Isomaltulose Crystallization and Spray-Drying for Non-Sticky Powder
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Solution Overview
Problem
The challenge lies in obtaining a solid isomaltulose product without the need for a centrifugation step, as the trehalulose component remains non-crystalline and liquid, making it difficult to separate isomaltulose crystals effectively from the saccharide solution.
Innovation Solution
A process involving the crystallization of isomaltulose to obtain crystals with a median diameter of 5 to 60 µm, followed by spray-drying the saccharide solution at an air temperature of 50 to 95°C to produce a solid material comprising 70 to 90% isomaltulose and 8 to 25% trehalulose, resulting in a spherical, dry, and non-sticky powder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If centrifugation is used to separate isomaltulose crystals from the saccharide solution, then isomaltulose can be obtained as a solid product, but the production process becomes complex and the syrup is left over as waste
Solution Approach 1:
The patent extracts and removes the trehalulose component from the saccharide solution through selective crystallization conditions, allowing isomaltulose to crystallize while trehalulose remains in the mother liquor. This extraction approach eliminates the need for centrifugation to separate crystals from syrup, as the unwanted trehalulose is already separated in the liquid phase.
Solution Approach 2:
The patent changes critical parameters including temperature (maintaining 30-60°C during crystallization), saccharide composition ratios (isomaltulose 60-90%, trehalulose 5-35%), and crystallization conditions to optimize isomaltulose crystallization while preventing trehalulose crystallization. These parameter changes enable direct solidification without centrifugation.
2Manufacturing precision
If centrifugation is used to separate isomaltulose crystals, then solid isomaltulose product can be obtained, but production time increases and productivity decreases
Solution Approach 1:
By extracting trehalulose into the mother liquor phase during controlled crystallization, the patent eliminates the time-consuming centrifugation step. The isomaltulose crystals can be directly filtered and dried, significantly reducing production time and increasing overall productivity while maintaining high purity.
Solution Approach 2:
The patent skips the centrifugation step entirely by designing a crystallization process where trehalulose remains dissolved in the mother liquor while isomaltulose crystallizes. This allows direct filtration and drying of crystals, rushing through the production process more efficiently without compromising purity.
3Device complexity
If the saccharide solution is directly solidified without centrifugation, then production process is simplified, but the presence of liquid trehalulose makes solidification difficult
Solution Approach 1:
The patent carefully controls temperature (30-60°C), saccharide composition ratios, and crystallization conditions to enable isomaltulose to crystallize while trehalulose remains in the liquid phase. These parameter changes allow the mixture to form a stable solid material where isomaltulose crystals are embedded in a trehalulose matrix, achieving both process simplification and product stability.
Solution Approach 2:
The patent creates a composite solid material consisting of crystalline isomaltulose particles embedded in an amorphous trehalulose matrix. This composite structure provides stability to the solid material, preventing collapse or deformation, while maintaining the simplified production process without centrifugation.
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
This method allows for the production of a solid isomaltulose product without centrifugation, achieving high purity and a high dissolution rate, with the resulting material being suitable for use in food products without altering their color or texture.
Implementation Method 1
a step of causing isomaltulose to crystalize to obtain crystals having a median diameter of 5 to 60 μm in the saccharide solution
Implementation Method 2
a step of spray-drying the saccharide solution containing the isomaltulose crystals at an air temperature of 50 to 95 degrees Celsius to obtain the solid material
Implementation Method 3
spray-drying the saccharide solution containing the isomaltulose crystals at an air temperature of 50 to 95 degrees Celsius
Data Source
Figure 1~2
AI summary
The purpose of the present invention is to provide a process for producing a solid material from a saccharide liquid and to provide a solid material of the saccharide solution. The present invention provides a process for producing an isomaltulose-containing solid material from a saccharide solution comprising isomaltulose, wherein a sucrose solution is subjected to action of an enzyme which produces isomaltulose from sucrose to prepare the saccharide solution comprising isomaltulose. The process comprises steps: (a) causing isomaltulose to crystallize to obtain crystals having a median diameter of 5 to 60 µm in said saccharide solution, wherein the median diameter is determined by laser diffraction particle size distribution measurement, and (b) spray-drying the saccharide solution containing the isomaltulose crystals at an air temperature of 50 to 95 degrees Celsius to obtain said solid material. The present invention provides a solid material comprising isomaltulose of an amount of 70 to 90 mass% and non-crystalline saccharide solution. The solid material is in a spherical form.