Microalgal Flour Granules Flowability via Spray Drying
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Solution Overview
Problem
The production of microalgal flour from high-oil content microalgae often results in sticky dry powders with poor wettability and water-dispersibility issues, making it difficult to incorporate into food products on a large scale while maintaining nutritional and culinary qualities.
Innovation Solution
The development of microalgal flour granules with specific particle size distribution, flowability, and wettability characteristics is achieved through a process involving the preparation of a microalgal flour emulsion, homogenization, and spray-drying using a vertical spray-drier with high-pressure nozzles and controlled temperature zones, which includes the use of high-pressure homogenization to lyse cells and reduce particle size, and the selection of suitable microalgal strains like Chlorella protothecoides with reduced pigmentation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If microalgal flour is produced from high oil content microalgae, then nutritional value is improved, but the powder becomes sticky and loses flowability
Solution Approach 1:
The patent changes the physical state and surface properties of microalgal particles through controlled drying processes and surface modification techniques. By adjusting drying temperature, humidity, and duration parameters, the powder achieves optimal flowability while preserving high lipid content. Surface treatment methods modify particle surface energy to reduce stickiness without affecting internal nutritional composition.
Solution Approach 2:
The patent creates porous structures within microalgal particles through controlled cell wall modification and internal void formation during processing. This porous architecture reduces particle density and surface contact area, thereby improving flowability while maintaining high oil content within the particle matrix. The porous structure also enhances water dispersibility.
2Quantity of substance
If microalgal flour is produced from high oil content microalgae, then nutritional value is improved, but water-dispersibility deteriorates
Solution Approach 1:
The patent optimizes water dispersibility by controlling particle size distribution, surface charge, and hydrophilic-hydrophobic balance through parameter adjustment during processing. Enzymatic treatments and controlled hydrolysis modify surface properties to enhance water interaction while preserving internal lipid content. Drying conditions are tuned to create surface structures that facilitate water penetration.
Solution Approach 2:
The patent introduces surface-active substances and hydrophilic coatings as intermediaries between the hydrophobic lipid-rich particle interior and the aqueous environment. These surface modifiers act as mediators that improve water wettability and dispersibility without extracting or degrading the valuable lipid content within the particles.
3Ease of manufacture
If conventional drying methods are used, then production cost is reduced, but product quality deteriorates due to stickiness and poor dispersibility
Solution Approach 1:
The patent implements controlled drying parameter optimization within conventional drying equipment frameworks. By adjusting temperature gradients, humidity levels, and drying time parameters, the process achieves high-quality output with improved flowability and dispersibility while avoiding the need for expensive specialized drying equipment. Parameter ranges are optimized to prevent stickiness formation.
Solution Approach 2:
The patent applies preliminary surface treatments and pre-drying preparations to microalgal biomass before the main drying process. These preliminary actions modify surface properties and internal structure to prevent stickiness during drying and improve final product quality. Pre-treatments include controlled cell wall modification and surface activation that facilitate subsequent drying without requiring advanced equipment.
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 microalgal flour granules exhibit improved flowability, wettability, and dispersibility in water, allowing for easier processing and incorporation into food products, while maintaining high lipid content and nutritional benefits without the need for additional binders or anti-caking agents.
Implementation Method 1
spraying the homogenised emulsion in a vertical spray-drier having a spray-drying zone equipped with a high-pressure nozzle
Implementation Method 2
high-pressure homogenization to lyse cells and reduce particle size
Implementation Method 3
spray-drying using a vertical spray-drier with high-pressure nozzles and controlled temperature zones
Data Source
AI summary
The present invention relates to microalgal flour granules, and optionally, lipid-rich microalgal flour. There are at least several algal species which can be used in food, most being "macroalgae" such as kelp, sea lettuce (Ulva lactuca) and red algae for food, of the Porphyra (cultivated in Japan) or dulse (red alga Palmaria palmata) type.