Spray Freezing Lactic Acid Bacteria Preservation
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Solution Overview
Problem
Existing methods for drying and freezing lactic acid bacteria and other microorganisms, such as spray drying and spray freezing, have limited commercial success due to low survival rates and inefficiencies, particularly when the products need to be viable after thawing or rehydrating.
Innovation Solution
A process that combines spray drying and freezing by first partially drying atomized particles with a drying gas and then freezing them in a cryogenic gas, with the frozen product being collected using a cyclone, optimizing the process to enhance bacterial survival and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If spray drying is used to dry lactic acid bacteria, then water removal is achieved, but bacterial survival rate deteriorates due to high temperature exposure
Solution Approach 1:
The invention changes the temperature parameter from high (conventional spray drying) to low (freeze drying regime), enabling water removal while preserving bacterial viability through controlled freezing and sublimation rather than thermal evaporation
Solution Approach 2:
The invention utilizes phase transition from liquid water to ice during freezing, then from ice directly to water vapor during freeze drying (sublimation), enabling water removal at low temperatures that preserve bacterial cells
2Temperature
If spray freezing is used to freeze lactic acid bacteria, then freezing is achieved, but commercial success deteriorates due to limited bacterial survival and rehydration capability
Solution Approach 1:
The invention applies preliminary freezing of the bacterial suspension before drying, creating a frozen matrix that protects bacterial cells during subsequent water removal and improves survival during storage and rehydration
Solution Approach 2:
The invention creates a composite frozen-dried product combining ice matrix with bacterial cells, where the frozen structure provides mechanical protection and the drying process removes water while maintaining cellular integrity
3Temperature
If conventional pellet freezing is used, then freezing is achieved, but process economy deteriorates due to high nitrogen gas consumption
Solution Approach 1:
The invention merges freezing and drying operations into a single freeze drying process, eliminating the need for separate freezing and drying equipment and reducing overall nitrogen gas consumption by combining the functions
4Productivity
If spray drying throughput is increased, then productivity is improved, but bacterial survival deteriorates due to excessive heat exposure
Solution Approach 1:
The invention changes the drying mechanism from heat-driven evaporation to sublimation-driven drying, enabling higher throughput while maintaining low temperatures that preserve bacterial survival through controlled freeze drying parameters
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 significantly improves the survival and stability of lactic acid bacteria, resulting in a more compact, efficient, and economically viable product with higher bacterial activity and easier rehydration, suitable for heat-labile materials like proteins and microorganisms.
Implementation Method 1
the atomized particles are (partly) dried by contacting with a drying gas
Implementation Method 2
the freezing is carried out by freezing the atomized particles in a cryogenic gas
Implementation Method 3
the frozen product is collected by means of a cyclone
Data Source
AI summary
The present invention relates to an improved method for preservation of e.g. microorganisms, especially lactic acid bacteria, said method includes spray freezing.