Bioactive Particle Preparation Through Spray, Cryogenic, and Vacuum Drying
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Solution Overview
Problem
Existing methods for producing bioactive particles, such as probiotics, face challenges with high energy consumption, low production capacity, difficulty in controlling particle size, and significant cell inactivation during drying, particularly in spray drying processes.
Innovation Solution
A method combining spray drying with liquid nitrogen quick-freezing and vacuum freeze drying, involving preheating the spray tower, atomizing feed liquid, forming dry-like particles with controlled hot air, freezing in a cooling pool, and final freeze drying, to achieve high-density and bioactive particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If direct freeze drying is used to maintain high probiotic cell activity, then cell activity is preserved, but energy consumption increases, production capacity decreases, and particle density becomes low
Solution Approach 1:
The drying process is divided into three distinct stages: spray drying for rapid water removal, liquid nitrogen quick-freezing for particle formation, and vacuum freeze drying for final drying. This segmentation allows each stage to optimize for its specific function, achieving both high productivity and cell activity preservation
Solution Approach 2:
The spray drying step performs preliminary water removal before freeze drying, reducing the water content that needs to be removed in the energy-intensive freeze drying stage. This preliminary action significantly reduces overall energy consumption while maintaining production capacity
2Productivity
If spray drying is used to control particle size and increase production capacity, then production capacity improves, but high-temperature air causes extensive inactivation of bacterial cells
Solution Approach 1:
The invention utilizes phase transition by introducing liquid nitrogen to quickly freeze the spray-dried particles. This rapid freezing preserves bacterial cell structure and activity by preventing thermal damage, while the spray drying stage maintains high production capacity through efficient water removal
Solution Approach 2:
The use of liquid nitrogen creates a cryogenic inert environment that protects bacterial cells from thermal inactivation. The nitrogen atmosphere prevents oxidative damage and thermal stress during the drying and freezing processes, maintaining high cell survival rates
3Productivity
If spray drying is used to remove water quickly, then water content decreases and production capacity increases, but particle density becomes low and fluidity deteriorates
Solution Approach 1:
The invention changes the physical parameters of the drying process by implementing a three-stage approach with controlled temperature, pressure, and humidity at each stage. This results in particles with optimized density and fluidity properties while maintaining high production capacity
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 method reduces water content, shortens drying time by 30%, increases probiotic survival rate to 60%, and enhances particle density and fluidity, facilitating packaging and storage.
Implementation Method 1
the feed liquid is atomized by an atomizer in the spray tower to form liquid droplets
Implementation Method 2
the liquid droplets are partially formed (surface is sufficiently dry) into dry-like particles
Implementation Method 3
a temperature at the top of the spray tower is controlled at 80-120° C.
Implementation Method 4
the solid particles are formed into granules after being completely frozen
Implementation Method 5
liquid nitrogen or dry ice (dry ice may also be used as the quick freezing medium) is kept in the cooling pool
Implementation Method 6
quickly transferring the granules formed in Step 4 to a freeze drying device for freeze drying
Implementation Method 7
vacuum freeze drying
Data Source
AI summary
A method for preparing bio-active particles by spray drying, liquid nitrogen quick-freezing, and vacuum freeze drying includes the following steps: transporting a feed liquid into a preheated spray tower, wherein the feed liquid forms liquid droplets after being atomized by an atomizer in the spray tower, dispersing air is introduced into a top of the spray tower, and the dispersing air disperses the atomized liquid droplets; introducing hot air into the top of the spray tower, wherein the liquid droplets are partially formed into dry-like particles after being dried by the hot air, the surface dried particles fall, through a bottom of the spray tower, into a cooling pool arranged under the spray tower, and the particles, after being frozen, are transferred to a freeze drying device for freeze drying.