Spray-drying, costs

Cook, E.M. Estimating Spray Drying Costs, Chemical Engineering Progress, June 1966, p. 93. Block, L.J. Estimating Machinery and Equipment, Erection Costs, Oil and Gas Journal, Aug. 6, 1973, p. 77.. 

Spray-drying costs are always a factor in determining the economics of an encapsulated product. Drying costs are related to the amount of water that must be removed in the spray-drying process. It is therefore advantageous to enter the drier at the highest possible solids that still gives... 

Starch octenylsuccinates offer excellent emulsifying properties, flavor oil retention and good oxidation resistance versus gum arabic. They can be made on a variety of starch bases, dextrins or fluidities which provide versatility and improved spray-drying costs. Starch octenylsuccinate are low in cost, domestically produced and are not subject to the market fluctuations that gum arabic encounters. 

Spray Drying Detailed descriptions of spray dispersion dryers, together with apphcation, design, and cost information, are given in Sec. 17. Product quality is determined by a number of properties such as particle form, size, flavor, color, and heat stability. Particle size and size distribution, of course, are of greatest interest from the point of view of size enlargement. 

The introduction of concentrated laundry detergent powders in Japan during 1986-1987 produced a substantial increase in the consumption of LAB in the subsequent 3-4 years as the market changed from low-density, spray-dried powders to the concentrated (compact) products. In these products, which may contain up to 40% surfactant, the cost/performance advantages of LAS are of significance. In addition, LAB sulfonic acid is well suited for the production of high-active, high-density (about 1.0 g/cm3) laundry powders by routes other... 

Some gum users now take gum in a pre-prepared form. Spray dried gum acacia has been used in pharmaceutical products for some time. The spray dried gum offers the pharmaceutical manufacturer a clean ready to use product. Instant forms of gum acacia have been offered by suppliers for some time. The instant products can be rapidly made into solution and used. Obviously the instant gum is more expensive. A manufacturer that uses gum as a minor ingredient may well find that the capital and labour cost of purifying raw gum is not cost effective. A company that uses gum acacia as a major ingredient might come to a different conclusion. Instantised gums pose different problems to the analytical chemist.. One approach that can be used is to have an optical rotation specification for the product. Even this approach is not entirely proof against a material that contains a blend of gums of different optical rotation. 

Microencapsulation using extrusion is mainly described for glassy carbohydrate matrices [14-16, 28-29]. The glassy carbohydrates, such as starch and maltodextrins, are melted at elevated temperature and low water contents and are intensively mixed with the active in the extrusion barrel. Extrusion has been used for volatile and unstable flavours. The shelf life of flavour oils could be extended from several months to 5 years, compared with 1 year for spray-dried materials. The main drawbacks of the technology are the high investments costs and the formation of rather large particles (500-1,000 pm). 

Possibly the most important, and least understood, aspect of spray-dried flavorings manufacture is the role the wall material plays in this process. The polymers utilized for this product are controlled by FDA constraints, cost, finished product labelling considerations and compatability, functionality and historical usage. Given these considerations, polymers selected for the retention and maintenance of labile flavors and aromas in industrial spray dried, food grade systems include both carbohydrate (hydrolyzed starches, "lipophilic starches, plant exudates) and protein. The importance of these wall materials should not be underestimated. 

Spray drying is one of the most cost effective and widely used methods of flavor encapsulation. While the process of spray drying is fairly straight forward, there are many variables relative to both sample preparation and actual drying conditions. 

Development of metal chelates suitable for employment in a spray drying system (28,29). Spray drying systems have been demonstrated to be more cost-effective than wet systems for control of SO2 emissions from power plants. 

Spray-dried powders are formulated to give the best overall cleaning performance and flow characteristics at the lowest possible formulation costs. Typical spray-dried detergent formulations are shown in Table 36.6. Slurry preparation is considered to be the single most important factor in spray drying. Control of the raw material order of addition, slurry solids level, slurry temperature, viscosity, and aeration enable manufacturers to deliver the desired final product characteristics. The spray tower itself is simply a contained heat source that removes moisture at a uniform rate dependent upon the quality and the quantity of feed to the dryer. If feed variables are not controlled, variability in the... 

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