Electrostatic Spray Drying for Flavor Encapsulation

Solution Overview

Problem

Conventional spray drying systems for flavor encapsulation require high temperatures, leading to flavor profile changes and increased energy costs, while reducing temperatures results in slower carrier film formation and flavor loss.

Innovation Solution

An electrostatic spray drying process that applies an electrostatic field to atomized emulsion droplets, reducing the need for high heat and allowing for the production of a free-flowing encapsulated powder at lower temperatures, using a formulation of 50-95% wall material and 5-50% core material, with optional additives for improved encapsulation efficiency and hydration properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high temperatures (150-210°C inlet) are used in conventional spray drying systems, then carrier film formation and dehydration are improved, but flavor profile degradation and energy consumption increase

Engineering Contradiction:

Improvecarrier film formationVSAvoidflavor profile degradation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the temperature parameter from conventional high temperatures (150-210°C inlet) to lower temperatures (50-150°C inlet, preferably 70-120°C), and introduces electrostatic field parameters (voltage 5-60 kV) to compensate for the reduced thermal energy, maintaining carrier film formation while preserving flavor profile

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the thermal mechanism (heat-driven carrier film formation) with an electrostatic mechanism (electrostatically-assisted atomization and drying), where electrostatic fields enhance droplet evaporation and carrier film formation efficiency at lower temperatures, substituting thermal energy with electrical field energy

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If high temperatures (150-210°C inlet) are used in conventional spray drying systems, then carrier film formation is improved, but energy consumption and pre-conditioning time increase

Engineering Contradiction:

Improvecarrier film formationVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent changes the temperature parameter from conventional high temperatures (150-210°C inlet) to lower temperatures (50-150°C inlet, preferably 70-120°C), and introduces electrostatic field parameters (voltage 5-60 kV) to compensate for the reduced thermal energy, maintaining carrier film formation while preserving flavor profile

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the thermal mechanism (heat-driven carrier film formation) with an electrostatic mechanism (electrostatically-assisted atomization and drying), where electrostatic fields enhance droplet evaporation and carrier film formation efficiency at lower temperatures, substituting thermal energy with electrical field energy

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Use of energy by moving object

If low temperatures (e.g., 120°C inlet) are used to reduce energy consumption, then energy costs decrease, but carrier film formation becomes slower and flavor retention deteriorates

Engineering Contradiction:

Improveenergy consumptionVSAvoidcarrier film formation

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The patent replaces the thermal mechanism (heat-driven carrier film formation) with an electrostatic mechanism (electrostatically-assisted atomization and drying), where electrostatic fields enhance droplet evaporation and carrier film formation efficiency at lower temperatures, substituting thermal energy with electrical field energy

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the temperature parameter from conventional high temperatures (150-210°C inlet) to lower temperatures (50-150°C inlet, preferably 70-120°C), and introduces electrostatic field parameters (voltage 5-60 kV) to compensate for the reduced thermal energy, maintaining carrier film formation while preserving flavor profile

Inventive Principle:

Principle #35Parameter changes

4Use of energy by moving object

If low temperatures (e.g., 120°C inlet) are used to reduce energy consumption, then energy costs decrease, but flavor retention and surface oil content control deteriorate

Engineering Contradiction:

Improveenergy consumptionVSAvoidflavor retention

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the thermal mechanism (heat-driven carrier film formation) with an electrostatic mechanism (electrostatically-assisted atomization and drying), where electrostatic fields enhance droplet evaporation and carrier film formation efficiency at lower temperatures, substituting thermal energy with electrical field energy

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the temperature parameter from conventional high temperatures (150-210°C inlet) to lower temperatures (50-150°C inlet, preferably 70-120°C), and introduces electrostatic field parameters (voltage 5-60 kV) to compensate for the reduced thermal energy, maintaining carrier film formation while preserving flavor profile

Inventive Principle:

Principle #35Parameter changes

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 process results in a product with improved encapsulation efficiency, faster hydration, reduced surface oil content, and a flavor profile closer to the original, with lower energy consumption and processing time, while minimizing flavor loss and oxidation.

Implementation Method 1

applying an electrostatic field at the site of atomization

Methodology Applied

Scientific EffectElectrostatic force: Electrostatics

Implementation Method 2

the application of an electrostatic field to convert a liquid emulsion to a free-flowing powder

Methodology Applied

Scientific EffectElectrostatic force: Electrostatics

Data Source

PatentUS11845052B2Flavor encapsulation using electrostatic atomization

Publication Date: 2023.12.19 FONA INTERNATIONAL LLC

AI summary

Disclosed is an electrostatic spray drying process for encapsulating a core material, such as a volatile flavor oil, within a carrier or wall material. The process is achieved by atomizing a liquid emulsion comprising the core material and the wall material, applying an electrostatic charge at the site of atomization, and drying the atomized emulsion into an encapsulated, free-flowing powder. Applying an electrostatic charge at the site of atomization allows the spray drying to be accomplished at significantly reduced temperatures, in particular, inlet temperatures in the range of 25° C. to 110° C., and outlet temperatures in the range of 25° C. to 80° C. The low drying temperatures impart improvements in the resulting encapsulated powdered product, including better retention of volatile flavor components, a flavor profile comparable to that of the starting liquid formulation, and better hydration and dissolution in water-based applications.