High total solid spray drying method

Abstract

The disclosure provides systems and methods for high total TS spray drying. The systems and methods include (1) a high concentration evaporation step in addition to the convention evaporation; (2) additional cavitation after high concentration; and (3) heating of the product prior to the spray drying. The heating of the product prior to spray drying can be achieved using cavitation after high concentration or via use of a heater providing fast heating, low residence time with no heating surfaces, such as e.g., an ohmic heater.

Description

HIGH TOTAL SOLID SPRAY DRYING METHOD CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application 63 / 580,005 (filed on September 1, 2023) which is incorporated by reference in its entirety. FIELD OF THE INVENTION

[0002] This disclosure relates to methods and systems for high total solid drying that utilize pre-evaporation and high concentration evaporation steps. BACKGROUND OF THE INVENTION

[0003] In existing spray drying systems and methods, the total solid (TS) content of the feed is typically limited by the viscosity of the feed at the time of atomizing. A buffer is typically needed between evaporator and spray dryer to balance capacity. The viscosity may increase after evaporation and before atomizing due to age thickening, which means that typically some margin is required on the TS out of the evaporator to absorb variations in age thickening of the feed.

[0004] Furthermore, traditional systems of evaporators and spray dryers have a buffer system in between to offer ease of operation in situations where the evaporator and spray dryer is difficult to align on capacity. 5-10 minutes if not 15 minutes of residence time is not uncommon. Because of this residence time the outlet concentration from the evaporator is normally kept low enough so that even after the onset of age thickening the concentrate is still in a viscosity range that allows for the product to be atomized.

[0005] What is needed are systems and methods allowing for higher TS spray drying. SUMMARY OF THE INVENTION

[0006] The disclosure provides systems and methods for high total sold (TS) drying.

[0007] One embodiment of the disclosure is a method for high total solid spray drying including: a. concentrating a product in an evaporator; b. further concentrating the product in a high concentration evaporator (such as e.g., a forced circulation evaporator) within an integrated holding volume (thereby negating need for a separate holding tank); c. optionally cavitating the product from step b.; and d. spray drying the product, wherein the spray drying includes heating the product immediately prior to atomization. Alternatively, the methodincludes: a. concentrating a product in an evaporator; b. further concentrating the product in a high concentration evaporator having an integrated holding volume; negating need for a separate holding tank; and c. spray drying the product, wherein the spray drying includes heating the product immediately prior to atomization.

[0008] In one embodiment, the spray drying includes pressurizing the product. In another embodiment, the step of spray drying includes pressurizing the product using a high pressure pump and heating the product. The heating of the product can be carried out before or after pressurizing. In certain embodiments, the spray drying includes pressurizing the product using a high pressure pump and heating the product. In other embodiments, the spray drying includes pressurizing the product using the high pressure pump and heating the product before pressurizing. In certain embodiments, the cavitator is used to heat the product before pressurizing the product. In some embodiments, the step of spray drying includes pressurizing the product using a high pressure pump and heating the product in an ohmic heater. In yet another embodiment, the step of spray drying includes pumping the product through a heater.

[0009] In other embodiments, the method also includes mixing the product from step b. prior to cavitating. In another embodiment, the method includes homogenizing the product after the cavitating in step c. and before spray drying in step c. In yet another embodiment, step b. further includes holding the concentrated product prior to cavitation.

[0010] In certain embodiments, the spray drying includes centrifugal atomization, low pressure atomization, or high pressure atomization. In one embodiment, the spray drying is high pressure atomization. In another embodiment, the spray drying is centrifugal atomization.

[0011] In certain embodiments, the heating includes heating the product to about 90 °C. In other embodiments, the heating includes heating the product for 1 to 4 seconds.

[0012] In some embodiments the product in step b. has a 65% total solid content. Alternatively, step b. increases the total solid content of the product stream by 10%.

[0013] Another embodiment of the disclosure is a system for high total solid spray drying including: an evaporator; a high concentration evaporator connected to and downstream from the evaporator; a cavitator connected to and downstream from the high concentration evaporator; a pump connected to and downstream from the cavitator; a heater connected to the pump; and a spray dryer. In some embodiments, the system for high total solid spray drying includes: an evaporator; a high concentration evaporator connected to and downstream from theevaporator; a cavitator (configured to heat) connected to and downstream from the high concentration evaporator; a pump connected to and downstream from the cavitator; a spray dryer. In certain embodiments, the high concentration evaporator is a forced circulation evaporator or a forced circulation flash evaporator. In an alternate embodiment, the system includes: an evaporator; a high concentration evaporator connected to and downstream from the evaporator; the high concentration evaporator including an integrated holding tank / volume, with the product at high shear conditions; a pump connected to and upstream from a cavitator placed as close to the atomization as technically possible; and a spray dryer, whereby the spray dryer is connected to the pump and the product to be spray dried is heated immediately prior to the spray dryer.

[0014] In certain embodiments, a heater heats the product to be spray dried immediately prior to the spray dryer. In other embodiments, the cavitator heats the product to be spray dried.

[0015] In other embodiment, an oil mixer is placed upstream of the cavitator and downstream from the high concentration evaporator. In other embodiments, the high concentration evaporator further also a holding volume and the holding volume is configured to hold product after concentration in the high concentration evaporator. In yet another embodiment, the high concentration evaporator further includes a cavitator. In some embodiments, this cavitator is configured to cavitate product prior to concentration in the high concentration evaporator.

[0016] In certain embodiments, the spray dryer includes a centrifugal atomizer, a low pressure atomizer, or a high pressure atomizer. In one embodiment, the spray dryer includes a high pressure atomizer, the pump is a high pressure pump, and the heater is an ohmic heater. In another embodiment, the spray dryer includes a high pressure atomizer, the pump is a high pressure pump, and the cavitator is used as the heater. In certain embodies, the system further includes a homogenizer and wherein the homogenizer is placed upstream of the pump.

[0017] Other features and advantages of the invention will be apparent from the detailed description and examples that follow. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The foregoing summary, as well as the following detailed description of the invention, will be better understood when read in conjunction with the appended figures. For the purpose of illustrating the invention, the figures demonstrate embodiments of the present invention. Itshould be understood, however, that the invention is not limited to the precise arrangements, examples, and instrumentalities shown.

[0019] FIG.1 shows a schematic arrangement of a system of the disclosure for a centrifugal and low pressure atomization configuration of the disclosure.

[0020] FIG.2A-2C show schematic arrangements of systems of the disclosure for a high pressure nozzle atomization configuration of the disclosure. DETAILED DESCRIPTION

[0021] This disclosure is related to methods and systems for high total solid drying. The disclosure involves passing the feed, such e.g., a diary product, through system for high total solid drying.

[0022] Wherein in existing systems, the feed is usually heated up to reduce viscosity, but only to a temperature where chemical reactions in the feed are still slow enough to allow for exposure for more than 1 minute, from the entrance of the heating step. In the systems and methods of the disclosure, the feed (product or product stream) is heated up less than a few seconds prior to atomization, which means that a higher temperature can be used without unacceptable chemical reactions taking place.

[0023] The methods of the disclosure can be used with existing spray drying facilities including facilities with a small footprint.

[0024] Without being bound by theory, it is thought that the systems and methods of the disclosure reduce the energy consumption and cost spray drying methods. In particular, in the systems and methods of the prior art, the most expensive de-hydration is in the spray drying chamber. In contrast, the methods and systems of the disclosure make it possible to increase the TS in the feed and thereby reduce the drying cost as well as the capacity of the drying chamber. In certain embodiments, the methods and systems allow for increases of 10% or more in the %TS. Furthermore, the methods and systems allow for increased capacity when compared to conventional systems and methods of the prior art.

[0025] In certain embodiments, the systems and method of the disclosure enable high solid (HS) spray drying by using one or more or each of following: i) a last evaporation step with high product shear rate and integrated buffer capability to eliminate influence of age thickening;ii) a cavitator to eliminate influence of age thickening and reduce viscosity before atomization; and iii) heating the product within seconds of the atomizing to reduce viscosity during atomizing with minimal chemical change impact. In certain embodiment, the heating can be carried out in the cavitator.

[0026] The systems and methods of the disclosure using additional method steps like cavitation prevent the formation of age thickening effects and lower the viscosity in the product.

[0027] In certain embodiments, the systems and methods of the disclosure include heating steps with very low holdup volume and holding time, like for example, ohmic heating or a cavitator for heating, both on low pressure and high pressure lines.

[0028] The general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as defined in the appended claims. Other aspects of the present invention will be apparent to those skilled in the art in view of the detailed description of the invention as provided herein. Definitions

[0029] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, representative illustrative methods, and materials are now described.

[0030] All publications and patents cited in this specification are herein incorporated by reference as if each individual publication or patent were specifically and individually indicated to be incorporated by reference and are incorporated herein by reference to disclose and describe the methods and / or materials in connection with which the publications are cited. The citation of any publication is for its disclosure prior to the filing date and should not be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention. Further, the dates of publication provided may be different from the actual publication dates, which may need to be independently confirmed.

[0031] It is noted that, as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. It isfurther noted that the claims may be drafted to exclude any optional element. As such, this statement is intended to serve as antecedent basis for use of such exclusive terminology as “solely,” “only” and the like in connection with the recitation of claim elements, or use of a “negative” limitation.

[0032] Each of the individual embodiments described and illustrated herein has discrete components and features which may be readily separated from or combined with the features of any of the other several embodiments without departing from the scope or spirit of the present invention. Any recited method can be carried out in the order of events recited or in any other order which is logically possible.

[0033] Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range, is encompassed within the invention. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges and are also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the invention.

[0034] As used herein, the term “about” when referring to a measurable value such as an amount, a temporal duration, and the like, is meant to encompass variations of ± 20% or ± 10%, more preferably ± 5%, even more preferably ± 1%, and still more preferably ± 0.1% from the specified value, as such variations are appropriate to perform the disclosed methods.

[0035] It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

[0036] As used herein, the terms “comprising,” “including,” “containing” and “characterized by” are exchangeable, inclusive, open-ended and do not exclude additional, unrecited elements or method steps. Any recitation herein of the term “comprising,” particularly in a description of components of a composition or in a description of elements of a device, is understood to encompass those compositions and methods consisting essentially of and consisting of the recited components or elements.

[0037] As used herein, the term “consisting of” excludes any element, step, or ingredient not specified in the claim element.

[0038] Before certain embodiments are described in greater detail, it is to be understood that this invention is not limited to certain embodiments described, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing certain embodiments only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims.

[0039] Ranges: throughout this disclosure, various aspects of the invention can be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 2.7, 3, 4, 5, 5.3, and 6. This applies regardless of the breadth of the range.

[0040] For clarity of disclosure, and not by way of limitation, the detailed description of the invention is divided into subsections that describe or illustrate certain features, embodiments, or applications of the present invention. Systems and Methods for High TS Spray Drying

[0041] The systems and methods provide high total solid (TS) spray drying. Compared to conventional systems, the systems and methods of the disclosure are able to achieve drying at high TS by using the following further process parameters: (1) a high concentration evaporation step in addition to the conventional evaporation; (2) optional additional cavitation after high concentration; and (3) heating of the product prior to the spray drying. In certain embodiments, the final heating step is carried out within seconds prior to the spray drying (atomization). The final heating step can be carried out using a separate heater or using a cavitator. In one embodiment, the system includes: an evaporator; a high concentration evaporator connected to and downstream from the evaporator; the high concentration evaporator including an integrated holding tank / volume, with the product at high shear conditions; a pump connected to and upstream from a cavitator placed as close to the atomization as technically possible; and a spray dryer, wherein the spray dryer is connected to the pump and wherein the a heater heats the product to be spray dried immediately prior to thespray dryer. In other embodiments, the method includes: concentrating a product in an evaporator; further concentrating the product in a high concentration evaporator having an integrated holding volume; negating need for a separate holding tank; and spray drying the product, whereby the spray drying includes heating the product immediately prior to atomization.

[0042] The systems of the disclosure can have two general configurations depending on the product and the type of atomization desired to be used during the spray drying. Both general configurations have several common features. In certain embodiments, the systems and methods are configured to allow for up to 30 minutes of residence time. As noted above, the existing systems typically allow for 15 minutes of residence time.

[0043] The first configuration is the centrifugal and other low pressure atomization configuration. In this configuration centrifugal or low pressure atomization is used during the spray drying. The second configuration is the high pressure nozzle atomization configuration. In this configuration, a high pressure nozzle is used for atomization during spray drying.

[0044] In both configurations, the system includes a conventional evaporator (a pre- evaporator) which preconcentrates the product before it enters a high concentration evaporator. The evaporator is connected to the high concentration evaporator and placed upstream of the high concentration evaporator.

[0045] For products exhibiting age thickening effects the upper target for viscosity out of conventional evaporator (such as e.g., the falling film evaporator) is between 50-100cP with 100cP considered quite high (if a margin for age thickening were to be ignored the limit might be 150cP). At which concentration point this happens depends on the product properties. Many dairy and food related products have a significant amount of protein present in the product. When evaporating a product like these it is most often the amount of protein that determines the point at which the viscosity of the product starts to rapidly increase. A good example of how this impact products with different amount of product comes from the different types of WPC. When concentrating these types of products in an evaporator, the resulting concentrations (TS) differ (WPC3547%TS, WPC6040 %TS, and WPC8032 %TS).

[0046] In some embodiments, in the high concentration evaporator, the %TS in product (media) increases. In certain embodiments, the concentration increases from about 55% TS toabout 65% TS. In other embodiments, the high concentration evaporator increases the % TS in the product by about 10%.

[0047] Depending on the product, the high concentration evaporator can also include a holding volume and / or an optional cavitator. In certain embodiments, the high concentration evaporator has a holding volume. Use of the holding volume allows for elimination of all holding tanks in the system. Accordingly, the systems and methods of the disclosure lack a holding tank after the high concentration evaporator. The systems are also configured to minimize the residence time between the individual method steps. In other embodiments, the high concentration evaporator provides high shear conditions.

[0048] In further embodiments, for product that behave very close to Newtonian, the viscosity limits out of the high concentration evaporator is in the range of 200 to 300cP. This value is higher partly because the flow of the product within the evaporator is better i.e., no yield stress or similar to impact the flow and partly because these products typically does not exhibit age thickening or other viscosity altering process after evaporation. Examples of such product are often mainly consisting of short carbohydrates that does not often end up in a spray dryer.

[0049] In certain embodiments, the high concentration evaporator includes an optional cavitator. When an the optional cavitator is present, it is placed upstream of the high concentration evaporator. The high concentration evaporator is connected to a downstream cavitator. In certain embodiments, the cavitator is integrated into a loop with the high concentration evaporator. Depending on the product, an oil mixer may be part of the system. When the oil mixer is present, it is placed between the high concentration evaporator and the cavitator, e.g., downstream from the high concentration evaporator and upstream from the cavitator.

[0050] The systems of the disclosure further include a pump that is connected to the cavitator, a heater that is connected downstream from the pump, and a spray dryer (e.g., a centrifugal atomizer, a low pressure atomizer, or a high pressure atomizer) downstream from the pump. The heater is placed so that the product is heated immediately prior to the spray dryer, such as e.g., 1 to 5 seconds prior to spray drying. The pump can be a feed pump or a high pressure pump.

[0051] Depending on the product, the system may also include a homogenizer. The homogenizer is placed downstream of the cavitator and either upstream (i.e., before) of the pump or downstream (i.e., after the pump).

[0052] When in operation, the product system is passing through the evaporator, where an initial concentration step occurs. The product is the further concentrated in the high concentration evaporator. In certain embodiments, the product after evaporation is held in a holding tank (volume) in the high concentration evaporator prior to passing through the other steps of the method.

[0053] Depending on the product, it is also possible to cavitate the product prior to being passed onto further steps of the method. After further concentration in the high concentration evaporator the product is cavitated. If the product contains oil in certain embodiments, the product is mixed prior to cavitation. After cavitation, the product is then prepared for spray drying. The product is pumped and then heated immediately prior to atomization.

[0054] Spray drying may involve pumping the feed through heater followed by spray drying, such as e.g., centrifugal atomization, low pressure atomization, and high pressure nozzle atomization.

[0055] Unlike conventional systems, the systems of the disclosure do not include a holding tank placed between evaporator and spray dryer. Furthermore, whereas conventional systems typically include a buffer system. The systems and methods of the disclosure do not require such a buffer system.

[0056] In addition, the systems and methods of the disclosure reduce age thickening.

[0057] Accordingly, one aspect of the disclosure is a system for high TS spray drying. In some embodiments, system has at least the following features: an evaporator; a high concentration evaporator connected to and downstream from the evaporator; a cavitator connected to and downstream from the high concentration evaporator; a pump connected to and downstream from the cavitator; and a spray dryer connected to the pump. The cavitator can be configured to heat the product. In other embodiments, the system has at least the following features: an evaporator; a high concentration evaporator connected to and downstream from the evaporator; a cavitator connected to and downstream from the high concentration evaporator; a pump connected to and downstream from the cavitator; a heater connected to the pump; and a spray dryer.

[0058] A variety of different high concentration evaporators can be used. In certain embodiments, the high concentration evaporator is forced circulation evaporator. In other embodiments, the high concentration evaporator is forced circulation flash evaporator.

[0059] Depending on the product and desired configuration, the system can also include an oil mixer placed upstream of the cavitator and downstream from the high concentration evaporator.

[0060] In certain embodiments, the high concentration evaporator includes a holding volume. The holding volume is designed to hold product after concentration in the high concentration evaporator. The holding volume allows elimination of holding tanks typically found between the evaporator and atomizer. In some embodiments, the high concentration evaporator also includes comprises a cavitator.

[0061] When present in the high concentration evaporator, the cavitator is configured to cavitate product prior to concentration in the high concentration evaporator.

[0062] The systems of the disclosure can use a variety of spray dryers including but not limited to a centrifugal atomizer, a low pressure atomizer, or a high pressure atomizer. As illustrated in FIG.1 and FIG.2A-C depending on the atomizer, the precise arrangement of the system may vary.

[0063] In certain embodiments, the system uses a high pressure atomizer. In such embodiments, the pump is a high pressure pump, and the heater is a heater configured for fast heating, low residence time, with no heating services, such as e.g., an ohmic heater. In other embodiments, the system uses a high pressure atomizer, the pump is a high pressure pump and the cavitator upstream of the high pressure pump is used to het the product.

[0064] Depending on the product, additional features may be added to the system. In one embodiment, the system includes a homogenizer which is placed upstream of the pump.

[0065] The disclosure also includes methods of operating the system.

[0066] Another aspect of the disclosure is directed to a method for high TS solid spray drying. The method for high TS spray drying generally includes: (a) concentrating a product in an evaporator; (b) further concentrating the product in a high concentration evaporator with integrated holding volume; (c) optionally cavitating the product from step (b); and (d) spray drying the (optionally cavitated) product. In one embodiment, the method includes cavitation.In another embodiment, the method omits cavitation. In the methods of the disclosure, the spray drying includes heating the product immediately prior to atomization.

[0067] The spray drying also includes pressurizing the product. For example, the spray drying includes pressurizing the product using a high pressure pump and heating the product in an ohmic heater.

[0068] The spray drying step of the method also includes pumping the feed through a heater.

[0069] Additional process parameters may be included depending on the product. For example, the method can also include mixing the product from step (b) prior to cavitating. Alternatively, or additionally, the method can also include homogenizing the product after the cavitating in step (c) and before spray drying in step (d). In certain embodiments the method involves holding the concentrated product (in a holding volume of the high concentration evaporator prior to cavitation.

[0070] As noted, a variety of different spray drying methods may be used. In certain embodiments, the spray drying includes centrifugal atomization, low pressure atomization, or high pressure atomization.

[0071] In certain embodiments, product leaving the high concentration evaporator has a 65% TS content, alternatively a greater than 56% TS content. In other embodiments, the high concentration evaporator increases the TS content by a minimum of 10%. Without being bound by theory, this TS increase is not achievable in a falling film setup (i.e., if one where to ignore the conventionally used limits and evaporate right to the edge of what the falling film evaporator would be able to do). The TS content increase may vary depending on the product. For example, in some embodiments, normal outlet concentration for skim milk ranges from 48%TS to 52%TS depending on milk quality and degree of protein standardization (i.e., some skim milk feeds will have a lower protein content that allows a higher concertation). In other embodiments, the product is infant formula or a similar nutritional product. These types of products often have very specific recipes but often end up with a target concentration between 55-60%TS after oil addition.

[0072] In some embodiments, the heating includes heating the product to about 90 °C; 80- 130 °C for high pressure; and / or 80-100 °C for low pressure. In other embodiments, the heating includes heating the product for 1 to 4 seconds immediately prior to the spray drying.In certain embodiments, the temperature adjustment can be used to adjust the whey protein nitrogen index (WPNI) of skim milk.

[0073] A discussion of exemplary configurations of the systems and methods of the disclosure follows. Centrifugal and Other Low Pressure Atomization Configuration

[0074] A schematic of a system of the disclosure which relies on centrifugal and low pressure atomization is shown in FIG.1. With reference to FIG.1, the system includes evaporator 110 connected to a high concentration evaporator 115 with optional holding volume 120 and also optionally connected optional cavitator 130. The high concentration evaporator 110 / holding volume 120 and optional cavitator 130 (if present) are connected to cavitator 150. In some embodiment, cavitator 150 is omitted (i.e., optional). Optionally, if needed oil mixer 140 is placed upstream of the cavitator 150. Downstream, cavitator 150 is connected to feed pump 170. Optionally homogenizer 160 (if needed) is placed between the cavitator 150 and feed pump 170. Feed pump is connected spray dryer 180.

[0075] When in operation, the product feed to be processed by the system passes through evaporator 110 into high concentration evaporator 115. When the optional holding volume 120 is present, the holding volume is 120 is attached high concentration evaporator 115 on the downstream (outlet side) such that the product feed passed through the holding volume after passing through the high concentration evaporator.

[0076] In some embodiments, the product feed also passes through the optional cavitator 130. The optional cavitator 130 may be located upstream of the high concentration evaporator 115 with optional holding volume 120 and downstream of evaporator 110. Alternatively, the optional cavitator 130 is located downstream of the high concentration evaporator 115 / holding volume 120. The product feed passes though the high concentration evaporator 115 / holding volume 120 into cavitator 150.

[0077] In certain embodiments, where needed, such as when the product feed contains oily substances, the product feed passes through oil mixer 140 which is located upstream of cavitator 150. The product feed then passes through feed pump 170 and finally into spray dryer 180, where the product is freeze dried.

[0078] Between feed pump 170 and spray dryer 180, the product feed can be heated rapidly with a low residence time and no heating surface. Accordingly, in this embodiment, heater 165is an indirect heater without a heating surface. When using indirect heating the heat travels through the surface as a dT is necessary to transfer the energy, in ohmic heating or cavitation the heat is generated inside the product so that none of the product contact surfaces have a higher temperature than the product. The spray dryer in this embodiment is a centrifugal spray dryer. Alternatively, the spray dryer relies on low pressure atomization for spray drying.

[0079] In certain embodiments, the heater is an ohmic heater. In one embodiment, the spray dryer includes a product pipe configured to accept the product from the pump (e.g., feed pump 170). In certain embodiments, the ohmic heater is incorporated into the product line, which gives a typical holding time of less than 1 second between the heater and atomizing nozzle. In other embodiments, the ohmic heater is omitted, and the cavitator 150 is used to heat the product, which also gives a typical holding time of less than 1 second between heater and atomizing nozzle. Without being bound by theory, the very short holding time enables to heat the product to 90 °C, alternatively 80-130 °C for high pressure, or alternatively 80-100 °C for low pressure prior to atomization without significant chemical changes of the heat sensitive product. This allows for reducing viscosity enough to get good atomization in the dryer, i.e., being within the working range for the given atomization system.

[0080] If the product feed requires further homogenization, the product feed is passed through homogenizer 160, which is placed between cavitator 150 and feed pump 170.

[0081] In some embodiments, the operation of the high concentration evaporator 115 is controlled by controller 190 (not shown). In certain embodiments, the controller 190 is a PID controller that is monitoring the outlet density of the evaporator and then adjusting the energy source so that the water removal matches the needed amount. When the high concentration evaporator has a holding volume, the changes in product density is very slow and can no longer be used as the primary controlling factor without resulting in significant variations in the outlet concentration. High Pressure Nozzle Atomization Configuration

[0082] A schematic of a system of the disclosure which relies on high pressure nozzle atomization is shown in FIG.2. With reference to FIG.2, evaporator 200 is connected to high concentration evaporator 210 with holding volume 215. The high concentration evaporator 210 with optional holding volume 215 is connected to cavitator 240. The cavitator 240 is in turn connected to high pressure pump 50 which is connected ohmic heater 260. Ohmic heater 260is in turn connected to spray dryer 270. If needed, an oil mixer 230 is placed upstream of the cavitator 240 and downstream of the high concentration evaporator 210 with optional holding volume 215. An optional cavitator 220 is placed between the evaporator 200 and the high concentration evaporator 210 with holding volume 215. Alternatively, an optional cavitator 220 is placed downstream of high concentration evaporator 210 / holding volume 215. If the oil mixer 230 is present, the optional cavitator 220 is upstream of the oil mixer 230.

[0083] In certain embodiments, a homogenizer 255 may be placed downstream of the cavitator 240 and upstream of the ohmic heater 260. The homogenizer 255 (if needed) may be placed upstream from the high pressure pump 250. In another embodiment, the homogenizer is placed downstream of the high pressure pump 250. The ohmic heater 260 is located a minimal distance upstream from the spray dryer 270 so that the product flowing the system is heated within seconds prior to atomization in the spray dryer 270. The spray dryer 270 contains a high-pressure nozzle that allows for atomization of the product.

[0084] When a system having high pressure nozzle atomization configuration is in operation, the product passes through evaporator into high concentration evaporator 210. If present, the optional holding volume 215 is attached to the downstream (outlet) side of the high concentration evaporator 210. Depending on the system, the system can also include an optional cavitator 220 through which the product passes. In certain embodiments, the optional cavitator 220 is placed upstream of the high concentration evaporator such that the product passes through the cavitator before the high concentration evaporator. Alternatively, the optional cavitator 220 is placed downstream of the high concentration evaporator 210 and / or optional holding volume 215. After the product passes through the high concentration evaporator 210 (with or without holding volume 215), the product is passes through cavitator 240 which is downstream from the high concentration evaporator 210. In certain embodiments, an oil mixer 230 is placed between the high concentration evaporator 210 (with or without holding volume 215) and the cavitator 240 such that the product is mixed prior to cavitation. After the product passes through cavitator 240, it is pressurized in high pressure pump 250. Depending on the product, a homogenizer is present either upstream or downstream of the high pressure pump 250. In some embodiments, the pressurized product after the high pressure pump 250 is heated in ohmic heater 260, which is downstream from the high pressure pump 250. The ohmic heater is placed a minimal distance downstream from the high pressure pump250 to allow for optimal atomization as the product passes through high pressure nozzles in spray dryer 270. In other embodiments, the cavitator 240 is used to heat the product. In these embodiments, the system omits the ohmic heater 260 and the high pressure pump 250 (and homogenizer 255 if present) are placed a minimal distance from spray dryer 270. In some embodiments, the high pressure pump pressurizes the product to a pressure of about 50 to about 300 bar, alternatively of about 100 to about 250 bar, alternatively about 150 to 230 bar, alternatively about 50 to about 250 bar.

[0085] In certain embodiments, the ohmic heater is incorporated in the product line right before product splits out into the different lances, which gives a typical holding time of 4 seconds between heater and atomizing nozzle. In other embodiments the holding time is from 2 to 6 seconds, alternatively from about 0.1 to 20 second, alternatively from 1 to 15 seconds, alternatively less than 12 seconds, alternatively less than 6 seconds. The short holding time enables to heat the product to 90 °C, alternatively 80-130 °C for high pressure, or alternatively 80-100 °C for low pressure prior to atomization, so that viscosity is reduced enough to get good atomization in the dryer.

[0086] In some embodiments, the operation of the high concentration evaporator 210 is controlled by controller 280 (not shown). In certain embodiments, the controller 280 is a PID controller that is monitoring the outlet density of the evaporator and then adjusting the energy source so that the water removal matches the needed amount. When the high concentration evaporator has a holding volume, the changes in product density gets very slow and can no longer be used as the primary controlling factor without resulting in significant variations in the outlet concentration.

[0087] In certain embodiments, the high concentration evaporator 115 or the high concentration evaporator 210 is a paraflash evaporator, i.e., a forced circulation flash evaporator. The paraflash evaporator includes a heat exchanger (such as e.g., a plate heat exchanger), an external separator, and a vacuum system.

[0088] In other embodiments, the paraflash evaporator operates as a forced circulation, suppressed boiling evaporator. By using liquid static head above the heat exchanger or a special orifice piece in the discharge line, vaporization is arrested until the product liquor flashes into the separator. Any crystallization then occurs and a suspended slurry result. Highliquid velocity flow combined with induced turbulence deters scaling on heat transfer surfaces and promotes longer production runs.

[0089] In certain embodiments, the paraflash evaporator increase the % TS in the base media (product) up from 55% TS to 65%TS. In other embodiments, the paraflash evaporator is designed with variable levels corresponding to a buffer of up to 30 minutes of operation on the spray dryer, which enables having flexibility for balancing of capacity between evaporator and dryer. In other embodiments, the frequent high shear rate exposure of the product inside the paraflash evaporator eliminates the tendency of age thickening which would otherwise have been significant at this combination of temperature and TS.

[0090] When the systems and methods of the disclosure utilize a paraflash evaporator, it is important to run the system under condition for the paraflash evaporator that achieves the desired TS concentration. In certain embodiments, this is achieved by measuring the inlet density of the product passing into the evaporator and converting it to %TS (using in certain embodiments a model that account for changes in temperature); (2) measuring inlet mass flow rate and by combining with inlet %TS calculating the required water removal; (3) adjusting the recirculation rate and temperature out of the evaporator (heat exchanger) (optionally with a recirculation loop) so that the water evaporation matches the desired rate. In certain embodiments, the adjusting accounts for the specific heat capacity of the product in the recirculation loop, i.e., accounting for temperature and composition (mainly %TS). In further embodiments, it is possible to account for fluctuations by monitoring the density in the paraflash holding volume (where present).

[0091] Through the use of a monitored paraflash evaporator with monitoring a very low variation in the %TS in feed to the spray dryer is achievable.

[0092] In embodiments of the disclosure where operation of the paraflash evaporator also includes a holding time, it is possible to improve (i.e., reduce) the %TS variation compared to conventional systems. Through the use of a paraflash evaporator (in particular with an optional holding volume) it is easier to control the %TS to a very high degree of accuracy compared to convention falling film evaporators or other evaporator where the energy source is indirectly controlled.

[0093] In other embodiments, the high concentration evaporator 115 or the high concentration evaporator 210 is a forced circuit evaporator. In other embodiments, the high concentration evaporator provides for a one-step heating and flashing.

[0094] The systems and methods of the disclosure may have controls to optimize the evaporation temperature and final concentration to optimize the concentration for the spray dryer.

[0095] In some embodiments of the systems after the product passes through the high concentration evaporator (such as e.g., the high concentration evaporator 115 or the high concentration evaporator 210), the viscosity exiting this concentration step will be higher that the viscosity that the atomization step is able to handle.

[0096] In certain embodiments, the high concentration evaporator is an evaporator without low shear zones. In these embodiments, the high concentration evaporator is configured to provide for additional holding time. The additional holding time is built into the evaporator via either a holdup volume that is integral with the high concentration evaporator or a separate holding tank attached to the high concentration evaporator.

[0097] The evaporator 110 or the evaporator 200 may be any conventional evaporator. In certain embodiments, the evaporator 110 or the evaporator 200 can be a force circulation evaporator or forced circulation flash evaporator.

[0098] Without being bound by theory, integration of the optional holding volume in the high concentration evaporator is thought to minimize changes in the %TS and concentration gradients. Furthermore, the high shear conditions enabled by use of the holding volume limit the possibility of age thickening. The reduced concentration gradient it thought to enable the spray dryer to better adjust without imposing undesired fluctuations due to the spray drying.

[0099] After evaporation in the high concentration evaporator in both configurations of the systems of the disclosure it is possible to add a cavitation step or other process step to improve product behavior or improve oil mixing for product that require oil addition. In certain embodiments of the disclosure, the systems and methods include a cavitator immediately after the high concentration evaporator. In other embodiments, the systems and methods also include an oil mixer.

[0100] As the product passes through the high concentration evaporator, the optional cavitator which is in line with high concentration evaporator and the optional oil mixer which isdownstream from the high concentration evaporator and in line with the high concentration evaporator, products enter another cavitator (such as e.g., cavitator 150 and cavitator 240).

[0101] In other embodiments, the ohmic heater 260 may be replaced by a heater 265. FIG. 2B shows an embodiment of the system having heater 265. Heater 265 can be any heater that provides for faster heating, low residence time and has no heating surfaces. The other features of the system shown in FIG.2B are identical as described in FIG.2A.

[0102] As noted below, in certain the systems of the disclosure include heaters, such as e.g., ohmic heater 260 or heater 260. In other embodiments, the systems of the disclosure do not contain a separate heater downstream of the high pressure pump 250. In one embodiment, the cavitator 240 is used to heat the product before the high pressure pump 250 (and homogenizer 255). This embodiment of the systems of the disclosure is shown in FIG.2C. In this embodiment, the high pressure pump 250 (and homogenizer 255) are placed close to the spray dryer 270 to minimize the distance (and thereby the holding time) between the heating step and the atomization step. The other features of the system shown in FIG.2C are identical to FIG. 2A.

[0103] In one embodiment of the centrifugal configuration, a paraflash evaporator is used. In this embodiment, the cavitator is placed on the product line shortly before feeding of rotary atomizer, so that the retention time after the cavitator before atomization is a few seconds.

[0104] In certain embodiments, the cavitator reduces the viscosity of the product due to shear effect. The cavitator is designed to increase the temperature of the product to 90 °C, so that viscosity is reduced enough to get good atomization in the dryer. Due to the short retention time undesired chemical changes of the product can still be avoided. Additional Heater Embodiments

[0105] Depending on the atomization type, in certain embodiments, the systems of the disclosure include heaters that allow further preheating of the product such as e.g., ohmic heater 260, heater 265, and heater 165, which has a low residence time. The placement of the heaters in the system depends on the atomization type. In these embodiments, the systems are configured such that all holding tanks and other non-needed residence time between processes. In addition, the system is configured to eliminate any low shear holding zones for the product. To allow for the further heaters, in certain embodiments the systems include a paraflash evaporator, i.e., a forced circulation flash evaporator. In some embodiments, when furtherheaters are used the paraflash evaporator includes a holding volume attached to evaporator on the downstream side of the system.

[0106] Embodiments of the systems with further heaters provide for a low residence time (after evaporation). The systems of the disclosure which incorporate additional heaters are able to operate the final concentration at a higher temperature without additional detrimental heat induced effects on the product.

[0107] In certain preferred embodiments, the further heater placed immediately upstream in of the spray dryer, such as e.g., the spray dryer 180 or the spray dryer 270. The spray dryer is position in the system in such a way that that heater is as close as possible to the atomization that heats the product up to a temperature as close as possible for the atomization to further lower the product viscosity right at the atomization.

[0108] In certain embodiments, the heaters have a very low hold up volume and holding time. The heaters can be used both on low pressure and high pressure lines. Further Features

[0109] In certain embodiments, the systems of the disclosure allow for a low-residence time. In these embodiments, the final evaporation / concentration step is placed physically close to the atomization / high pressure pump. In certain embodiments when the dryer is configured provide high pressure atomization, the system includes an upstream high pressure pump, such as e.g., high pressure pump 250. In some embodiments, the high pressure pump is upstream of the heater, such as e.g., the ohmic heater. In other embodiments, the system omits the heater and the cavitator is used for heating.

[0110] Via use of the high concentration evaporators and the additional the additional heater, the systems and methods of the disclosure allow for operation at a higher temperature than normal. This configuration also allows for use of a higher concentration of the product while still having sufficient viscosity to atomize the product.

[0111] In some embodiments, the feed to the pre-evaporator (e.g., evaporator 110 and evaporator 200) are monitored and controlled to achieve the desired %TS entering the high concentration evaporator.

[0112] In certain embodiments, the systems and methods of the disclosure include heating to reduce viscosity. In some embodiments, the heating is done with an indirect heater, i.e. heater165 with no heating surfaces, heater 265, or an ohmic heater 260. In other embodiments, the heating is done using the cavitator. The heating is as close as possible to the spray dryer.

[0113] In other embodiments, the systems and methods reduce viscosity using a cavitator incorporated into the high concentration evaporator. In these embodiments, the product is exposed to high shear conditions in buffer tank incorporated in the high concentration evaporator. In these embodiments, the high concentration evaporator includes optional cavitator 130 or optional cavitator 220.

[0114] Without further description, it is believed that one of ordinary skill in the art can, using the preceding description and the following illustrative examples make and utilize the present invention and practice the claimed methods. The following working examples, therefore, specifically point out the preferred embodiments of the present invention and are not to be construed as limiting in any way the remainder of the disclosure. EXAMPLES

[0115] Examples 1 to 4 describe configurations of the systems and methods of the disclosure. While these examples describe the configuration of the system and methods of the disclosure for a specific application, the same configuration(s) can be used for other applications. Example 1 – Baby Food with Oil Addition

[0116] This example provides a configuration of a high pressure nozzle atomization embodiment of the disclosure. Specifically, this example provides a configuration for baby food with oil addition after evaporation and use of high pressure nozzles for atomization shown in FIG.2A.

[0117] In this embodiment, the evaporator is a paraflash evaporator. The paraflash evaporator is used to increase the TS content in the baby food (the base media) from 55% TS to 65% TS.

[0118] The paraflash evaporator is designed with variable level corresponding to a buffer of up to 30 minutes of operation on the spray dryer, which enables having flexibility for balancing of capacity between evaporator and the spray dryer. The frequent high shear rate exposure of the product inside the paraflash eliminates the tendency of age thickening which would otherwise have been significant at this combination of temperature and TS.

[0119] Furthermore, in this embodiment, oil dosing with static mixer and a cavitator are placed between paraflash evaporator and homogenizer / high pressure pump. The cavitator ensures very good premix prior to homogenization and reduces the viscosity of the product.

[0120] In certain embodiments, a heater, such as e.g., an ohmic heater, is incorporated in the high pressure product line right before product splits out into the different lances, which gives a typical holding time of 4 seconds between heater and atomizing nozzle. In other embodiments, the cavitator is used to heat the product, which gives a typical holding time of 4 seconds between pump and atomizing nozzle.

[0121] The short holding time enables to heat the product to 90 °C prior to atomization, so that viscosity is reduced enough to get good atomization in the dryer. Example 2 – Skim Milk Powder production

[0122] This example provides a configuration of a centrifugal atomization of the disclosure. Specifically, this example provides a configuration can be made in an application for Skim Milk Powder production using rotary atomizer.

[0123] For centrifugal atomization of Skim Milk Powder, the system uses a paraflash evaporator is used in the configuration shown in FIG.1. The paraflash evaporator increase the % TS in the base media (skim milk) up from 55% TS to 65%TS. The paraflash evaporator is designed with variable levels corresponding to a buffer of up to 30 minutes of operation on the spray dryer, which enables having flexibility for balancing of capacity between evaporator and dryer. The frequent high shear rate exposure of the product inside the paraflash evaporator eliminates the tendency of age thickening which would otherwise have been significant at this combination of temperature and TS.

[0124] The cavitator is placed on the product line shortly before feeding of rotary atomizer, so that the retention time after the cavitator before atomization is a few seconds.

[0125] The cavitator reduces the viscosity of the product due to shear effect. The cavitator is designed to increase the temperature of the product to 90C, so that viscosity is reduced enough to get good atomization in the dryer. Due to the short retention time, undesired chemical changes of the product can still be avoided.Example 3 – Rotary Atomizer and Heat Sensitive Product

[0126] This example provides a configuration of a rotary atomization of the disclosure. Specifically, this example provides a configuration can be made in an application for very heat sensitive products using rotary atomizer where even the few seconds of holding time at high temperature before atomization is too long.

[0127] In this configure a paraflash evaporator is used as the high concentration evaporator. The paraflash evaporator brings the base media up from 55% TS to 65%TS. The paraflash is designed with variable level corresponding to a buffer of up to 30 minutes of operation on the spray dryer, which enables having flexibility for balancing of capacity between evaporator and dryer. The frequent high shear rate exposure of the product inside the paraflash eliminates the tendency of age thickening which would otherwise have been significant at this combination of temperature and TS.

[0128] The cavitator is placed on product line shortly before feeding of rotary atomizer. The cavitator reduces the viscosity of the product due to shear effect. The cavitator is designed to increase the temperature only a few degrees to keep chemical changes of the product low.

[0129] A heater, e.g., an ohmic heater, is incorporated in the product pipe inside the atomizer, which gives a typical holding time of far less than 1 second between heater and atomizing nozzle. The very short holding time enables to heat the product to 90 °C prior to atomization without significant chemical changes of the heat sensitive product. This allows for reducing viscosity enough to get good atomization in the dryer. Example 4 – Rotary Atomizer and Heat Sensitive Product

[0130] This example provides a configuration of a rotary atomization of the disclosure. Specifically, this example provides a configuration can be made in an application for very heat sensitive products using rotary atomizer where even the few seconds of holding time at high temperature before atomization is too long.

[0131] In this configure a paraflash evaporator is used as the high concentration evaporator. The paraflash evaporator brings the base media up from 55% TS to 65%TS. The paraflash is designed with variable level corresponding to a buffer of up to 30 minutes of operation on the spray dryer, which enables having flexibility for balancing of capacity between evaporator and dryer. The frequent high shear rate exposure of the product inside the paraflash eliminates thetendency of age thickening which would otherwise have been significant at this combination of temperature and TS.

[0132] The cavitator is placed on product line shortly before feeding of rotary atomizer. The cavitator reduces the viscosity of the product due to shear effect. The cavitator is designed to increase the temperature only a few degrees to keep chemical changes of the product low. The cavitator is also designed to heat the product and thus be used in place of the heater, e.g., ohmic heater, described in Example 3 above. The cavitator is placed in the product line such allow a typical holding time of far less than 1 second between cavitator (hater) and atomizing nozzle. The very short holding time enables to heat the product to 90 °C prior to atomization without significant chemical changes of the heat sensitive product. This allows for reducing viscosity enough to get good atomization in the dryer. Example 6 – Target Concentration out of high concentration evaporator

[0133] The target is in the range of minimum 10% relative increase in %TS for the product. Such an increase is not achievable in a falling film setup (i.e., if one where to ignore the conventionally used limits and evaporate right to the edge of what the falling film evaporator would be able to do). As the protein content increase (i.e., initial target concentration), the relative concentration increase is expected to be more difficult. So, the base 10% target can be considered to be quite conservative for skim milk and infant formula but very ambitious for WPC80. As an example, the literature describes how it is possible to concentrate skim milk to 55% TS in a falling film evaporator (unknown level of protein standardization), but above 52% TS is not used on an industrial scale. pre evap normal target TS % TS % (10% target) TS % (20% stretch target) WPC35 47 51.7 56.4 WPC60 40 44 48 WPC80 32 35.2 38.4 skim milk 52 57.2 62.4 infant formula 60 66 72

[0134] While the invention has been described and illustrated herein by references to various specific materials, procedures, and examples, it is understood that the invention is not restricted to the particular combinations of material and procedures selected for that purpose. Numerous variations of such details can be implied as will be appreciated by those skilled in the art. It is intended that the specification and examples be considered as exemplary, only, with the true scope and spirit of the invention being indicated by the following claims. All references, patents, and patent applications referred to in this application are herein incorporated by reference in their entirety. EMBODIMENTS

[0135] The invention provides also the following non-limiting embodiments.

[0136] Embodiment 1 is method for high total solid spray drying comprising: a. concentrating a product in an evaporator; b. further concentrating the product in a high concentration evaporator having an integrated holding volume; negating need for a separate holding tank; and c. spray drying the product, wherein the spray drying includes heating of the product immediately prior to atomization.

[0137] Embodiment 2 is the method of embodiment 1, wherein the product in the integrated holding volume is in a high shear condition.

[0138] Embodiment 3 is the method of embodiment 2, wherein the spray drying comprises pressurizing the product using a high pressure pump and heating the product.

[0139] Embodiment 4 is the method of embodiment 3, wherein the spray drying comprises pressurizing the product using the high pressure pump and heating the product before pressurizing.

[0140] Embodiment 5 is the method of embodiment 3, wherein the spray drying comprises pressurizing the product using the high pressure pump and heating the pressurized product.

[0141] Embodiment 6 is the method of embodiment 5, comprising heating the pressurized product in an ohmic heater.

[0142] Embodiment 7 is the method of any one of embodiment 1 to 6, wherein the spray drying comprises pumping the product through a heater.

[0143] Embodiment 8 is the method of any one of embodiments 1 to 7, further comprising mixing the product from step b. prior to cavitating.

[0144] Embodiment 9 is the method of any one of embodiments 1 to 8, further comprising homogenizing the product after step b. and before spray drying in step c.

[0145] Embodiment 10 is the method of any one of embodiments 1 to 9, further comprising cavitating the product after step b.

[0146] Embodiment 11 is the method of any one of embodiments 1 to 10, wherein the spray drying comprises centrifugal atomization, low pressure atomization, or high pressure atomization.

[0147] Embodiment 12 is the method of anyone of embodiments 1 to 11, wherein the heating of the product comprises heating the product to about 90 °C.

[0148] Embodiment 13 is the method of any one of embodiments 1 to 12, wherein the product in step b. has approximately 65% total solid content.

[0149] Embodiment 14 is the method of any one of embodiments 1 to 13, wherein step b. increases the total solid content by approximately 10%.

[0150] Embodiment 15 is the method of any one of embodiments 1 to 14, wherein the heating comprises heating the product for 1 to 4 seconds.

[0151] Embodiment 16 is a system for high total solid spray drying of a product comprising: an evaporator; a high concentration evaporator connected to and downstream from the evaporator; the high concentration evaporator including an integrated holding tank / volume, with the product to be spray dried at high shear conditions; a pump connected to and upstream from a cavitator placed as close to the atomization as technically possible; and a spray dryer, wherein the spray dryer is connected to the pump and wherein the product to be spray dried is heated immediately prior to the spray dryer.

[0152] Embodiment 17 is the system of embodiment 16, wherein a heater heats the product to be spray dried immediately prior to the spray dryer.

[0153] Embodiment 18 is the system of embodiment 16, wherein the cavitator heats the product to be spray dried.

[0154] Embodiment 19 is the system of any one of embodiments 16 to 18, wherein the high concentration evaporator is a forced circulation evaporator or a forced circulation flash evaporator.

[0155] Embodiment 20 is the system of any one of embodiments 16 to 19, further comprising an oil mixer placed upstream of a cavitator and downstream from the high concentration evaporator.

[0156] Embodiment 21 is the system of any one of embodiments 16 to 20, wherein the high concentration evaporator further comprises a holding volume and wherein the holding volume is configured to hold product after concentration in the high concentration evaporator.

[0157] Embodiment 22 is the system of any one of embodiments 16 to 21, wherein the high concentration evaporator further comprises a cavitator.

[0158] Embodiment 23 is the system of embodiment 17, wherein the cavitator is configured to cavitate product prior to concentration in the high concentration evaporator.

[0159] Embodiment 24 is the system of any one of embodiments 16 to 18, wherein the spray dryer comprises a centrifugal atomizer, a low pressure atomizer, or a high pressure atomizer.

[0160] Embodiment 25 is the system of embodiment 24, wherein the spray dryer comprises a high pressure atomizer and wherein the pump is a high pressure pump.

[0161] Embodiment 26 is the system of embodiment 24, wherein the product is heated using an ohmic heater.

[0162] Embodiment 27 is the system of any one of embodiments 16 to 27 wherein the system further comprises a homogenizer and wherein the homogenizer is placed downstream of the pump and the cavitator.

Claims

CLAIMS What is claimed is:

1. A method for high total solid spray drying comprising: a. concentrating a product in an evaporator; b. further concentrating the product in a high concentration evaporator having an integrated holding volume; negating need for a separate holding tank; and c. spray drying the product, wherein the spray drying includes heating of the product immediately prior to atomization.

2. The method of claim 1, wherein the product in the integrated holding volume is in a high shear condition.

3. The method of claim 2, wherein the spray drying comprises pressurizing the product using a high pressure pump and heating the product.

4. The method of claim 3, wherein the spray drying comprises pressurizing the product using the high pressure pump and heating the product before pressurizing.

5. The method of claim 3, wherein the spray drying comprises pressurizing the product using the high pressure pump and heating the pressurized product.

6. The method of claim 5, comprising heating the pressurized product in an ohmic heater.

7. The method of any one of claim 1 to 6, wherein the spray drying comprises pumping the product through a heater.

8. The method of any one of claims 1 to 7, further comprising mixing the product from step b. prior to cavitating.

9. The method of any one of claims 1 to 8, further comprising homogenizing the product after step b. and before spray drying in step c.

10. The method of any one of claims 1 to 9, further comprising cavitating the product after step b.

11. The method of any one of claims 1 to 10, wherein the spray drying comprises centrifugal atomization, low pressure atomization, or high pressure atomization.

12. The method of anyone of claims 1 to 11, wherein the heating of the product comprises heating the product to about 90 °C.

13. The method of any one of claims 1 to 12, wherein the product in step b. has approximately 65% total solid content.

14. The method of any one of claims 1 to 13, wherein step b. increases the total solid content by approximately 10%.

15. The method of any one of claims 1 to 14, wherein the heating comprises heating the product for 1 to 4 seconds.

16. A system for high total solid spray drying of a product comprising: an evaporator; a high concentration evaporator connected to and downstream from the evaporator; the high concentration evaporator including an integrated holding tank / volume, with the product to be spray dried at high shear conditions; a pump connected to and upstream from a cavitator placed as close to the atomization as technically possible; and a spray dryer, wherein the spray dryer is connected to the pump and wherein the product to be spray dried is heated immediately prior to the spray dryer.

17. The system of claim 16, wherein a heater heats the product to be spray dried immediately prior to the spray dryer.

18. The system of claim 16, wherein the cavitator heats the product to be spray dried.

19. The system of any one of claims 16 to 18, wherein the high concentration evaporator is a forced circulation evaporator or a forced circulation flash evaporator.

20. The system of any one of claims 16 to 19, further comprising an oil mixer placed upstream of a cavitator and downstream from the high concentration evaporator.

21. The system of any one of claims 16 to 20, wherein the high concentration evaporator further comprises a holding volume and wherein the holding volume is configured to hold product after concentration in the high concentration evaporator.

22. The system of any one of claims 16 to 21, wherein the high concentration evaporator further comprises a cavitator.

23. The system of claim 17, wherein the cavitator is configured to cavitate product prior to concentration in the high concentration evaporator.

24. The system of any one of claims 16 to 18, wherein the spray dryer comprises a centrifugal atomizer, a low pressure atomizer, or a high pressure atomizer.

25. The system of claim 24, wherein the spray dryer comprises a high pressure atomizer and wherein the pump is a high pressure pump.

26. The system of claim 24, wherein the product is heated using an ohmic heater.

27. The system of any one of claims 16 to 26, wherein the system further comprises a homogenizer and wherein the homogenizer is placed downstream of the pump and the cavitator.

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