High-Bulk-Density Lactose Powder via Turbo-Concentration Drying
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Solution Overview
Problem
Existing methods for producing lactose-containing powders from dairy by-products, such as whey or permeate, result in products with low bulk density, high energy consumption, and potential protein denaturation, leading to undesirable properties like agglomeration and clumping, especially for high dry matter content applications.
Innovation Solution
A process involving turbo-concentration and turbo-drying to produce a lactose-containing powder with a dry matter content of at least 90% and a dispersed bulk density of 0.65 g/cm³ or higher, achieved through a turbo-concentrator and turbo-dryer using a rotor to form a turbulent film and control crystal formation, eliminating the need for spray drying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If spray drying is used to produce lactose-containing powder, then high dry matter content (96-97%) is achieved, but energy consumption increases significantly (25-60% of total energy cost) and bulk density remains low
Solution Approach 1:
The invention changes the operating parameters of the evaporator (temperature, pressure, residence time) to achieve ultra-concentration directly in the liquid phase before drying, reducing the moisture content to be removed in the drying step and thereby lowering energy consumption
Solution Approach 2:
The invention combines the concentration and ultra-concentration steps into a continuous evaporator system, merging two separate operations into one integrated unit that achieves both concentration to 60% dry matter and ultra-concentration to 88% dry matter in sequence
2Quantity of substance
If spray drying is used to produce lactose-containing powder, then high dry matter content (96-97%) is achieved, but bulk density remains low causing agglomeration and clumping
Solution Approach 1:
The invention performs preliminary ultra-concentration of the lactose-containing liquid to 88% dry matter content before drying, creating a pre-concentrated feed that dries more efficiently and produces particles with better packing characteristics and higher bulk density
Solution Approach 2:
The invention changes the physical state and concentration of the feed material before drying by ultra-concentrating it to 88% dry matter, which fundamentally alters the drying dynamics and particle formation to achieve higher bulk density
3Productivity
If high temperature is used in concentration steps to achieve high dry matter content, then drying efficiency is improved, but protein denaturation occurs
Solution Approach 1:
The invention performs preliminary ultra-concentration to 88% dry matter content before drying, reducing the moisture that needs to be evaporated during drying and thereby allowing lower drying temperatures that preserve protein stability
Solution Approach 2:
The invention changes the concentration parameter of the feed to 88% dry matter content, which fundamentally reduces the energy and temperature requirements for the subsequent drying step, protecting thermally sensitive proteins
4Manufacturing precision
If multiple processing steps including crystallization and sieving are used, then product purity is improved, but device complexity and production time increase
Solution Approach 1:
The invention merges concentration, ultra-concentration, and drying operations into a continuous integrated process using a multi-effect evaporator followed by a dryer, eliminating separate batch crystallization, filtration, and sieving steps while maintaining product purity
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 yields a high-quality lactose powder with improved bulk density, reduced hygroscopicity, and enhanced stability, minimizing agglomeration and clumping, while reducing energy consumption and production steps.
Implementation Method 1
a rotor, arranged in the cylindrical tubular body and comprising a shaft provided with elements radially projecting therefrom; supplying a continuous flow of the above-mentioned lactose-containing liquid in this turbo-concentrator, so as to form, through the action of this rotor, a turbulent film continuous flow
Implementation Method 2
a heating jacket to bring this cylindrical tubular body to a predetermined temperature value
Implementation Method 3
drying this powdered mixture until a product in powder form having a dry matter content of at least 90% by weight on its total weight is obtained
Data Source
AI summary
A product in powder form having a dry matter content of at least 90% by weight on its total weight and containing lactose in a quantity of at least 85% by weight on its total weight, as well as having a high bulk density; moreover a process for the production of this product in powder form is disclosed, comprising the steps of vacuum-concentrating a lactose-containing liquid, mixing the so-concentrated liquid with a lactose-containing powder and with a high dry matter content and, finally, drying the so-obtained powdered mixture.