Meng Wai Woo

Single Droplet Drying Technique to Study Drying Kinetics Measurement and Particle Functionality: A Review

Advances in the study of the rate processes in spray drying have helped improve product quality. Single droplet drying (SDD) is an established method for monitoring the drying kinetics and morphological changes of an isolated droplet under a controlled drying environment, mimicking the droplet convective drying process in spray drying. To enhance particle quality requires understanding of both the particle formation process and knowledge of how different particle properties are affected by the drying conditions used. The latest development in the SDD technique enables evaluation of these aspects by incorporating a dissolution test in the drying experiment. The experiment is realized by attaching a solvent droplet to a dried/semi-dried single particle in situ and then video-recording the resultant morphological changes. Some of the particle (e.g., crystallinity) properties obtained under different drying conditions can be modelled using the measured droplet drying kinetics. This paper reviews the applications of SDD experiments in measuring the drying kinetics and monitoring the droplet morphological changes during drying. Some examples of extending the glass filament SDD technique to examine particle functionalities are discussed. SDD experiments are shown to be a powerful tool for particle engineering due to its ability to study both the external convective transport process of a single droplet and to understand the different particle functionalities of the resultant single dried particle.

Colloidal transport phenomena of milk components during convective droplet drying

Material segregation has been reported for industrial spray-dried milk powders, which indicates potential material migration during drying process. The relevant colloidal transport phenomenon and the underlying mechanism are still under debate. This study extended the glass-filament single droplet drying technique to observe not only the drying behaviour but also the dissolution behaviour of the correspondingly dried single particle. At progressively longer drying stage, a solvent droplet (water or ethanol) was attached to the semi-dried milk particle and the interaction between the solvent and the particle was video-recorded. Based on the different dissolution and wetting behaviours observed, material migration during milk drying was studied. Fresh skim milk and fresh whole milk were investigated using water and ethanol as solvents. Fat started to accumulate on the surface as soon as drying was started. At the initial stage of drying, the fat layer remained thin and the solubility of the semi-dried milk particle was much affected by lactose and protein present underneath the fat layer. Fat kept accumulating at the surface as drying progressed and the accumulation was completed by the middle stage of drying. The results from drying of model milk materials (pure sodium caseinate solution and lactose/sodium caseinate mixed solution) supported the colloidal transport phenomena observed for the milk drying. When mixed with lactose, sodium caseinate did not form an apparent solvent-resistant protein shell during drying. The extended technique of glass-filament single droplet approach provides a powerful tool in examining the solubility of individual particle after drying.

Optimization of the Spray Drying Operating Parameters—A Quick Trial-and-Error Method

This short communication reports an optimization approach to effectively determine suitable spray drying operating parameters for a pilot-scale dryer. The proposed optimization approach is essential, as pilot-scale investigations and medium-scale contract productions often involve usage of standard spray dryer units which is not specifically designed for the feed material used. This optimization approach was developed based on past studies on the effect and relationship of the many spray drying operating parameters and highlights two factors which has to be solved (or considered) chronologically: dripping problem, followed by product caking problem. Based on this proposed approach, an algorithm was developed in a case study to optimize an available spray dryer for our future experimental study on wall deposition. In this case, the operating parameters were determined under minimal experimental runs. This proposed optimization approach will be a useful tool for operators and experimenters utilizing spray dryers of similar type, particularly in exploring new feed materials. Depending on the optimization objectives and experimental limitations, different algorithms can be developed. Apart from that, interesting deposition pattern was also observed in the case study. This short communication also reported on the design of an internal rig for further studies on wall deposition.

Artificial Neural Network Modeling of the Deposition Rate of Lactose Powder in Spray Dryers

A spray dryer is the ideal equipment for the production of food powders because it can easily impart well-defined end product characteristics such as moisture content, particle size, porosity, and bulk density. Wall deposition of particles in spray dryers is a key processing problem and an understanding of wall deposition can guide the selection of operating conditions to minimize this problem. The stickiness of powders causes the deposition of particles on the wall. Operating parameters such as inlet air temperature and feed flow rate affect the air temperature and humidity inside the dryer, which together with the addition of drying aids can affect the stickiness and moisture content of the product and hence its deposition on the wall. In this article, an artificial neural network (ANN) method was used to model the effects of inlet air temperature, feed flow rate, and maltodextrin ratio on wall deposition flux and moisture content of lactose-rich products. An ANN trained by back-propagation algorithms w...

The impact of atomization on the surface composition of spray-dried milk droplets.

The dominant presence of fat at the surface of spray-dried milk powders has been widely reported in the literature and described as resulting in unfavourable powder properties. The mechanism(s) causing this phenomenon are yet to be clearly identified. A systematic investigation of the component distribution in atomized droplets and spray-dried particles consisting of model milk systems with different fat contents demonstrated that atomization strongly influences the final surface composition. Cryogenic flash-freezing of uniform droplets from a microfluidic jet nozzle directly after atomization helped to distinguish the influence of the atomization stage from the drying stage. It was confirmed that the overrepresentation of fat on the surface is independent of the atomization technique, including a pressure-swirl single-fluid spray nozzle and a pilot-scale rotary disk spray dryer commonly used in industry. It is proposed that during the atomization stage a disintegration mechanism along the oil-water interface of the fat globules causes the surface predominance of fat. X-ray photoelectron spectroscopic measurements detected the outermost fat layer and some adjacent protein present on both atomized droplets and spray-dried particles. Confocal laser scanning microscopy gave a qualitative insight into the protein and fat distribution throughout the cross-sections, and confirmed the presence of a fat film along the particle surface. The film remained on the surface in the subsequent drying stage, while protein accumulated underneath, driven by diffusion. The results demonstrated that atomization induces component segregation and fat-rich surfaces in spray-dried milk powders, and thus these cannot be prevented by adjusting the spray drying conditions.

The mechanisms of the protective effects of reconstituted skim milk during convective droplet drying of lactic acid bacteria

Reconstituted skim milk (RSM) is a reputed protective carrier for improving the survival ratio of lactic acid bacteria (LAB) after spray drying; however the underlying mechanisms of the prominent protection remains unclear. In this study, the inactivation histories of two LAB strains during droplet drying with four carriers were experimentally determined, and the effects of droplet drying parameters on LAB inactivation were investigated. For the first time, the possible contribution of each RSM components to the maintenance of LAB viability during drying was discussed. Rapid inactivation of LAB cells only started at the later stage of drying, where RSM could maintain viability better upon both high droplet temperature and low moisture content than the other three carriers tested. Such protective effects was attributed to calcium and milk proteins rather than lactose. Upon the rapidly increasing droplet temperature at the later stage, calcium might enhance the heat resistance of LAB cells, whereas proteins might lead to a mild temperature variation rate which was beneficial to cell survival. LAB cells dried in the reconstituted whole milk showed the most advanced transition of rapid viability loss, with transition temperature at around 60°C, in contrast to 65-70°C in lactose and MRS carriers and 75°C in the RSM carrier. The detrimental effects could be due to the high level of milk fat content. The proposed effects of each RSM components on LAB viability would be useful for constructing more powerful protectants for production of active dry LAB cells via spray drying.

Uniform amorphous lactose microspheres formed in simultaneous convective and dehydration antisolvent precipitation under atmospheric conditions

A simultaneous convection-dehydration and antisolvent precipitation approach has been shown to produce uniform microsized lactose particles from aqueous droplet at atmospheric pressure. Microparticles with high uniformity having diameters of between 1.0 and 2.4 μm have been obtained. The precipitation of the microparticles is driven by a unique self-assembly mechanism that cannot be fully elucidated by supersaturation alone. Further analysis suggests that structural changes in the solvent/antisolvent mixture, due to hydrophobic hydration, could play a role in the precipitation process observed.

Attrition of Victorian brown coal during drying in a fluidized bed

ABSTRACT Analyzing the attrition of Victorian brown coal during air and steam fluidized bed drying, the change in particle size distribution over a range of initial moisture contents (60% to 0%) and residence times (0 to 60 minutes) was determined. Dried at a temperature of 130°C with a fluidization velocity 0.55 m/s and an initial particle size of 0.5–1.2 mm, both fluidization mediums show a shift in the particle size distribution between three and four minutes of fluidization, with a decrease in mean particle size from 665 µm to around 560 µm. Using differential scanning calorimetry (DSC), the change in particle size has been attributed to the transition between bulk and non-freezable water (approximately 55% moisture loss) and can be linked to the removal of adhesion water, but not to fluidization effects. This is proved through the comparison of air fluidized bed drying, steam fluidized bed drying, and fixed bed drying—the fixed bed drying is being used to determine the particle size distribution as a function of drying. The results show the three drying methods produce similar particle size distributions, indicating that both fluidization and fluidization medium have no impact upon the particle size distribution at short residence times around ten minutes. The cumulative particle size distribution for air and steam fluidized bed dried coal has been modeled using the equation Pd = A2 + (A1 − A2)/(1 + (d/x0)p), with the resultant equations predicting the effects of moisture content on the particle size distribution. Analyzing the effect of longer residence times of 30 and 60 minutes, the particle size distribution for steam fluidized bed dried coal remains the same, while air fluidized bed dried coal has a greater proportion of smaller particles.

Three-Dimensional Numerical Investigation of a Mono-Disperse Droplet Spray Dryer: Validation Aspects and Multi-Physics Exploration

Many studies have been carried out on using computational fluid dynamics (CFD) to explore spray-drying phenomena. However, due to the complexity of the drying process in a conventional spray dryer, including the wide droplet size distribution, complicated particle trajectory, and difficulty in taking online measurements, validation of the computational codes or the models remains a challenging task. In this study, experimental conditions employed in a more defined spray-drying condition, published recently on the spray drying of mono-disperse skim milk droplets in a vertical cylindrical chamber, are simulated using ANSYS FLUENT. We have examined the effects of droplet-dispersion patterns on the drying results and found ways to incorporate more practical shrinkage models into the code to make simulations more realistic. Through a comparison with the relevant experimental results on 10∼50 wt% skim milk published recently by the same group, we have identified a few areas that urgently need more detailed research. Using the revised sets of codes established here, we simulated skim milk droplets (with a uniform size between 180 μm to 220 μm) spray dried by 90°C to 180°C hot-air streams. The quantitative drying history data predicted by our new model would help ensure better understanding of the system.

Effects of ionic and nonionic surfactants on milk shell wettability during co-spray-drying of whole milk particles.

Mixing surfactants with whole milk feed before spray drying could be a commercially favorable approach to produce instant whole milk powders in a single step. Pure whole milk powders obtained directly from spray drying often have a high surface fat coverage (up to 98%), rendering them less stable during storage and less wettable upon reconstitution. Dairy industries often coat these powders with lecithin, a food-grade surfactant, in a secondary fluidized-bed drying stage to produce instant powders. This study investigated the changes in wetting behavior on the surface of a whole milk particle caused by the addition of surfactants before drying. Fresh whole milk was mixed with 0.1% (wt/wt) Tween 80 or 1% (wt/wt) lecithin (total solids), and the wetting behavior of the shell formed by each sample was captured using a single-droplet drying device at intermediate drying stages as the shell was forming. The addition of surfactants improved shell wettability from the beginning of shell formation, producing more wettable milk particles after drying. The increase in surfactant loading by 10 times reduced the wetting time from around 30s to <5s. At the same loading of 1% (wt/wt; total solids), milk particles with Tween 80 were much more wettable than those with lecithin (<5s compared with >30s). We proposed that Tween 80 could adsorb at the oil-water interface of fat globules, making the surface fat more wettable, whereas lecithin tends to combine with milk proteins to form a complex, which then competes for the air-water surface with fat globules. Spray-drying experiments confirmed the greatly improved wettability of whole milk powders by the addition of either 0.1% (wt/wt) Tween 80 or 1% (wt/wt) lecithin; wetting time was reduced from 35±4s to <15s. To the best of our knowledge, this is the first time that a dynamic droplet drying system has been used to elucidate the complex interactions between ionic or nonionic surfactants and milk components (both proteins and fat), as well as the resultant effect on the development of milk particle functionality during drying.