Spray Drying Volatile Retention via Temperature Control
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Solution Overview
Problem
Conventional spray drying methods often result in the loss of volatile compounds during the drying process, leading to a reduction in flavor intensity and quality, especially when high temperatures are used to expedite the process, which can negatively impact the flavor and fragrance of natural and synthetic materials in food and consumer products.
Innovation Solution
A method involving spray drying with an inlet temperature of less than 100°C and an air inlet dew point of −10° C. to 5° C. is used to retain at least 20% of the original volatile compounds, employing commercially available spray dryer nozzles and geometries, and potentially a secondary fluid-bed drying step to maintain flavor and fragrance intensity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high temperature spray drying is used to expedite the drying process, then productivity is improved, but volatile compounds are lost and flavor quality deteriorates
Solution Approach 1:
The patent applies parameter changes by operating the spray dryer at a controlled inlet temperature of 80-100°C rather than conventional higher temperatures. This specific temperature range optimizes the balance between drying efficiency and volatile compound retention, resolving the contradiction between productivity and substance loss
Solution Approach 2:
The patent employs preliminary action by pre-heating the spray drying air to a specific temperature range (80-100°C) before the drying process begins. This controlled pre-heating prepares the system to achieve rapid drying while preventing excessive temperature rise that would cause volatile loss, thus resolving the contradiction
2Productivity
If high temperature spray drying is used to produce large volume of powder quickly, then productivity is improved, but flavor intensity and quality are reduced
Solution Approach 1:
The patent changes the temperature parameter to a controlled 80-100°C inlet range, which enables high productivity through rapid drying while preserving flavor intensity. This parameter optimization allows large volume production without sacrificing quality
Solution Approach 2:
The patent ensures continuity of useful action by maintaining steady-state operating conditions at the optimized temperature range throughout the drying process. This continuous control prevents temperature fluctuations that would cause flavor degradation, enabling consistent high-quality production
3Ease of manufacture
If conventional spray drying is used, then manufacturing simplicity is maintained, but volatile compound retention is poor
Solution Approach 1:
The patent achieves volatile compound retention through parameter changes in the spray drying process, specifically controlling inlet temperature to 80-100°C and outlet temperature to 40-60°C. These modified parameters enable conventional equipment to retain volatiles without requiring complex additional systems
Solution Approach 2:
The patent applies self-service by using the spray dryer's own controlled temperature system to achieve volatile retention. The process utilizes the inherent heating and air circulation of the spray dryer, optimized through parameter control, rather than requiring external protection systems
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 effectively retains high levels of volatile compounds, resulting in a stable, high-intensity flavor composition with authentic quality that maintains sensory perception and consumer preference, even after long-term storage, and is suitable for various applications in food and consumer products.
Implementation Method 1
The liquid feed is fed to an atomizer, which is a device that breaks up the liquid stream into tiny droplets. This atomization takes place within the drying chamber so that the droplets are immediately exposed to hot air that initiates rapid moisture evaporation.
Implementation Method 2
spray drying is a common industrial method for drying liquid solutions or slurries by spraying into a stream of hot gas
Data Source
AI summary
The present invention relates to spray-dried compositions capable of retaining volatile compounds and methods relating to the same. The present invention also relates to the powders produced by such methods.