YiAi Lfrzcnn / Lznz / E / YiAi Table 2: Total Oil / Encapsulation Efficiency Total oil (g) Surface oil (%) Encapsulation efficiency Control 1 18.2 0.05 90.9 Example 1 18.6 0.02 92.8 Example 2 18.5 0.05 92.3 Table 3: Particle size analysis: D50 (pm) Control 1 49.3 Example 1 88.6 Example 2 85.9

[70] When comparing the samples prepared using the present technology (Examples 1 and 2) with the control sample, it was found that the samples provided larger particle sizes overall. Example 1 and Example 2 have a D50 of 8.6 pm and 85.9 pm, respectively, larger than the control sample (49.3 pm). There was no significant difference in particle size between Example 1 and Example 2. Table 4: Moisture content Moisture content (%) Control 1 1.6 Example 1 3.2 Example 2 3.0

[71] The samples from Example 1 and Example 2 had moisture contents of approximately 3%, as shown in Table 4. Although these are slightly higher than those of the control spray-dried sample, they are both below an acceptable moisture content limit of 5%.

[72] SEM images depicting the particle structure of samples made using a traditional spray-drying process (Control 1) and the present technology (Examples 1 and 2) are shown in Figure 7, Figure 8, and Figure 9, respectively. Figures 6 and 7 show that the products from Examples 1 and 2 resulted in larger, agglomerated particles with multiple particles adhering to one another. In contrast, the traditional spray-drying sample from Control 1 resulted in a discrete spherical structure with smaller particles, as shown in Figure 7. Lfrzcnn / Lznz / E / YiAi Example 3-4 Materials and methods:

[73] Example 3 and Example 4 were created using the same materials and processes described in Example 1 (loaded with 20 kVAC) and Example 2 (loaded with 50 kVAC), respectively. The amount of water used in these examples was approximately 150 parts to make an emulsion with a solids content of approximately 40%. The processing parameters are summarized in Table 5. Table 5: Processing parameters and observations Example #3 Example #4 Processing Parameters: Spray Nozzle HVLCHFAC Spray Nozzle charged with 20 kVAC HVLCHFAC Spray Nozzle charged with 50 kVAC Emulsion Solids Content (%) 40 40 Inlet Temperature (°C) 90 90 Outlet Temperature (°C) 50 50 Supply Gas Nitrogen Nitrogen Atomizing Gas Pressure (kg / cm2) 4.22 4.22 Atomizing Gas Temperature (°C) 90 90 Emulsion Feed Rate (ml / min) 180 180 Visual Appearance of Final Product Free-flowing Powder Free-flowing Powder Result and observation:

[74] The samples prepared by the present technology with a charged voltage of 20 kVAC (Example 3) and 50 kVAC (Example 4) and lower solids content (40% solids) were both free-flowing dry powders.

[75] In terms of total oil loading and encapsulation efficiency, as shown in Table 6 below, the two samples have higher encapsulation efficiency than control sample 1, Example 1 and Example 2, which used an emulsion with a higher solids content. There was no significant difference in encapsulation efficiency as a result of the different charging voltages, 20 kVAC (Example 3) versus 50 kVAC (Example 4). Lfrzcnn / Lznz / E / YiAi Table 6: Total Oil / Encapsulation Efficiency: Total oil (g) Surface oil (%) Encapsulation efficiency (%) Example 3 19.2 0.03 95.9 Example 4 19.3 0.01 9 6.6 Table 7: Particle size analysis: D50 (pm) Example 3 21.9 Example 4 37.7

[76] The samples in Example 3 and Example 4 had smaller particle sizes and lower D50 compared to the samples in Example 1 and Example 2. It is believed that the lower solids content of the emulsion used in Examples 3 and 4 resulted in smaller atomized emulsion qites at 4.22 kg / cm² due to a lower viscosity compared to Examples 1 and 2, which used a higher solids content emulsion that had a higher emulsion viscosity. To optimize the particle size distribution, the solids content can be adjusted. Lfrzcnn / Lznz / E / YiA Table 8: Moisture content Moisture content (%) Example 3 1.7 Example 4 2.1

[77] The moisture content of Example 3 and Example 4 both showed an acceptable moisture content limit below 5%, as shown in Table 8.

[78] SEM images of the samples from Example 3 and Example 4 are shown in Figure 10 and Figure 11, respectively. Comparing the particle structure shown in Figure 10 with that in Figure 11, it can be seen that, at lower solids content, the difference in charging voltage has an effect on the resulting structure of the spray-dried product. The higher charging voltage used in Example 4 helped promote a more agglomerated particle structure, while the lower charging voltage used in Example 3 resulted in more discrete particles. Examples 5, 6, 7 and 8: lowest temperature Materials and methods:

[79] A series of samples were prepared using the same formulation as Examples 1, 2, 3, and 4 at a lower inlet temperature of 60°C. Examples 5 and 6 contained the same amount of emulsion solids content as Example 1 and Example 2 at 55% solids. Examples 7 and 8 contained the same amount of emulsion solids content as Examples 3 and 4 at 40% solids. The process parameters are shown in Table 9 below. Lfrzcnn / Lznz / E / YiAi Table 9: Processing parameters and observations Example #5 Example #6 Example #7 Example #8 Processing Parameters: Spray Nozzle HVLCHFAC Spray Nozzle charged with 20 kVAC HVLCHFAC Spray Nozzle charged with 50 kVAC HVLCHFAC Spray Nozzle charged with 20 kVAC HVLCHFAC Spray Nozzle charged with 50 kVAC Emulsion Solids Content (%) 55 55 40 40 Inlet Temperature (°C) 60 60 60 60 Outlet Temperature (°C) 50 50 50 50 Supply Gas Nitrogen Nitrogen Nitrogen Nitrogen Atomizing Gas Pressure (kg / cm2) 4.22 4.22 4.22 4.22 Atomizing Gas Temperature (°C) 90 90 90 90 Emulsion Feed Rate (mi / min) 180 180 180 180 Visual appearance of the final product Free-flowing powder Free-flowing powder Free-flowing powder Free-flowing powder Result and observation:

[80] All finished samples were dried after the lowest temperature process (60°C) and collected as a free-flowing powder. Total oil / Encapsulation efficiency

[81] Overall, all samples made with the lower inlet temperature of 60°C showed higher encapsulation efficiency than control sample 1 by 91%. Unlike when using an inlet temperature of 90°C, the charging voltage showed an effect on total oil content and encapsulation efficiency when dried at an inlet temperature of 60°C. It was found that, comparing Example 5 with Example 6, total oil content and encapsulation efficiency decreased with increasing charging voltage when the emulsion solids content was 55%. However, total oil content and encapsulation efficiency increased with increasing charging voltage, as shown in Example 7 and Example 8, when using an emulsion with a lower solids content (40%). Lfrzcnn / Lznz / E / YiAi Table 10: Total Oil / Encapsulation Efficiency Total oil (g) Encapsulation efficiency (%) Example 5 19.0 95.0 Example 6 18.5 92.5 Example 7 18.4 91.9 Example 8 18.8 93.9 Particle size:

[82] In general, the samples made with the lower solids content emulsion (Examples 7 and 8) showed smaller particle sizes than the samples made with the higher solids content emulsion (Examples 5 and 6), as shown in Table 11. Table 11: Particle size D50 (pm) Example 5 75.2 Example 6 77.3 Example 7 20.7 Example 8 29.5 Lfrzcnn / Lznz / E / YiAi Moisture content Table 12: Moisture content Moisture content (%) Example 5 4.1 Example 6 4.0 Example 7 3.7 Example 8 3.0

[83] All samples showed a moisture content lower than the acceptable moisture content limit of 5%, demonstrating the ability to dry the emulsion from liquid to free-flowing dry powder at 60°C using the HVLCHFAC spray nozzle.

[84] SEM images of the samples from Examples 5, 6, 7, and 8, which were made using an inlet temperature of 60°C and with different load voltages and solids contents, are shown in Figure 12, Figure 13, Figure 14, and Figure 15, respectively. Comparing Figure 12 with Figure 13, it can be seen that, at a solids loading of 55% for the samples, there was no significant difference in particle structure as a result of the different load voltages (20 kVAC for the sample in Figure 12 and 50 kVAC for the sample in Figure 13). Both product samples showed an agglomerated structure. However, when comparing Figure 14 with Figure 15, it can be seen that, at a solids loading of 40% for the samples, there is a difference in the particle structure as a result of the different loading voltages (20 kVAC for the sample in Figure 14 and 50 kVAC for the sample in Figure 15).A higher voltage load helped promote agglomeration, as shown in Figure 15.

[85] The present technology and the manner and process of making and using it are now described in terms so complete, clear, concise, and exact as to enable a person skilled in the art to whom the present technology pertains to making and using it. It should be understood that the foregoing describes some features and advantages of the invention and that modifications may be made to it without departing from the spirit and scope of the technology now described as set forth in the following claims.

Claims

1. A method for preparing an encapsulated product having a core component encapsulated within a wall material comprising the steps of: forming an emulsion by emulsifying at least one core material with at least one liquid solvent and at least one wall material; atomizing the emulsion into droplets using an atomizing gas and an atomizer connected to a high-voltage, low-current alternating current source supplying a voltage charge to the droplets in the range of approximately 2 kV to approximately 200 kV; spraying the charged droplets into a drying chamber; drying the droplets in the drying chamber by contacting the droplets with a drying gas introduced at an inlet of the drying chamber, wherein the drying chamber has an inlet temperature adjusted from approximately 25°C to approximately 150°C and an outlet temperature from approximately 25°C to approximately 110°C;and collect the dried droplets as an encapsulated product.

2. The method according to claim 1, wherein the core material comprises from 5% to 50% by weight, and the wall material comprises from 50% to 95% by weight, based on the total dry weight of the core material and the combined Lfrzcnn / Lznz / E / YiA wall material.

3. The method according to any of claims 1 to 2, wherein the emulsion is introduced into the atomizer at a feed rate of approximately 20 ml / min to approximately 400 ml / min.

4. The method according to any of claims 1 to 3, wherein the atomizing gas is an inert gas.

5. The method according to claim 4, wherein the atomizing gas is pressurized.

6. The method according to claim 5, wherein the atomizing gas is pressurized to a pressure of 0.35 kg / cm2 to 8.44 kg / cm2.

7. The method according to any of claims 1 to 6, wherein the drying gas has an oxygen content of less than 5%.

8. The method according to claim 7, wherein the drying gas has a flow rate of approximately 70 liters per second (L / s) to approximately 8,496 L / s.

9. The method according to any of claims 1 to 8, wherein the method further comprises the steps of separating the drying gas from the dried droplets and recirculating the drying gas to the inlet of the drying chamber.

10. The method according to claim 9, wherein the drying gas is processed to remove moisture before introducing the recirculated drying gas into the inlet of the drying chamber.

11. The method according to claim 9 or 10, wherein the recirculated drying gas is mixed with nitrogen gas so that the drying gas has an oxygen content of less than 5% by volume.

12. The method according to any one of claims 1 to 11, wherein the wall material comprises at least one material selected from carbohydrates, proteins, gums, lipids, waxes, food-grade polymers, celluloses, phospholipids, and cell wall materials.

13. The method according to any of claims 1 to 12, wherein the core material comprises a volatile oil.

14. The method according to any of claims 1 to 13, wherein the core material comprises one or more flavoring components.

15. The method of any one of claims 1 to 12, wherein the core material is selected from animal oils, vegetable oils, animal protein, vegetable protein, starch, starch derivatives, coffee, tea, vegetable juices, fruit juices, milk protein fractions, eggs, cereal, stevia, animal feed, cocoa powder, vitamins, nutraceuticals, coloring agents, perfumes, fragrances, spices, enzymes, pharmaceutical actives, agricultural actives, pharmaceutically or nutritionally acceptable salts, ceramic materials, catalyst supports, microalgae, hemoglobin, and combinations thereof.

16. The method according to any of claims 1 to 15, wherein the high voltage alternating current source is a high voltage, low current, high frequency alternating current source.

17. The method according to claim 16, wherein the high frequency is in the range of approximately 3 MHz to approximately 30 MHz.

18. The method according to any of claims 1 to 15, wherein the high voltage alternating current source is a high voltage, low current, low frequency alternating current source.

19. The method according to claim 18, wherein the low frequency is in the range of approximately 50 kHz to approximately 3 MHz.

20. The method according to any of claims 1 to 19, wherein the high voltage alternating current source is an electrical resonant transformer circuit.

21. An encapsulated product prepared by the method of any of claims 1 to 20.

22. The product according to claim 21, wherein the product has a surface oil content of approximately 0.5% by weight or less based on the weight of the product.

23. The product according to any of claims 21 to 22, wherein the product has an average particle size of approximately 80 pm to approximately 600 pm.

24. A spray drying system for drying a liquid into a dry powder, the system comprising: (a) a drying chamber having an inlet through which the drying chamber receives a drying gas to dry the liquid, and an outlet through which the dry powder can be collected; (b) an atomizer adapted to receive the liquid and arranged to atomize the liquid in the drying chamber into droplets, which come into contact with the drying gas in the drying chamber; (c) a high-voltage alternating current source in electrical contact with the atomizer and configured to impart an electrical charge to the liquid atomized by the atomizer.

25. The system according to claim 24, wherein the high voltage alternating current source is a high voltage, low current Lfrzcnn / Lznz / E / YiAi and high frequency alternating current source.

26. The system according to claim 25, wherein the high frequency is in the range of approximately 3 MHz to approximately 30 MHz.

27. The system according to claim 24, wherein the high-voltage alternating current source is a high-voltage, low-current, low-frequency alternating current source.

28. The system according to claim 27, wherein the low frequency is in the range of approximately 50 kHz to approximately 3 MHz.

29. The system in accordance with any of claims 24 to 28, wherein the high voltage is in the range of approximately 2 kVAC to approximately 200 kVAC.

30. The system in accordance with any of claims 24 to 29, wherein the low current is less than 1 mA.

31. The system in accordance with any of claims 24 to 30, wherein the high voltage alternating current source is an electrical resonant transformer circuit.

32. The system according to any of claims 24 to 31, wherein the atomizer is a dual-fluid spray nozzle, a rotary atomizing nozzle, or a pressurized nozzle. Lfrzcnn / Lznz / E / YiAi 33. The system according to claim 32, wherein the atomizer has a hollow electrode that is in electrical contact with the high-voltage alternating current source.

34. The system according to claim 33, wherein the atomizer has a nozzle body and the hollow electrode is arranged within the nozzle body.

35. The system according to any of claims 32 to 34, wherein the atomizer further includes a liquid inlet for receiving the liquid to be atomized, and the liquid inlet is coupled to the hollow electrode so that the liquid is received and travels through the hollow electrode.

36. The system according to any of claims 24 to 35, wherein the system further includes a recirculation unit in communication with the inlet and outlet of the drying chamber, the recirculation unit comprising a condenser, for processing the drying gas leaving the outlet, to remove moisture from the drying gas, and a heater, for heating the processed drying gas before introducing the processed drying gas into the inlet of the drying chamber.

37. The system according to any of claims 24 to 36, wherein the atomized droplets in the drying chamber form a spray cloud. Lfrzcnn / Lznz / E / YiAi 38. The system according to claim 37, wherein the spray droplet cloud develops a capacitance.

39. The system according to claim 5 38, wherein the high voltage alternating current source is tuned for resonance with the capacitance developed in the spray cloud.