Antimicrobial Powder Co-Drying for Hygroscopic Stability
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Solution Overview
Problem
Conventional methods for producing antimicrobial powders, such as spray drying or drum drying, result in unstable hygroscopic compounds like neutralized vinegar and cultured celery juice, which quickly absorb moisture and form sticky lumps or syrups, necessitating the use of undesirable carriers that complicate food products and are high in sodium or synthetic.
Innovation Solution
A process involving co-drying a low molecular weight antimicrobial organic acid (e.g., sodium acetate) with a hygroscopic ingredient (e.g., cultured celery juice) to form a stable crystal structure that includes both anhydrous and hydrate forms, allowing for high-temperature drying and enhanced shelf stability without carriers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If spray drying or drum drying is used to produce antimicrobial powder, then the process is simple and cost effective, but the resulting powder is unstable and hygroscopic, quickly absorbing moisture and forming sticky lumps
Solution Approach 1:
The patent changes the drying parameters by using deep vacuum drying instead of conventional atmospheric pressure spray drying or drum drying. This parameter change allows the antimicrobial compound to be dried below its melt point, preventing thermal degradation while achieving stable, non-hygroscopic powder form without requiring carriers
Solution Approach 2:
The patent utilizes phase transition control by drying the antimicrobial compound under deep vacuum conditions to form a stable glassy phase rather than allowing moisture absorption and phase change to hydrate crystals. This phase transition approach prevents the compound from reverting to unstable hydrate forms that cause lumping
2Stability of the object's composition
If carriers such as maltodextrin, corn syrup, gums, or proteins are added to stabilize the powder, then the powder becomes stable and non-hygroscopic, but the food product becomes complicated and the label looks bad
Solution Approach 1:
The patent extracts and eliminates the need for carriers by using deep vacuum drying technology. This allows the antimicrobial compound to be dried directly to a stable, non-hygroscopic powder form without requiring additional stabilizing agents, thereby simplifying the product composition and labeling
3Temperature
If deep vacuum drying is used to convert cultured celery juice solids to dry form, then the temperatures used are below the melt point, but the product becomes extremely hygroscopic and difficult to handle
Solution Approach 1:
The patent optimizes the deep vacuum drying parameters by controlling the pressure and temperature conditions to achieve a stable glassy phase formation. This parameter optimization prevents the product from becoming excessively hygroscopic while maintaining the benefits of low-temperature drying below the melt point
4Quantity of substance
If plating salts are used to hold liquid material, then the powder can be formed, but only 5-10% liquid material can be held without losing flow properties, requiring extreme amounts of carrier
Solution Approach 1:
The patent replaces the mechanical plating salt absorption method with a thermal field-based deep vacuum drying process. This substitution allows the liquid material to be directly converted to stable powder form through controlled evaporation and phase transition, eliminating the need for plating salts and excessive carriers
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting antimicrobial powder maintains its dry form under ambient conditions for extended periods, with minimal moisture absorption, offering improved stability and reduced sodium content compared to conventional methods.
Implementation Method 1
This resultant powder rapidly absorbs moisture, reverting to the more stable sodium acetate tri-hydrate crystal structure
Implementation Method 2
drying the liquid slurry composition to produce an antimicrobial powder
Implementation Method 3
converts the particles to the more stable trihydrate crystal form
Data Source
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AI summary
An antimicrobial powder, which includes a low molecular weight antimicrobial organic acid and a hygroscopic ingredient, is prepared according to a process wherein the components are combined in a solution to form a liquid slurry composition prior to drying to form a powder, such that drying the liquid slurry composition involves co-drying the components. The low molecular weight antimicrobial organic acid in the antimicrobial powder can be present in a crystal phase of both anhydrous and hydrate forms. The antimicrobial powder exhibits excellent properties, such as shelf stability, without the requirement of encapsulating agents. Methods for preparing the antimicrobial powders as well as applications of the antimicrobial powders in food and beverage products are also disclosed.