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1
Zbicinski, Ireneusz, Krzysztof Ciesielski, and Bangguo Ge. "Mechanism of Particle Agglomeration for Single and Multi-Nozzle Atomization in Spray Drying: A Review." Processes 10, no. 4 (2022): 727. http://dx.doi.org/10.3390/pr10040727.
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This paper reviews experimental works on the effects of single nozzle location and multi-nozzle atomization on the mechanism of particle agglomeration in spray drying. In addition to the naturally occurring primary agglomeration, forced and secondary agglomeration is observed as an effect of different nozzle positions or multiple-nozzle atomization in spray drying. Particle size diameters in the spray drying process for atomization from a single nozzle located at the top of the tower are larger than at the bottom of the tower because of the lower ambient air temperatures and longer residence time in the agglomeration zone. The trend of reduction in particle size is observed in all analyzed works when the nozzle is moved down towards the air inlet, due to droplets’ exposure to higher air temperatures and shorter residence time in the drying chamber. Conditions of droplet–droplet, dry–dry or sticky–dry collisions leading to the development of coalescence, agglomeration and rebound zones for multiple-nozzle atomization are described and discussed. Typically, log normal PSD was found for single-nozzle spraying whereas for multi nozzle arrangement, bi-modal particle size distribution was found both for drying in lab and industrial scale.
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Ye, Xingxing, Yexun Shi, Liming Shen, Peng Su, and Ningzhong Bao. "Optimization of Spray-Drying Process with Response Surface Methodology (RSM) for Preparing High Quality Graphene Oxide Slurry." Processes 9, no. 7 (2021): 1116. http://dx.doi.org/10.3390/pr9071116.
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The “Drying-redissolution” method is promising for the industrial production of high-concentration well-dispersed graphene oxide slurry (GOS). As the potential key step in this method, the spray drying process requires a statistical investigation which guides the large-scale preparation of graphene oxide powder (GOP). This work systematically studies the effects of operating parameters, including nozzle airflow rate (439–895 L·h−1), atomization pressure (0.5–0.7 MPa), and liquid feed rate (3.0–9.0 mL·min−1), by using the response surface methodology integrated Box–Behnken design (RSM–BBD), aiming to produce GOP with high yield and easy re-dispersion. The optimized spray drying condition is predicted to be 439 L·h−1, 0.59 MPa, and 9.0 mL·min−1, at which a powder yield of 70.45% can be achieved. The experimentally obtained GOP has an average particle size of 11.65 μm and the low crumpling degree of the particle morphology results in the good re-dispersibility (97.95%) and excellent adsorption performance (244.1 mg·g−1) of GOP. The GOS prepared by the spray-dried GOP possess low viscosity and high exfoliation efficiency with a single-layer fraction up to 90.8%, exhibiting good prospects for application. This work first applied the RSM–BBD model on the spray drying process of GO, and evidenced the possibility of producing high-quality GO slurry with the “drying-redissolution” method.
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Panão, Miguel. "Ultrasonic Atomization: New Spray Characterization Approaches." Fluids 7, no. 1 (2022): 29. http://dx.doi.org/10.3390/fluids7010029.
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In particle engineering, spray drying is an essential technique that depends on producing sprays, ideally made of equal-sized droplets. Ultrasonic sprays appear to be the best option to achieve it, and Faraday waves are the background mechanism of ultrasonic atomization. The characterization of sprays in this atomization strategy is commonly related to the relation between characteristic drop sizes and the capillary length produced by the forcing frequency of wavy patterns on thin liquid films. However, although this atomization approach is practical when the intended outcome is to produce sprays with droplets of the same size, drop sizes are diverse in real applications. Therefore, adequate characterization of drop size is paramount to establishing the relations between empirical approaches proposed in the literature and the outcome of ultrasonic atomization in actual operating conditions. In this sense, this work explores new approaches to spray characterization applied to ultrasonic sprays produced with different solvents. The first two introduced are the role of redundancy in drop size measurements to avoid resolution limitation in the measurement technique and compare using regular versus variable bin widths when building the histograms of drop size. Another spray characterization tool is the Drop Size Diversity to understand the limitations of characterizing ultrasonic sprays solely based on representative diameters or moments of drop size distributions. The results of ultrasonic spray characterization obtained emphasize: the lack of universality in the relation between a characteristic diameter and the capillary length associated with Faraday waves; the variability on drop size induced by both liquid properties and flow rate on the atomization outcome, namely, lower capillary lengths produce smaller droplets but less efficiently; the higher sensibility of the polydispersion and heterogeneity degrees in Drop Size Diversity when using variable bin widths to build the histograms of drop size; the higher drop size diversity for lower flow rates expressed by the presence of multiple clusters of droplets with similar characteristics leading to multimodal drop size distributions; and the gamma and log-normal mathematical probability functions are the ones that best describe the organization of drop size data in ultrasonic sprays.
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Bheekhun, Nadiir, Abd Rahim Abu Talib, and Mohd Roshdi Hassan. "Tailoring Aerogel for Thermal Spray Applications in Aero-Engines: A Screening Study." Advances in Materials Science and Engineering 2018 (October 17, 2018): 1–11. http://dx.doi.org/10.1155/2018/5670291.
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Irregular silica aerogel particles had been tailored to a regular spherical shape within the proper granulometric size range for thermal spraying. Silica aerogel is an ultralow dense and highly porous nanomaterial with its thermal conductivity being the lowest than any solids. Although silica aerogels possess fascinating physical properties, their implementation is limited to aerogel-doped blankets in the aerospace industry. Due to space constraints, these heat insulative and fireproof blankets are not encouraged by aero-engine manufacturers, and hence, alternatives are being sought. Although it was thought that an aerogel-based thermally sprayed coating may be applicable, aerogel powders are extremely challenging to be injected and deposited by thermal spray guns because of their inappropriate granulometric and morphological properties. Consequently, this study intends to tailor the aerogel powders accordingly. Aerogel-based slurries with yttria-stabilized zirconia as a secondary ceramic were prepared and spray-dried according to a modified Taguchi experimental design in order to appreciate the effect of both the slurry formulation and drying conditions such as the solid content, the ratio of yttria-stabilized zirconia : aerogel added, the amount of dispersant and binder, inlet temperature, atomization pressure, and feeding rate on the aforementioned characteristics of the resulting spray-dried powder. Uniformity was found to be the most influenced one (F-ratio = 62.40) by the overall spray-drying process. Solid content had the most significant effect on median particle size (p value = 0.035) and volume fraction (p value = 0.010) but did not affect uniformity significantly (p value = 0.065). Furthermore, a strong positive and significant correlation existed (Pearson’s r = 0.930) between median particle size and volume fraction. Based on the derived relationships, an optimised condition to achieve the maximum median particle size was then predicted and verified experimentally. The optimised aerogel-based spray-dried powder had a median particle size, volume fraction, and uniformity of 28.93 ± 0.726 μm, 64.45 ± 0.535, and 0.475 ± 0.002, respectively. Finally, the morphology of the optimised powder was noticed to have been changed from irregular shapes to spherical or donut-like granules which made them within the frame of thermally sprayable. However, when the optimised spray-dried powder was weighed, the quantity was found to be 10% only from the total weight of ceramics within the slurry prior to spray-drying, which makes it uneconomically reasonable for subsequent thermal spraying.
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Xu, Qing, Ruixin Wang, Fan Zhang, Ruifang Wang, Long Wu, and Bo Lin. "Spray Freezing Coating on the Carrier Particles for Powder Preparation." Coatings 12, no. 7 (2022): 896. http://dx.doi.org/10.3390/coatings12070896.
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Carrier particle spray freeze-drying is a new technology with high added value for thermosensitive powder spray freeze-drying. The technology includes the following steps: atomization, coating, freezing, and drying. Due to the action of carrier particles, the condensation of frozen droplets in the conventional spray freeze-drying process is overcome. However, there are many influencing factors involved in the process of freezing coating. The mechanism of the complex droplet collision freezing process still needs to be studied. In this paper, from the perspective of spray freezing coating after atomized droplets collide with low-temperature carrier particles, the coating process and freezing process of single droplets impacting the sphere are analyzed microscopically. The freezing coating processes of static and dynamic carrier particles are reviewed. Moreover, the surface evaluation of powder and equipment development for creating powder products is discussed.
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Taboada, Martha L., Doll Chutani, Heike P. Karbstein, and Volker Gaukel. "Breakup and Coalescence of Oil Droplets in Protein-Stabilized Emulsions During the Atomization and the Drying Step of a Spray Drying Process." Food and Bioprocess Technology 14, no. 5 (2021): 854–65. http://dx.doi.org/10.1007/s11947-021-02606-1.
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AbstractThe goal of this study was to investigate the changes in oil droplet size in whey protein–stabilized emulsions during the atomization and the subsequent drying step of a spray drying process. For this purpose, experiments were performed in an atomization rig and a pilot spray dryer with two commercial pressure swirl atomizers. By comparing the oil droplet size before atomization, after atomization, and after spray drying, the changes in oil droplet size during each process step were quantified. The effect of oil droplet breakup during atomization was isolated by atomizing emulsions with 1 wt.% oil content and a protein to oil concentration ratio of 0.1. At 100 bar, the Sauter mean diameter of oil droplet size was reduced from 3.13 to 0.61 μm. Directly after breakup, coalescence of the oil droplets was observed for emulsions with a high oil content of 30 wt.%, leading to a droplet size after atomization of 1.15 μm. Increasing the protein to oil concentration ratio to 0.2 reduced coalescence during atomization and oil droplets with a mean diameter of 0.92 μm were obtained. Further coalescence was observed during the drying step: for an oil content of 30 wt.% and a protein to oil concentration ratio of 0.1 the mean droplet size increased to 1.77 μm. Powders produced at high oil contents showed a strong tendency to clump. Comparable effects were observed for a spray drying process with a different nozzle at 250 bar. The results confirm that droplet breakup and coalescence during atomization and coalescence during drying have to be taken into consideration when targeting specific oil droplet sizes in the product. This is relevant for product design in spray drying applications, in which the oil droplet size in the powder or after its redispersion determines product quality and stability.
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Gawałek, Jolanta. "Effect of Spray Dryer Scale Size on the Properties of Dried Beetroot Juice." Molecules 26, no. 21 (2021): 6700. http://dx.doi.org/10.3390/molecules26216700.
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Experiments detailing the spray drying of fruit and vegetable juices are necessary at the experimental scale in order to determine the optimum drying conditions and to select the most appropriate carriers and solution formulations for drying on the industrial scale. In this study, the spray-drying process of beetroot juice concentrate on a maltodextrin carrier was analyzed at different dryer scales: mini-laboratory (ML), semi-technical (ST), small industrial (SI), and large industrial (LI). Selected physicochemical properties of the beetroot powders that were obtained (size and microstructure of the powder particles, loose and tapped bulk density, powder flowability, moisture, water activity, violet betalain, and polyphenol content) and their drying efficiencies were determined. Spray drying with the same process parameters but at a larger scale makes it possible to obtain beetroot powders with a larger particle size, better flowability, a color that is more shifted towards red and blue, and a higher retention of violet betalain pigments and polyphenols. As the size of the spray dryer increases, the efficiency of the process expressed in powder yield also increases. To obtain a drying efficiency >90% on an industrial scale, process conditions should be selected to obtain an efficiency of a min. of 50% at the laboratory scale or 80% at the semi-technical scale. Designing the industrial process for spray dryers with a centrifugal atomization system is definitely more effective at the semi-technical scale with the same atomization system than it is at laboratory scale with a two-fluid nozzle.
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Liu, Jian Hua, Tao Huang, Huan Ran Zhang, and Rui Xiang Wang. "Prepare Uniformity Superfine WO3 by Spray Drying." Advanced Materials Research 399-401 (November 2011): 731–35. http://dx.doi.org/10.4028/www.scientific.net/amr.399-401.731.
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Precursor of tungsten was obtained by spray drying process with high purity APT crystal liquor as material. The precursor was analysized by electron microscopy and X-ray. A suitable spray drying process was found through the morphology and powder structure. The influence of atomization disk rotational speed, the concentration ratio of ammonia to WO3 in APT liquor and APT liquor’s concentration on particle size, structure and morphology of the ball precursor were studied. Uniformity superfine WO3 was obtained from precursor by calcined.
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Kasten, Georgia, Íris Duarte, Maria Paisana, Korbinian Löbmann, Thomas Rades, and Holger Grohganz. "Process Optimization and Upscaling of Spray-Dried Drug-Amino acid Co-Amorphous Formulations." Pharmaceutics 11, no. 1 (2019): 24. http://dx.doi.org/10.3390/pharmaceutics11010024.
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The feasibility of upscaling the formulation of co-amorphous indomethacin-lysine from lab-scale to pilot-scale spray drying was investigated. A 22 full factorial design of experiments (DoE) was employed at lab scale. The atomization gas flow rate (Fatom, from 0.5 to 1.4 kg/h) and outlet temperature (Tout, from 55 to 75 °C) were chosen as the critical process parameters. The obtained amorphization, glass transition temperature, bulk density, yield, and particle size distribution were chosen as the critical quality attributes. In general, the model showed low Fatom and high Tout to be beneficial for the desired product characteristics (a co-amorphous formulation with a low bulk density, high yield, and small particle size). In addition, only a low Fatom and high Tout led to the desired complete co-amorphization, while a minor residual crystallinity was observed with the other combinations of Fatom and Tout. Finally, upscaling to a pilot scale spray dryer was carried out based on the DoE results; however, the drying gas flow rate and the feed flow rate were adjusted to account for the different drying chamber geometries. An increased likelihood to achieve complete amorphization, because of the extended drying chamber, and hence an increased residence time of the droplets in the drying gas, was found in the pilot scale, confirming the feasibility of upscaling spray drying as a production technique for co-amorphous systems.
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Al Zaitone, Belal, Abdulrahim Al-Zahrani, Osama Ahmed, Usman Saeed, and Aqeel Ahmad Taimoor. "Spray Drying of PEG6000 Suspension: Reaction Engineering Approach (REA) Modeling of Single Droplet Drying Kinetics." Processes 10, no. 7 (2022): 1365. http://dx.doi.org/10.3390/pr10071365.
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The spray drying technique is suitable for different kinds of liquid dispersions and can be easily optimized to produce solid particles with tailored properties. The spray drying technique is a complex process. As an example, it is difficult to track drying kinetics, shape, and morphological changes on the scale of a single droplet. To better understand the effect of drying process variables on dried particle formation, it is useful to observe the drying of single droplets. Fundamental processes, such as mass and heat transfer, can then be easily monitored and compared with theoretical models. Acoustic levitation enables droplet/particle suspension in the air without any mechanical contact. Experiments in the acoustic levitator can be used to mimic the drying process in the spray dryer. The drying kinetics of single droplets of PEG6000 into solid particles was studied. Droplets with an initial polymer concentration (PEG6000 aqueous solution of 5%, 10%, and 15% (w/w)) were investigated at different gas drying temperatures. The size of the droplet, moisture content, and the shape evolution of the droplet/particle during the drying process were studied. The experimental drying curves were compared with the Reaction Engineering Approach (REA). The REA models were shown to provide a very good agreement for drying behavior, with a relative error of about ±3% between the initial and predicted droplet mass. This model can be implemented into the large-scale modeling of spray drying using Computational Fluid Dynamics (CFD).
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Boel, Eline, Robin Koekoekx, Sien Dedroog, et al. "Unraveling Particle Formation: From Single Droplet Drying to Spray Drying and Electrospraying." Pharmaceutics 12, no. 7 (2020): 625. http://dx.doi.org/10.3390/pharmaceutics12070625.
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Spray drying and electrospraying are well-established drying processes that already have proven their value in the pharmaceutical field. However, there is currently still a lack of knowledge on the fundamentals of the particle formation process, thereby hampering fast and cost-effective particle engineering. To get a better understanding of how functional particles are formed with respect to process and formulation parameters, it is indispensable to offer a comprehensive overview of critical aspects of the droplet drying and particle formation process. This review therefore closely relates single droplet drying to pharmaceutical applications. Although excellent reviews exist of the different aspects, there is, to the best of our knowledge, no single review that describes all steps that one should consider when trying to engineer a certain type of particle morphology. The findings presented in this article have strengthened the predictive value of single droplet drying for pharmaceutical drying applications like spray drying and electrospraying. Continuous follow-up of the particle formation process in single droplet drying experiments hence allows optimization of manufacturing processes and particle engineering approaches and acceleration of process development.
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Almansour, Khaled, Raisuddin Ali, Fawaz Alheibshy, et al. "Particle Engineering by Nano Spray Drying: Optimization of Process Parameters with Hydroethanolic versus Aqueous Solutions." Pharmaceutics 14, no. 4 (2022): 800. http://dx.doi.org/10.3390/pharmaceutics14040800.
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Nano spray drying has emerged as an outstanding platform for engineering micro- and nanoparticles, with growing applications in various areas of drug delivery. As a new technology involving distinct technical design, parameters of the nano spray drying process are not fully elucidated. In a quality-by-design approach, the aim of the current study was to gain thorough understanding of critical determinants of product characteristics in the Büchi Nano Spray Dryer B-90. Following a factorial experimental design, a series of spray drying experiments were conducted to gain new insights into the influences of the inlet temperature, the spray solvent, and the solute concentration in the spray solution on the yield, the moisture content, and the particle size of the nano spray-dried powder material. Special consideration was given to the potential of using hydroethanolic in comparison with aqueous solvent systems and to particle engineering for pulmonary drug delivery. Lactose and mannitol, widely used as excipients in dry powder inhalation formulations, were used as model materials. Lactose and mannitol are known to spray dry in amorphous and crystalline forms, respectively. The yields of spray drying of lactose and mannitol amounted generally to 71.1 ± 6.6% w/w and 66.1 ± 3.5% w/w, respectively. The spray-dried materials exhibited generally a number-weighted median particle diameter of 1.6 ± 0.2 μm and a volume-weighted median particle diameter of 5.1 ± 1.0 μm. A detailed analysis of the results improved understanding of the interplay between process parameters in the Nano Spray Dryer. The results demonstrate that optimization of spray generation is the key to yield optimization. On the other hand, particle size is determined by the spray mesh pore size and the spray solution degree of saturation. Selection of an appropriate spray solvent and using spray solution additives could optimize spray flow. In parallel, the spray solvent and the solute concentration in the spray solution determine the degree of saturation. Guidance on optimization of particle engineering by nano spray drying is provided.
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Sobulska, Mariia, Pawel Wawrzyniak, and Meng Wai Woo. "Superheated Steam Spray Drying as an Energy-Saving Drying Technique: A Review." Energies 15, no. 22 (2022): 8546. http://dx.doi.org/10.3390/en15228546.
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Drying is an extremely energy-intensive process. Superheated steam as a drying medium can improve the energy efficiency of the drying processes. In superheated steam drying, waste heat can be recovered by condensing the exhaust steam or raising its specific enthalpy. Spray drying is widely used in industry, even though its energy efficiency is often low. Substitution of air by superheated steam as a drying medium in a spray dryer may reduce the energy consumption of the drying process by 20–30%; moreover, if excess steam generated by moisture evaporation is upgraded to a higher temperature level and reused for drying, the energy demand could be decreased by even 80%. A literature review showed that superheated steam spray drying was successfully applied for both thermally resistant and a wide range of thermally sensitive materials. Superheated steam drying gives a number of advantages in terms of product properties, i.e., higher particle porosity due to rapid moisture evaporation results in improved powder rehydration properties. Additionally, steam drying may be applied for in situ particle crystallization. Taking into account the advantages of superheated steam drying and the potential application of this technology in spray drying systems, there is a great need for further research in this field. This literature review aimed to present an energy-saving solution, i.e., superheated steam spray drying process, showing its advantages and potential applications, followed by drying kinetics, providing analysis of the research papers on experimental studies as well as mathematical modeling of this drying technique.
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Tiwari, Ram Hari, Mohit Mangla, Mohit Sanduja, and Amit Kumar Nayak. "Preparation Of Diosgenin-Encapsulated Microspheres By Spray Drying Technique." International Journal of Membrane Science and Technology 10, no. 4 (2023): 2525–37. http://dx.doi.org/10.15379/ijmst.v10i4.3634.
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Diosgenin, a naturally occurring steroid sapogenin possessing diverse therapeutic properties, represents a bioactive compound of interest. However, its complete pharmaceutical utilization has been impeded by inherent challenges, primarily associated with poor aqueous solubility and stability. In the present investigation, we introduce an innovative methodology for fabricating diosgenin-encapsulated microspheres through the utilization of the spray drying technique. The spray drying process involves the transformation of a solution containing diosgenin into finely dispersed microspheres through atomization, followed by rapid drying in a hot air stream. Various formulation parameters, encompassing the selection of encapsulating material, surfactants, and process conditions, were methodically optimized to attain elevated encapsulation efficiency and precise control over release characteristics. The microspheres thus prepared underwent assessment for percentage yield, encapsulation efficiency, particle size, and in vitro drug release. Results indicate the generation of uniform microspheres exhibiting heightened diosgenin encapsulation and enhanced physical stability. Additionally, in vitro release studies demonstrated sustained and controlled diosgenin release from the microspheres, underscoring their potential for protracted therapeutic effects. Encapsulation efficiency, release kinetics, and physicochemical attributes of the microspheres were found to be contingent upon the choice of encapsulating material and process parameters. In conclusion, the fabrication of diosgenin-encapsulated microspheres employing the spray drying technique represents a promising strategy to augment the bioavailability and therapeutic efficacy of diosgenin. These microspheres hold considerable promise for applications within the pharmaceutical and nutraceuticals industries serving as a platform for the advancement of innovative drug delivery systems.
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Zhu, Menghuan, Dongna Zhang, Lili Zhang, et al. "Spray-Dried Inhalable Powder Formulations of Gentamicin Designed for Pneumonic Plague Therapy in a Mouse Model." Pharmaceutics 14, no. 12 (2022): 2646. http://dx.doi.org/10.3390/pharmaceutics14122646.
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Infection with Yersinia pestis (Y. pestis) may cause pneumonic plague, which is inevitably fatal without treatment. Gentamicin (GM), an aminoglycoside antibiotic, is a drug commonly used in the treatment of plague. However, it requires repeated intramuscular or intravenous administration. Pulmonary drug delivery is noninvasive, with the advantages of local targeting and reduced risk of systemic toxicity. In this study, GM powders were prepared using spray-drying technology. The powders displayed good physical and chemical properties and met the requirements for human pulmonary inhalation. The formulation of the powders was optimized using a 32 full factorial design. A formulation of 15% (w/w) of L-leucine was prepared, and the spray-drying process parameters using an inlet temperature of 120°C and a 15% pump rate were determined to produce the best powder. In addition, the optimized GM spray-dried powders were characterized in terms of morphology, crystallinity, powder fluidity, and aerodynamic particle size distribution analysis. In a mouse model of pneumonic plague, we compared the therapeutic effects among three administration routes, including subcutaneous injection, liquid atomization, and dry powder atomization. In conclusion, our data suggest that inhalation therapy with GM spray-dried powders is an effective treatment for pneumonic plague.
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Han, Qiuge, Dawei Zhang, Xuedong Liu, et al. "Experimental Study on Atomization Characteristics of Swirl Nozzle under Annular Airflow Impingement." Fluids 9, no. 3 (2024): 80. http://dx.doi.org/10.3390/fluids9030080.
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Pressure nozzles are widely used in spray drying and other industries. In order to improve the atomization characteristics of pressure cyclone nozzles, a new type of annular jet gas impingement atomization device is developed. We use high-speed imaging and digital image processing and other methods to analyze the spray characteristics of the different annular device configurations (using four, six, and eight tubes) and under different gas–liquid mass flow rates. It is shown that with an increase in the Air–Liquid mass Ratio (ALR), the liquid film breakup process changes from undulating sheet breakup to perforated sheet breakup and the breakup length decreases. The breakup length decreases the most under the condition of six-tube airflow with the range of 31–55%, while the Sauter mean diameter (SMD) basically does not change. With the increase in ALR and the Weber number of liquid (Wel), the droplet size distribution becomes more uniform. The spray characteristics of the atomizer assisted by gas jets reaches the best state when Wel = 4596.3 and m˙g = 1.97 g/s. The experimental conclusions have some guiding significance for the design and optimization of the atomization devices in spray drying towers.
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Xiong, Feng-kui, Yue-jin Yuan, Ying-ying Xu, Jing-yu Li, Zhe Zhao, and Li-bin Tan. "Modeling Study of a Microbial Spray-Drying Process Based on Real-Time Sampling." Processes 10, no. 9 (2022): 1789. http://dx.doi.org/10.3390/pr10091789.
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The process of microbial spray-drying has inherent defects such as short time, complexity, and non-visualization of particle trajectory. However, there has been a lack of effective methods for real-time sampling, rehydration, and non-destructive storage of dried particles, as well as mathematical modeling of the drying process of yeast particles based on sampling and measurement data. Therefore, firstly, a real-time sampling system was developed which completed real-time sampling, rehydration, and non-destructive storage of spray-dried particles, and realized the real reproduction of the changes of yeast particles in the process of spray drying. The laws that the motion trajectory of microbial particles during spray drying are divided into the first cycle region and the reflux cycle region were concluded, and the partition mechanism was explored. Then, based on the sampling data and the law of heat and mass transfer, a mathematical model of porous media was established to predict the variation of moisture content and rehydration survival rate of dried microbial particles with drying time. Finally, the mathematical model was tested by a microbial spray drying experiment, and the maximum errors between the predicted value and the test value of moisture content and rehydration survival rate were Xmax1=0.027(d.b) and Qvmax1=1.06%, respectively, both were less than 5% which proved the correctness of the mathematical model of porous media and laid a foundation for the study of the damage mechanism of microbial spray drying.
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Isleroglu, Hilal, and Izzet Turker. "Evaluation of Process Conditions for Ultrasonic Spray-Freeze Drying of Transglutaminase." Food Technology and Biotechnology 58, no. 1 (2020): 38–48. http://dx.doi.org/10.17113/ftb.58.01.20.6544.
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In this study, a commercial transglutaminase enzyme was dried using an ultrasonic spray freeze drying method and the effects of the process conditions were optimized to maximize the final transglutaminase activity. Accordingly, process parameters affecting enzyme activity were selected, such as nozzle frequency (48 and 120 kHz), flow rate (2, 5 and 8 mL/min) and plate temperature for secondary drying (25, 35 and 45 °C). Moreover, the effects of different pH values (pH=2.0 and 9.0) and high temperature (80 °C) on enzyme activity, physical properties and particle morphology of transglutaminase were discussed. According to the results, transglutaminase preserved its activity despite ultrasonic spray freeze drying. Sonication enhanced the enzyme activity. Using the desirability function method, the optimum process conditions were determined to be flow rate 3.10 mL/min, plate temperature 45 °C and nozzle frequency 120 kHz. The predicted activity ratio was 1.17, and experimentally obtained ratio was 1.14±0.02. Furthermore, enzyme produced by ultrasonic spray freeze drying had low moisture values (2.92-4.36 %) at 8 h of drying. When the morphological structure of the transglutaminase particles produced by ultrasonic spray freeze drying under the optimum conditions was examined, spherical particles with pores on their surfaces were observed. In addition, flow properties of the transglutaminase powders were considered as fair under most conditions according to the Carr index.
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Pasero, Lorena, Francesca Susa, Riccardo Chiavarino, et al. "Tailoring Dry Microparticles for Pulmonary Drug Delivery: Ultrasonic Spray Freeze-Drying with Mannitol and Salbutamol Sulphate." Processes 11, no. 11 (2023): 3096. http://dx.doi.org/10.3390/pr11113096.
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Spray freeze-drying has emerged as a valid alternative to traditional spray drying to produce therapeutic dry microparticles. In particular, the spherical shape and high porosity of spray freeze-dried microparticles make them suitable for pulmonary drug delivery through dry powder inhalers. However, an appropriate particle size and fine particle fraction are required to guarantee lung deposition. This study used ultrasonic spray freeze-drying to generate dry microparticles composed of mannitol either alone or added with the bronchodilator salbutamol sulphate. The influence of the solid concentration and the feed flow rate on the particle size, morphology, surface area, porosity, and crystallinity was investigated. Growing particle size was observed, increasing the concentration and feed flow rate. Similarly, the addition of the drug led to a larger particle size and surface area. The in vitro simulation of drug deposition highlighted the dependence of the aerodynamic properties on the solid concentration and feed flow rate. Due to the lower density and particle geometric size, the highest fine particle fraction (26%) and smallest mass median aerodynamic diameter (4.4 μm) were reached at the lowest solid concentration and feed flow rate.
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Xin, Xing, Sinemobong Essien, Kiri Dell, Meng Wai Woo, and Saeid Baroutian. "Effects of Spray-Drying and Freeze-Drying on Bioactive and Volatile Compounds of Smoke Powder Food Flavouring." Food and Bioprocess Technology 15, no. 4 (2022): 785–94. http://dx.doi.org/10.1007/s11947-022-02779-3.
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AbstractTransforming liquid smoke to powder form can provide convenience for use and storage. Liquid smoke was prepared by fast pyrolysis technology using a fluidised bed and converted to smoke powder by spray-drying or freeze-drying processes. Both drying processes effectively retained the bioactive compounds in the powder encapsulates with retention efficiencies up to 80%. The bioactive capacities were approximately two times higher than liquid smoke. Spray-drying did not induce thermal damage to the bioactive compounds, and the dominant compounds were retained in the powders. Gas chromatography–mass spectrometry and principal component analysis indicated that the chemical composition was not significantly changed after both drying methods, but small molecular carbonyls, furans and phenols were partially lost. The spray-dried particles had a spherical shape, while freeze-dried particles had irregular shapes because of different powder preparation methods. The particle size of spray-dried powders was in the range of 6.3 to 6.9 µm, while the value for freeze-dried powders was decreased from 580.4 to 134.7 µm by increasing the maltodextrin concentration. The freeze-dried powders performed better in terms of flowability and cohesiveness because of their relatively high density and large particle size. This study revealed that both encapsulation methods could efficiently prepare smoke powder. Spray-drying process would be suitable for large-scale production, while freeze-drying could be used to optimize the encapsulation efficiency of bioactive compounds.
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Rodrigues, Larissa, Gustavo Paiva, Hugo M. Lisboa, et al. "Impact of Spray Drying Parameters on Lactose-Free Milk Powder Properties and Composition." Journal of Agricultural Studies 8, no. 3 (2020): 32. http://dx.doi.org/10.5296/jas.v8i3.15886.
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Lactose-free milk powders are an interesting topic, as the industry still struggles with the enhanced stickiness of the material. To better understand this topic, an industrial scale spray-dryer was used to assess the influence of process parameters on the powder properties of lactose-free milk. A simple design of experiments was conducted varying the inlet temperature in combination with the atomization flow rate. The intention was to set different driving forces for drying in combination with the different surfaces are for mass transport. Yield is typically the process bottleneck, but from results, high inlet temperature combined with small droplet size resulted in a 50.73% yield. Powder's moisture contents were between 0.53% and 5%, and water activity between 0.21 and 0.43, being all values within a safety threshold for storage. From bulk and tap density results, all powders revealed to be cohesive with the Hausner ratio above 1.5. Color measurements revealed off white samples, with a tendency to become brown when higher inlet temperatures are used, possibly due to Maillard reactions. Powder particle size ranged from 5.6 to 13.5 mm and revealed extensive agglomeration, possibly due to some protein denaturation at the particle surface. Inlet temperature revealed to be the most influential parameter on all properties.
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Guirlanda, Christiano Pedro, Izabela Dutra Alvim, and Jacqueline Aparecida Takahashi. "Atomization of Cocoa Honey Using Whey Protein Isolate to Produce a Dry Formulation with Improved Shelf Life for Industrial Application." Foods 12, no. 23 (2023): 4269. http://dx.doi.org/10.3390/foods12234269.
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Cocoa honey, a by-product obtained during the processing of cocoa, is a juice rich in pectin, organic acids, minerals and phenolic compounds with antioxidant properties. Fresh cocoa honey is quickly fermented due to its high content of reducing sugars, such as fructose and glucose, which limits its shelf life. Currently, cocoa honey is only commercialized in frozen form, as logistical challenges prevent the wide distribution or export of this by-product for applications in the market of sweets, jellies, beverages, confectionery, and nutraceutical foods among others. Spray-drying technology is a viable prospect for the large-scale stabilization of products such as cocoa honey, with less heat exposure compared to other conventional drying methods. This work aimed to evaluate the efficacy of drying adjuvants for a rapid removal of the water present in cocoa honey via atomization, since this process minimizes the effects of glass transition temperature (Tg) related to materials with high sugar contents. Physical parameters such as the moisture content, hygroscopicity, particle size, and yield of the products obtained were determined. Cocoa honey presented 85.3 ± 0.20 g/100 g of moisture. The formulations successfully decreased moisture content, which was lower than 11.72 ± 0.08 g/100 g in the formulations. Water activity ranged between 0.1464 ± 0.0043 and 0.1562 ± 0.029, with no significant difference between the formulations. The hygroscopicity of cocoa honey powders ranged from 29.29 to 29.87 g of water/100 g of cocoa honey. The combination of 20% maltodextrin and 1% whey protein isolate (WPI) led to the best yield, resulting in a free-flowing powder as the final product. On the other hand, the formulation composed of maltodextrin and whey protein isolate in the ratio of 29:1, respectively, led to the most stable product, with less loss of phenolic compounds during the drying process (6.04%). Regarding particle diameter, 90% of the accumulated distribution did not exceed 57 μm. The greatest dispersion of particles occurs in the Ma20W10 formulation with a span of 2.72, inferring greater variation in size between small (7.01 ± 0.06 μm), medium (18.25 ± 0.37 μm), and large (56.65 ± 1.17 μm) particles. The use of whey protein isolate as an adjuvant proved to be an efficient drying process in the production of cocoa honey powder, and was also advantageous for enriching the nutritional content of the final product due to its protein origin. Furthermore, the combination of spray-drying technology and the use of whey protein isolate as adjuvant led to a free-flowing cocoa honey powder with an adequate particle size and benefits in terms of shelf-life extension, providing new opportunities for the commercialization of cocoa honey as an ingredient for the food industry, with benefits for the circular economy.
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Ubhe, Anand, and Gerard G. M. D’Souza. "Preparation and Evaluation of Polymeric Microparticles of Human Recombinant IL-1 Receptor Antagonist by Spray Drying." Drug Delivery Letters 10, no. 4 (2020): 308–13. http://dx.doi.org/10.2174/2210303110999200727171802.
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Background: Formulating protein drugs into delivery systems with high drug loading is particularly challenging. Another major hurdle for formulation processes generally used for protein drugs is their scalability. In this article, we present the application of spray drying to prepare polymeric microparticles of human recombinant IL-1 receptor antagonist (IL-1 ra). Objective: The objective of this study was to formulate polymeric microparticles entrapping a therapeutic protein, human recombinant IL-1 ra using a spray drying process. Methods: IL-1 ra was formulated using three polymers viz. gelatin, pectin, and sodium alginate by using a spray drying process to produce polymer entrapped drug microparticles. A single drug to polymer ratio was used in the three drug-polymer formulation combinations. The prepared microparticles were evaluated for morphology by scanning electron microscopy, average particle size by dynamic light scattering and drug entrapment efficiency by ELISA. Results: Microparticles of three drug-polymer combinations were prepared using the Buchi B-90 spray dryer. The morphology of the three types of polymeric microparticles was found to be uniform by scanning electron microscopy. The average particle size for the three formulations ranged from 1 to 2.2 μ with a low standard deviation implying narrow particle size distribution. The drug loading efficiency ranged from 62 to 90 % W/W for the three formulations. Conclusion: The presented study demonstrates the feasibility of using spray drying to prepare morphologically uniform polymer entrapped protein drug microparticles with high drug entrapment efficiency.
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Vidović, Senka, Milica Ramić, Rita Ambrus, Jelena Vladić, Piroska Szabó-Révész, and Aleksandra Gavarić. "Aronia Berry Processing by Spray Drying." Food technology and biotechnology 57, no. 4 (2019): 513–24. http://dx.doi.org/10.17113/ftb.57.04.19.6369.
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The main aim of this study is to analyze the solid-liquid extraction followed by spray drying as a technological pathway for utilization of aronia fruit dust, a byproduct of filter tea factory. In the current study, ultrasound-assisted extraction was applied for the production of aronia liquid feed and maltodextrin was used as a carrier and encapsulating agent. In spray drying, the influence of inlet temperature and maltodextrin type and mass fraction on process efficiency and powder properties were observed. The physical and chemical properties of the obtained powders were characterized. It was determined that the powder produced using inlet temperature 140 °C and 40 % maltodextrin with dextrose equivalent (DE) 19.7 had the most desirable characteristics. It was observed that the increase in maltodextrin mass fraction decreases the powder moisture content, hygroscopicity and the content of bioactive compounds, but increases water solubility index and particle size. The increase in dextrose equivalent of maltodextrin increases the powder hygroscopicity and water solubility index, while the increase of inlet temperature causes a decrease in moisture content of aronia powders.
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Shepard, Kimberly B., Amanda M. Pluntze, and David T. Vodak. "Simultaneous Spray Drying for Combination Dry Powder Inhaler Formulations." Pharmaceutics 14, no. 6 (2022): 1130. http://dx.doi.org/10.3390/pharmaceutics14061130.
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Spray drying is a particle engineering technique used to manufacture respirable pharmaceutical powders that are suitable for delivery to the deep lung. It is amenable to processing both small molecules and biologic actives, including proteins. In this work, a simultaneous spray-drying process, termed simul-spray, is described; the process involves two different active pharmaceutical ingredient (API) solutions that are simultaneously atomized through separate nozzles into a single-spray dryer. Collected by a single cyclone, simul-spray produces a uniform mixture of two different active particles in a single-unit operation. While combination therapies for dry powder inhalers containing milled small molecule API are commercially approved, limited options exist for preparing combination treatments that contain both small molecule APIs and biotherapeutic molecules. Simul-spray drying is also ideal for actives which cannot withstand a milling-based particle engineering process, or which require a high dose that is incompatible with a carrier-based formulation. Three combination case studies are demonstrated here, in which bevacizumab is paired with erlotinib, cisplatin, or paclitaxel in a dry powder inhaler formulation. These model systems were chosen for their potential relevance to the local treatment of lung cancer. The resulting formulations preserved the biologic activity of the antibody, achieved target drug concentration, and had aerosol properties suitable for pulmonary delivery.
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Eslamian, Morteza, and Nasser Ashgriz. "Effect of Atomization Method on the Morphology of Spray-Generated Particles." Journal of Engineering Materials and Technology 129, no. 1 (2006): 130–42. http://dx.doi.org/10.1115/1.2400270.
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Effect of various atomization methods and solute concentration on the morphology of spray dried magnesium sulphate particles is investigated. Four types of atomizers are characterized and tested including (i) a vibrating mesh nebulizer, (ii) a splash plate nozzle, (iii) an air mist atomizer, and (iv) a pressure atomizer. Several types of particle morphologies are identified in this research. Spray characteristics, such as droplet number density, droplet size, and velocity, and accompanying atomizing air have major influence on the drying and morphology of the particles. High initial solute concentrations result in the formation of thick-walled particles, and this prevents the particles to burst. It is found to be difficult to obtain fully filled magnesium sulphate particles, even for saturated solutions at room temperature because the solution equilibrium saturation changes substantially with temperature.
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Li, Zheng Min, Min Tan, Bing Jiang, Zhi Wei Chen, and Wei Jiang Si. "Particle Shape Characterization of Inorganic Powders by SEM and Image Analysis." Advanced Materials Research 177 (December 2010): 18–21. http://dx.doi.org/10.4028/www.scientific.net/amr.177.18.
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The shape of inorganic powder particles, prepared by spray-drying process, is close to sphere, and the dry conditions have greater effect on the sphericity. The particle shape is normally described by words or shown by micrographs — these are qualitative and imprecise. In order to characterize the particle shape quantitatively, three shape factors, i.e. aspect ratio (M), roundness (R) and concavity (C), are proposed to describe the particle shape of the inorganic powders in different aspects. An image process method, that “holes” were filled and then particle clusters were separated, was developed and applied in scanning electron microscope (SEM) image in which some particles with “shadow” contact with each other. Mean shape factors, based on about 500 particles in 10 micrographs, are proposed to characterize the particle shape of the inorganic powders. The determination results of four inorganic powders show that cracking catalyst powders without silicon additive and produced after rebuilding of the spray-drying device are closer to spheres.
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Al-Zoubi, Nizar, Shadi Gharaibeh, Ahmad Aljaberi, and Ioannis Nikolakakis. "Spray Drying for Direct Compression of Pharmaceuticals." Processes 9, no. 2 (2021): 267. http://dx.doi.org/10.3390/pr9020267.
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Tableting by direct compression (DC) is one of the simplest and most cost-effective drug manufacturing approaches. However, most active pharmaceutical ingredients (APIs) and excipients lack the compression and flow properties required to meet the needs of high-speed industrial tablet presses. Therefore, the majority of DC APIs and excipients are modified via processing/co-processing particle engineering techniques to boost their properties. Spray drying is one of the most commonly employed techniques to prepare DC grades of APIs and excipients with prominent advantages. This review aims to present an overview of the commercially marketed and investigationally-prepared DC APIs and excipients produced by spray drying.
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Triboli, Edison Paulo De Ros, and Jorge Andrey Wilhelms Gut. "Study of Spray-dried Yoghurt Production in a Pilot-scale Equipment Using Drying Agents to Reduce Wall Deposition." International Journal of Food Engineering 12, no. 8 (2016): 793–803. http://dx.doi.org/10.1515/ijfe-2015-0355.
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Abstract The objective of this study was to determine suitable conditions for yoghurt spray drying in a pilot-scale equipment with a rotary atomizer using drying auxiliary agents to reduce wall deposition in the drying chamber. First, the effects of the main process variables (disk rotation speed: 25,000–30,000 rpm; inlet air temperature: 160–180 °C; feed flow rate: 5.2–8.7 kg/h) were studied with a 23 central composite experimental design. Following, six different drying agents (maltodextrins 5 dextrose equivalent [DE] and 10 DE, EmCap®, acacia gum, skimmed milk and fumed silica) were tested to identify the most promising additive to improve process yield. Excellent results on wall deposition, product recovery, product color and particle size distribution span were achieved with fumed silica Aerosil® at 3 %, 26,000-rpm atomizer speed, 160 °C inlet air temperature and 8.7 kg/h yoghurt feed flow rate. The action of the fumed silica on particle agglomerates produced a free-flowing powder with good homogeneity.
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Daggupati, V. N., G. F. Naterer, K. S. Gabriel, R. J. Gravelsins, and Z. L. Wang. "Effects of atomization conditions and flow rates on spray drying for cupric chloride particle formation." International Journal of Hydrogen Energy 36, no. 17 (2011): 11353–59. http://dx.doi.org/10.1016/j.ijhydene.2010.10.094.
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Tay, Jamie Boon Jun, Xinying Chua, Cailing Ang, et al. "Effects of Spray-Drying Inlet Temperature on the Production of High-Quality Native Rice Starch." Processes 9, no. 9 (2021): 1557. http://dx.doi.org/10.3390/pr9091557.
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Rice starch is a common functional ingredient used in various food applications. The drying regime to obtain dry starch powder is an important processing step, which affects the functional properties of the starch. The application of extreme thermal treatment during the conventional drying process tends to elicit irreversible changes to the rice starch, resulting in the loss of desired functionalities. In a previous study, we reported the development of a novel low temperature spray-drying based process which efficiently dries waxy rice starch, while preserving its physicochemical properties and functionalities. This study, a follow-up to the previous report, evaluated the effect of different spray-drying inlet temperatures on the production yield, physicochemical properties, and functionalities of waxy rice starch. Increasing the inlet temperature from 40 °C to 100 °C resulted in an increase in the process yield from 74.83% to 88.66%, respectively. All spray dried waxy rice starches possessed a low moisture content of less than 15%, and a consistent particle size (median ~6.00 μm). Regardless of the inlet temperatures, the physicochemical functionalities, including the pasting characteristics and flowability, were similar to that of the native waxy rice starch. The molecular and A-type crystalline structure of the waxy rice starches were also conserved. An inlet temperature of 60 °C represented the optimum temperature for the spray-drying process, with a good yield (84.55 ± 1.77%) and a low moisture content (10.74 ± 1.08%), while retaining its native physicochemical functionalities and maximizing energy efficacy.
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Jamil Ur Rahman, Umair, and Artur K. Pozarlik. "Numerical Study and Experimental Validation of Skim Milk Drying in a Process Intensified Counter Flow Spray Dryer." Energies 14, no. 16 (2021): 4974. http://dx.doi.org/10.3390/en14164974.
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This research presents 3D steady-state simulations of a skim milk spray drying process in a counter-current configuration dryer. A two-phase flow involving gas and discrete phase is modeled using the Eulerian–Lagrangian model with two-way coupling between phases. The drying kinetics of skim milk is incorporated using the Reaction Engineering Approach. The model predictions are found to be in accordance with the experimental temperature measurements with a maximum average error of 5%. The validated computational model is employed further to study the effects of nozzle position, initial spray Sauter Mean Diameter (SMD), air inlet temperature, and feed rate on the temperature and moisture profiles, particle impact positions, drying histories, and product recovery at the outlet. The location of the nozzle upwards (≈23 cm) resulted in maximum product recovery and increased the mean particle residence time at the outlet. A similar trend was observed for the highest feed rate of 26 kg/h owing to the increased spray penetration upstream in the chamber. The maximum evaporation zone was detected close to the atomizer (0–10 cm) when the spray SMD is 38 µm, whereas it shifts upstream (40–50 cm) of the dryer for an SMD of 58 µm. The high air inlet temperature resulted in enhanced evaporation rates only in the initial 10–20 cm distance from the atomizer. The results obtained in this study are beneficial for the development of the novel vortex chamber-based reactors with a counter flow mechanism.
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Nasarudin, Nur Anis Syafiqa, and Mohd Sharizan Md Sarip. "POTENTIAL OF RICE BRAN PROTEIN POWDER PRODUCTION TO INCREASE PADDY INDUSTRY PRODUCTIVITY." Prosiding Seminar Sosial Politik, Bisnis, Akuntansi dan Teknik 5 (December 9, 2023): 144. http://dx.doi.org/10.32897/sobat.2023.5.0.3092.
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The demand for alternative protein sources has been steadily increasing due to concerns about sustainability and animal welfare. Rice bran, a byproduct of rice milling, is a potential source of protein with high nutritional value. This study aims to investigate the production of rice bran protein powder using a pilot-scale ultrasonic spray dryer.The research methodology involves several key steps. First, rice bran is collected from the milling process and undergoes a series of pretreatment steps, including defatting and protein extraction. The extracted protein solution is then concentrated and purified to remove impurities and enhance protein content. The resulting protein solution is then fed into a pilot-scale ultrasonic spray dryer for powder production. The pilot-scale ultrasonic spray dryer offers advantages such as precise control over particle size, improved solubility, and reduced agglomeration. The drying conditions, including inlet air temperature, feed rate, and atomization pressure, are optimized to obtain a high-quality protein powder with desirable physicochemical properties. The produced rice bran protein powder is characterized for its protein content, amino acid profile, functional properties (such as solubility, emulsifying capacity, and foaming ability), and particle size distribution. These properties are evaluated to assess the feasibility of using rice bran protein powder in various food applications, including bakery products, beverages, and nutritional supplements. The results of this study provide insights into the potential of rice bran protein as an alternative protein source and highlight the effectiveness of pilot-scale ultrasonic spray drying as a production method. The findings contribute to the development of sustainable protein ingredients and support the utilization of rice bran, a byproduct that would otherwise be underutilized or discarded.
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Buljat, Ana Maria, Tamara Jurina, Ana Jurinjak Tušek, Davor Valinger, Jasenka Gajdoš Kljusurić, and Maja Benković. "Applicability of Foam Mat Drying Process for Production of Instant Cocoa Powder Enriched with Lavender Extract." Food technology and biotechnology 57, no. 2 (2019): 159–70. http://dx.doi.org/10.17113/ftb.57.02.19.6064.
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The foam mat drying process is a simple and economical alternative to spray and freeze drying. It is considerably cheaper due to rapid drying at low temperatures, preservation of nutritional quality and easy reconstitution. Basic principle of the process is conversion of a liquid or a semi-liquid foodstuff to foam and thin layer drying of the foam. This study explores the possibility of the foam mat drying for production of instant cocoa powder enriched with lavender (Lavandula × hybrida L.) extracts. The aqueous extraction of lavender was optimized using Taguchi orthogonal array design. Extracts obtained under optimal conditions were added to a mixture of egg white, cocoa powder, sugar and gelatine. Mixtures were blended for 4 min to obtain stable foam which was dried at three different temperatures (t=50, 60 and 70 °C) and milled into a powdered product. Drying rates were obtained from the experimental data using nonlinear model estimation. Flow properties, bulk density, particle size distribution, reconstitution and sensory properties of the final product were also assessed. Based on the obtained data, the drying process was best described by Page’s drying model. Samples dried at lower temperature (t=50 °C) exhibited the best powder flow and reconstitution properties. Sensory analysis resulted in similar findings: powder samples dried at lower temperatures had better appearance, colour and taste. The obtained data confirm the suitability of the foam mat drying for the production of instant cocoa powder enriched with lavender extract.
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Sadiq, Uzma, Harsharn Gill, Jayani Chandrapala, and Fatima Shahid. "Influence of Spray Drying on Encapsulation Efficiencies and Structure of Casein Micelles Loaded with Anthraquinones Extracted from Aloe vera Plant." Applied Sciences 13, no. 1 (2022): 110. http://dx.doi.org/10.3390/app13010110.
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The encapsulation efficiency (EE%) and structural changes within the Anthraquinones-encapsulated casein micelles (CM) powders were evaluated in this study. For this purpose, the anthraquinone powder extracted from Aloevera, its freeze-dried powder (FDP) and whole leaf Aloe vera gel (WLAG) has been encapsulated in CM through ultrasonication prior to spray dying to produce nanocapsules: CM encapsulated anthraquinone powder (CMAQP), CM encapsulated freeze-dried powder (CMFDP) and CM encapsulated Whole leaf aloe vera gel (CMWLAG). Based on the pH of the solution before drying, CMAQP had the highest EE% following spray drying. However, due to air-interface-related dehydration stresses, SD resulted in a slight decrease in the EE% of anthraquinones (aloin, aloe-emodin, and rhein) in CMAQP. Meanwhile, a significant increase in EE% of CMFDP was observed compared to the aqueous state. According to SEM findings, the particle size of CMAQP was 2.39 µm and ξ-potential of ~−17mV. The CMFDP had a rough fractal surface with large particle sizes and potential of 3.49 µm and ~−11mV respectively. CM deformed, having the least EE% and lowest ξ-potential (−4.5 mV). Spray drying enhances melanoidin formation in CMWLAG, as evidenced by the highest chroma values. The results suggested that EE%, stability, and degree of Maillard reaction are closely linked to the type of anthraquinone encapsulated, the pH of the solution, and the nanostructure of casein micelles during spray drying.
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Jamil Ur Rahman, Umair, Artur Krzysztof Pozarlik, Thomas Tourneur, Axel de Broqueville, Juray De Wilde, and Gerrit Brem. "Numerical Study toward Optimization of Spray Drying in a Novel Radial Multizone Dryer." Energies 14, no. 5 (2021): 1233. http://dx.doi.org/10.3390/en14051233.
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In this paper, an intensified spray-drying process in a novel Radial Multizone Dryer (RMD) is analyzed by means of CFD. A three-dimensional Eulerian–Lagrangian multiphase model is applied to investigate the effect of solids outlet location, relative hot/cold airflow ratio, and droplet size on heat and mass transfer characteristics, G-acceleration, residence time, and separation efficiency of the product. The results indicate that the temperature pattern in the dryer is dependent on the solids outlet location. A stable, symmetric spray behavior with maximum evaporation in the hot zone is observed when the solids outlet is placed at the periphery of the vortex chamber. The maximum product separation efficiency (85 wt %) is obtained by applying high G-acceleration (at relative hot/cold ratio of 0.75) and narrow droplet size distribution (45–70 µm). The separation of different sized particles with distinct drying times is also observed. Smaller particles (<32 µm) leave the reactor via the gas outlet, while the majority of big particles leave it via the solids outlet, thus depicting in situ particle separation. The results revealed the feasibility and benefits of a multizone drying operation and that the RMD can be an attractive solution for spray drying technology.
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Ogrodowska, Dorota, Małgorzata Tańska, Paweł Banaszczyk, et al. "Influence of Selected Compositions of Wall Materials and Drying Techniques Used for Encapsulation of Linseed Oil and Its Ethyl Esters." Applied Sciences 14, no. 4 (2024): 1372. http://dx.doi.org/10.3390/app14041372.
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The aim of the study was to compare the encapsulation of linseed oil and its ethyl esters using two coating materials (maltodextrin with whey protein concentrate (WPC) vs. maltodextrin with gum arabic) and two drying methods (spray-drying vs. freeze-drying) to obtain powders with the highest oxidative stability. A comparison was made based on the properties of emulsions (morphology, particle size distribution, and stability) and powders (morphology, physicochemical properties, fatty acid composition, and oxidative stability). The powder’s oxidative stability was determined based on the Rancimat protocol. The most uniform distribution of oil droplets in prepared emulsions was stated for ethyl esters in a mixture of maltodextrin and gum arabic. Emulsions with WPC had a bimodal character, while those with gum arabic had a monomodal character. Gum arabic promoted emulsion stability, while in samples containing WPC, sedimentation and creaming processes were more visible. Powders obtained using spray-drying had a spherical shape, while those obtained by freeze-drying were similar to flakes. Although encapsulation efficiency was the highest for freeze-dried powders made of linseed ethyl esters with gum arabic, the highest oxidative stability was stated for powders made by spray-drying with WPC as wall material (independently of linseed sample form). These powders can be easily applied to various food matrices, increasing the share of valuable α-linolenic acid.
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Gardouh, Ahmed, Sherif Shaker, Zainab Z. Ali, and Mamdouh Ghorab. "Silymarin Spray-Dried Proliposomes: Preparation, Characterization and Cytotoxic Evaluation." Drug Delivery Letters 10, no. 1 (2020): 14–23. http://dx.doi.org/10.2174/2210303109666190722114211.
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Background: Most liposomes problems are due to stability and consistency. Proliposomes is one of the solutions to overcome the disadvantage of liposomes. They are available in dry powder form, it is easy to distribute, transfer, measure and store. Objective: The aim of the present study was to find a novel method of preparing Silymarin proliposomes and study the effect of cholesterol concentrations and surfactant types on the physicochemical properties of silymarin proliposomes and its in-vitro release. Methods: Silymarin proliposomes were prepared by combining two simple methods ethanol injection method for liposomes preparation followed by the spray drying method to get a dry powder. The physicochemical properties including particle size, TEM, SEM, FTIR, encapsulation efficiency and dissolution studies were studied. Results: The particle size of silymarin liposomes were below 552.36 ± 17.63 nm but after reconstitution of silymarin proliposomes, the particle size was in the micro range due to the influence of the spray drying process. Cholesterol concentration was ranged from 50 to 150 mg per formula. Increasing Cholesterol concentration caused a significant increase in liposomes particle size and reduction in encapsulation efficiency. Three non-ionic surfactants were used to prepare silymarin proliposomes Tween 80, Cremophor RH 40 and Poloxamer 407. Formula F1 prepared with Phosal® 53 MCT (300 mg), Tween 80 (50 mg), cholesterol (50 mg) and Silymarin (140 mg) showed the smallest particle size (2066 ± 164.87 nm) upon reconstitution in water, highest encapsulation efficiency (89.51 ± 0.43%), and fastest in vitro release compared to other formulas. Cytotoxicity of Silymarin, formula F1 and formula F1/blank was assessed using an MTT assay on MCF-7, HepG2 and HBF-4 cells. The cytotoxic effect of silymarin was enhanced by loading it on proliposomes. Conclusion: Silymarin was successfully formulated into proliposomes combining ethanol injection and spray drying methods. The cytotoxicity of silymarin was improved when loaded on proliposomes owing to the formula.
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Ousset, Aymeric, Joke Meeus, Florent Robin, Martin Schubert, Pascal Somville, and Kalliopi Dodou. "Comparison of a Novel Miniaturized Screening Device with Büchi B290 Mini Spray-Dryer for the Development of Spray-Dried Solid Dispersions (SDSDs)." Processes 6, no. 8 (2018): 129. http://dx.doi.org/10.3390/pr6080129.
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Spray-drying is an increasingly popular technology for the production of amorphous solid dispersions (ASDs) in the pharmaceutical industry that is used in the early evaluation and industrial production of formulations. Efficient screening of ASD in the earliest phase of drug development is therefore critical. A novel miniaturized atomization equipment for screening spray-dried solid dispersions (SDSDs) in early formulation and process development was developed. An in-depth comparison between the equipment/process parameters and performance of our novel screening device and a laboratory Büchi B290 mini spray-dryer was performed. Equipment qualification was conducted by comparing the particle/powder attributes, i.e., miscibility/solid state, residual solvent, and morphological properties of binary SDSDs of itraconazole prepared at both screening and laboratory scales. The operating mode of the miniaturized device was able to reproduce similar process conditions/parameters (e.g., outlet temperature (Tout)) and to provide particles with similar drug–polymer miscibility and morphology as laboratory-scale SDSDs. These findings confirm that the design and operation of this novel screening equipment mimic the microscale evaporation mechanism of a larger spray-dryer. The miniaturized spray-dryer was therefore able to provide a rational prediction of adequate polymer and drug loading (DL) for SDSD development while reducing active pharmaceutical ingredient (API) consumption by a factor of 120 and cycle time by a factor of 4.
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Dong, X. L., B. K. Kim, C. J. Choi, K. S. Park, and Z. D. Zhang. "Synthesis of Nd2Fe14B powders by spray-drying and reduction–diffusion processes." Journal of Materials Research 16, no. 4 (2001): 1083–89. http://dx.doi.org/10.1557/jmr.2001.0150.
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The magnetic Nd–Fe–B powders were prepared by a mechanochemical method, including the processes of spray drying, debinding, milling, H2 reduction, Ca reduction, and washing. The liquid solution dissolved with various metal salts was first spray-dried to prepare the precursor powders having uniformly dispersed Nd, Fe, and B components. The precursor powders in turn were subjected to the subsequent processes. The particle size of the resultant Nd–Fe–B powders was about 1 μm. Effects of the process parameters on phases, morphologies, microstructures, compositions, and thermal properties of the powders were investigated.
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Repajić, Maja, Ivona Elez Garofulić, Nina Marčac Duraković, et al. "Physico-Chemical Characterization of Encapsulated Fennel Essential Oil under the Influence of Spray-Drying Conditions." Processes 12, no. 3 (2024): 577. http://dx.doi.org/10.3390/pr12030577.
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In this study, fennel essential oil (EO) was spray-dried, varying the wall material type (two-component blends of maltodextrin (MD), β-cyclodextrin (β-CD) and gum arabic (GA)), the wall material ratio (1:1, 1:3 and 3:1) and the drying temperature (120, 160 and 200 °C). A total of 27 powders were analyzed for their moisture content, solubility, hygroscopicity, bulk density and particle size, while powder recovery and oil retention were determined in terms of encapsulation efficiency. The morphology and chemical composition of the powder obtained under optimal conditions were additionally analyzed by scanning electron microscopy and gas chromatography-mass spectrometry. The results showed that all of the powders had generally good properties, exhibiting a low moisture content, high powder recovery and high oil retention. A 1:3 MD:GA mixture and a drying temperature of 200 °C were found to be optimal for the spray-drying of fennel EO, producing a powder with a low moisture content (3.25%) and high solubility (56.10%), while achieving a high powder recovery (72.66%) and oil retention (72.11%). The chemical profiles of the initial and encapsulated fennel EO showed quantitative differences without qualitative changes, with an average 24.2% decrease in the volatiles in the encapsulated EO. Finally, spray-drying proved to be a successful tool for the stabilization of fennel EO, at the same time expanding the possibilities for its further use.
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Gutiérrez Suárez, Jairo Andrés, Carlos Humberto Galeano Urueña, and Alexánder Gómez Mejía. "Parametric CFD Study of Spray Drying Chamber Geometry: Part I—Effects on Airflow Dynamics." ChemEngineering 9, no. 1 (2025): 5. https://doi.org/10.3390/chemengineering9010005.
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Internal airflow dynamics play a crucial role in spray drying engineering by governing particle transport and, consequently, the quality of dried products. For this application, airflow dynamics represent short- and long-timescale behaviors across the main jet and recirculation regions and have been related, among other factors, to spray chamber design. This study examines the parametric effects of key geometrical design parameters on internal airflow dynamics using Design of Experiments (DOE) methodologies and 3D Computational Fluid Dynamics (CFD) simulations. The CFD model adopts a cost-efficient approach, including adaptive mesh refinement (AMR) methods, enabling running multiple simulation cases while retaining turbulence-resolving capabilities. The results provide quantitative parameter–response relationships, offering insights into the impact of chamber geometry on complex airflow behaviors. Among the parameters studied, the chamber aspect ratio strongly influences the strength of external recirculation flows. The inlet swirl primarily governs the stability of central and recirculating flows, while the conical–cylindrical section topology, in conjunction with the jet Reynolds number, affects flow impingement on walls, predominantly caused by the precession and reversal of the central jet. This methodology demonstrates significant potential for future studies on particle drying, equipment, process scale-up, and alternative chamber configurations in spray drying systems.
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Singh, Saurabh, Sachin Kumar Singh, Malti G. Chauhan, et al. "Quality by Design-based Optimization of Formulation and Process Variables for Controlling Particle Size and Zeta Potential of Spray Dried Incinerated Copper Nanosuspension." Recent Innovations in Chemical Engineering (Formerly Recent Patents on Chemical Engineering) 12, no. 3 (2019): 248–60. http://dx.doi.org/10.2174/2405520412666190627144845.
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Background: In the present study copper nanosuspension was prepared from Incinerated Copper Powder (ICP) by top down media milling. Glycyrrhiza glabra (GG) and Gum Acacia (GA) were used as stabilizers in the formulation. Methods: Box Behnken Design was used to investigate the effect of formulation and process variables on particle size and zeta potential and optimize their ratio to get target product profile. The ratio of GA and GG to ICP was varied along with milling time and its speed. Further the prepared nanosuspensions were solidified using spray drying. Results: The particle size was found to be decreased with the increase in GG to ICP ratio, milling time and milling speed, whereas, reverse effect on particle size was observed with an increase in GA to ICP ratio. The zeta potential was found to be increased with the increase in GG to CB ratio and milling speed and it decreased with the increase in GA to ICP ratio and milling time. The obtained value for particle size was 117.9 nm and zeta potential were -9.46 mV which was in close agreement with the predicted values by the design which was, 121.86 nm for particle size and -8.07 mV for zeta potential respectively. This indicated the reliability of optimization procedure. The percentage drug loading of copper in the nanosuspension was 88.26%. The micromeritic evaluation of obtained spray dried nanoparticles revealed that the particles were having good flow and compactibility. Conclusion: It can be concluded that application of media milling, design of experiment and spray drying have offered very good copper nanosuspension that has the potential to be scaled up on industrial scale.
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Ouranidis, Andreas, Nikos Gkampelis, Catherine Markopoulou, Ioannis Nikolakakis, and Kyriakos Kachrimanis. "Development of a Nanocrystal Formulation of a Low Melting Point API Following a Quality by Design Approach." Processes 9, no. 6 (2021): 954. http://dx.doi.org/10.3390/pr9060954.
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Preparation of nanocrystal formulations by wet media milling and spray-drying is a reliable technique to enhance dissolution and ameliorate absorption limitations of poorly soluble BCS II drugs. However, when thermosensitive compositions are dried at high temperatures, the risks of particle aggregation and thermal degradation must be considered. The present study investigates the effects of nanosuspension formulation variables when performing the spray drying process at equidistant temperatures above and below the melting point. Towards this purpose, Fenofibrate is exploited as a model drug of unfavorable pharmacokinetic profile and low melting point (79–82 °C), properties that render thermal processing a nontrivial task. Rationalizing the system’s behavior by combining molecular simulations with QbD methodology, the preparation of stable nanocrystals can be “steered” in order to avoid undesirable melting. The statistically resolved operational conditions showed that Fenofibrate Critical Quality Attribute–compliant nanosuspensions i.e., bearing hydrodynamic diameter and ζ-potential of 887 nm and −16.49 mV, respectively, were obtained by wet milling drug to Pharmacoat and mannitol weighted optimum ratios of 4.075% and 0.75%, after spray drying at the desired temperature of 77 °C. In conclusion, we present a quality assurance methodology of nano-comminution generally applicable for thermo-labile BCS II drugs.
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Kieckhefen, Paul, Swantje Pietsch-Braune, and Stefan Heinrich. "Product-Property Guided Scale-Up of a Fluidized Bed Spray Granulation Process Using the CFD-DEM Method." Processes 10, no. 7 (2022): 1291. http://dx.doi.org/10.3390/pr10071291.
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In this work, a method to predict the surface structures of particles produced by fluidized bed spray layering granulation using the CFD-DEM method was developed. A simple state-variable/event tracking approach was implemented to capture indirect quantifiers of the progression of structure-forming microprocesses. The state of the droplet at the time of impact on the particle surface, as well as the time required for drying, is correlated to product properties that quantify surface structure morphology such as roughness. A workflow for scale-up of fluidized bed granulation guided by product-property predictors is presented. The approach was tested on a demonstration case from the literature, where a particle core is coated with sodium benzoate solution. The experiment was scaled-up by a factor of eight to pilot-scale using the developed method. Varying the number of nozzles in use in the pilot-scale granulation affected the particle surface roughness due to the differing drying conditions encountered. On this basis, the ability of the tracked-quantity approach to capture the relationship between product properties and geometric feature or process conditions is demonstrated.
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Chávez-Rodríguez, Arturo M., Jaime David Pérez-Martínez, Vrani Ibarra-Junquera, et al. "Microencapsulation of Banana Juice from Three Different Cultivars." International Journal of Food Engineering 9, no. 1 (2013): 9–16. http://dx.doi.org/10.1515/ijfe-2012-0169.
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AbstractIn order to effectively process and utilize surplus bananas and those without the quality for export, in this research it is proposed to microencapsulate the banana juice by means of spray drying and using maltodextrin as the covering material. Three cultivars Enano gigante (Musa AAA, subgroup Cavendish), and the tetraploids hybrids (AAAA), FHIA-17 and FHIA-23 were selected for this research. Being Enano gigante, the cultivar shows the highest glass transition temperature. The drying parameters were established, depending upon the ratio of juice/maltodextrin and the drying air temperature. The optimal drying air temperature was 220°C for the three cultivars with a 20% juice/maltodextrin ratio for both the Enano Gigante and the FHIA-23, while in the FHIA-17 there were no significant differences between the juice/maltodextrin ratios. The morphology and size distribution of the microcapsules were observed by a scanning electron microscopy. The number of particles is directly proportional to the temperature and inversely proportional to the juice/maltodextrin ratio. A Weibull particle size distribution was common to all treatments. There is a correlation between the principal components and clustering analyses with the optimization of the system. The principal components analysis considers three Weibull parameters (obtained from the particle size distribution) and the powders moisture percentage.
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Ebuehi, Osaretin N. I. "The Design of a Tomato Powder Processing Plant with a Capacity of 75,000 Tonnes Per Annum in Oyo State, Nigeria, West Africa." European Journal of Engineering and Formal Sciences 4, no. 2 (2021): 46. http://dx.doi.org/10.26417/332lsy90d.
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This project designed a plant that will process 250 tonnes of raw tomatoes per day. The duration of this production was spread across 24 hours and operated for 300 days in a year, which gave a yield of 17.5 tons of tomato powder per day. From these specifications, the best process route was synthesized. The process route selected involved choosing and sorting the tomatoes, washing, blanching, blending, spray drying (as the drying process), packaging and labeling. Through a series of investigations, the most feasible way to dry tomato powder on an industrial scale proved to be the spray-drying method because the process was very rapid, required low labor cost, and was relatively simple to operate and sustain. The particle size was also easy to control with this technology, making it easy to correlate with product standards. The equipment to be used was then identified which included the machine vision, a spray washer, a water Blancher, an industrial blender, a spray dryer, and a powder packaging machine. Material and energy balance were evaluated around the whole plant. A process flow diagram and basic piping and instrumentation diagram were also computed using engineering software such as Microsoft Visio. From the previous work done, the selected process unit, the spray dryer, was designed with a detailed piping and instrumentation diagram made around it. The site of the plant was resolved, adjacent oriental foods along the Lagos-Ibadan Expressway. It was necessary to site the plant in an area where raw materials can easily be delivered to. The area selected was directly linked to a major highway, the Lagos-Ibadan Expressway, thereby making transport quite affordable. The site layout alongside the plant layout was constructed. The layouts clearly showed the standard flow process.
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Yang, Xing, Jian Shen, Jia Liu та ін. "Spray-Drying of Hydroxypropyl β-Cyclodextrin Microcapsules for Co-Encapsulation of Resveratrol and Piperine with Enhanced Solubility". Crystals 12, № 5 (2022): 596. http://dx.doi.org/10.3390/cryst12050596.
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The synergistic therapeutic benefits of resveratrol (RES) and piperine (PIP) have been proven for the treatment of various diseases. This study reports, for the first time, spray-drying of hydroxypropyl β-cyclodextrin (HP-β-CD) microcapsules for combined delivery of resveratrol and piperine. Phase solubility studies indicated that there was a strong interaction between the active ingredients and HP-β-CD, and both active ingredients can bind stably to HP-β-CD. The results of FTIR, XRD, and DSC demonstrated that RES-PIP/HP-β-CD inclusion complexes were successfully formed, with the RES and PIP encapsulated into the hollow spherical cavity of HP-β-CD. The results of SEM showed that the spray-dried microcapsules displayed a smooth surface and uniform particle size. Upon the formation of the spray-dried microcapsules, both RES and PIP presented significantly enhanced solubility. The results of DPPH and ABTS+ scavenging activity assays showed that the spray-drying process did not adversely influence the antioxidant activity of the bioactives, and the addition of PIP increased the antioxidation performance of RES.
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Hwang, Sungjun, Yousoo Han, and Douglas J. Gardner. "Characterization of CNC Nanoparticles Prepared via Ultrasonic-Assisted Spray Drying and Their Application in Composite Films." Nanomaterials 13, no. 22 (2023): 2928. http://dx.doi.org/10.3390/nano13222928.
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The ultrasonic-assisted spray dryer, also known as a nano spray dryer and predominantly used on a lab scale in the pharmaceutical and food industries, enables the production of nanometer-sized particles. In this study, the nano spray dryer was applied to cellulosic materials, such as cellulose nanofibrils (CNFs) and cellulose nanocrystals (CNCs). CNC suspensions were successfully dried, while the CNF suspensions could not be dried, attributable to their longer fibril lengths. The nano spray drying process was performed under different drying conditions, including nebulizer hole sizes, solid concentrations, and gas flow rates. It was confirmed that the individual particle size of nano spray-dried CNCs (nano SDCNCs) decreased as the nebulizer hole sizes and solid contents of the suspensions decreased. The production rate of the nano spray dryer increased with higher solid contents and lower gas flow rates. The resulting nano SDCNCs were added to a polyvinyl alcohol (PVA) matrix as a reinforcing material to evaluate their reinforcement behavior in a plastic matrix using solvent casting. After incorporating the 20 wt.% nano SDCNCs into the PVA matrix, the tensile strength and tensile modulus elasticity of the neat PVA nanocomposite film increased by 22% and 32%, respectively, while preserving the transparency of the films.
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Baghi, Fatemeh, Sami Ghnimi, Emilie Dumas, and Adem Gharsallaoui. "Microencapsulation of Antimicrobial trans-Cinnamaldehyde: Effect of Emulsifier Type, pH, and Drying Technique." Applied Sciences 13, no. 10 (2023): 6184. http://dx.doi.org/10.3390/app13106184.
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Two plant-based emulsifiers, soybean lecithin and pea protein isolate, were studied for their emulsifying and encapsulating capacities of an antimicrobial molecule, trans-cinnamaldehyde (TC), at two different pH values, three and seven, and after drying with two different techniques, spray-drying and freeze-drying. To characterize the obtained capsules, various physicochemical tests were conducted to examine particle size, encapsulation efficiency, thermal and moisture stability, and powder morphology. The spray-dried (SD) and freeze-dried (FD) powders had an average particle size of 8.35 µm and 144.49 µm, respectively. The SD powders showed similar encapsulation efficiency (EE) for soybean lecithin and pea protein isolate with an average value of 95.69%. On the other hand, the FD powders had lower EE compared to SD powders, with an average of 58.01% for lecithin-containing powders and 83.93% for pea-protein-containing powders. However, the water content of FD powders (2.83%) was lower than that of SD powders (4.72%). The powders prepared at pH 3 showed better thermal stability. Morphological analysis showed spherical particles for SD powders and irregular shapes for FD powders. Nanoemulsions as well as dried powders showed interesting antimicrobial activities against Escherichia coli and Listeria innocua, confirming their potential use as natural preservatives in foods.