Spray drying droplets

Each spray-dried droplet forms a single particle whose size is determined by the droplet size, the dissolved solids of the feed solution, and the density of the resulting solid particle. For a given formulation and process, both the solid content and density of the powder remain constant within a batch and from batch to batch therefore, the distribution of the primary particle size is determined by the droplet size distribution. A narrowly distributed particle size can be achieved with a well-designed atomizer and controlled process parameters. 

During the process, the aqueous silicate solution is introduced into the upper portion of the gas-fired spray dryer and passes through a spray nozzle or a disk atomizer (see Figure 22.5). The speed of the spray wheel may be about 11,000 rpm. The finely and evenly dispersed liquid comes into contact with upwardly directed hot air. Typical spray tower tanperatures are about 180°C [21] with inlet temperatures of about 260-300°C and outlet air temperatures of above lOO C. The resultant spray-dried droplets adopt the form of hollow microspheres. The silicate particles are collected at the spray dryer s bottom and are withdrawn by a screw conveyor. The amorphous sodium silicate may have a bulk density on the order of 250-500 g/L, an SiOjiNajO molar ratio of 2.04 1, and an ignition loss on the order of 19-20%. Its mean particle size can be on the order of 100-200 pm. The material may be subjected to further milling to modify the form and density of the powder [51,63]. 

Structure Formation within Spray-Dried Droplets Mathematical Modelling of Spray Polymerisation... 

The second step is to disperse the core material being encapsulated in the solution of shell material. The core material usually is a hydrophobic or water-knmiscible oil, although soHd powders have been encapsulated. A suitable emulsifier is used to aid formation of the dispersion or emulsion. In the case of oil core materials, the oil phase is typically reduced to a drop size of 1—3 p.m. Once a suitable dispersion or emulsion has been prepared, it is sprayed into a heated chamber. The small droplets produced have a high surface area and are rapidly converted by desolvation in the chamber to a fine powder. Residence time in the spray-drying chamber is 30 s or less. Inlet and outlet air temperatures are important process parameters as is relative humidity of the inlet air stream. 

Spray Drying and Agglomeration. Most instant coffee products are spray-dried. Stainless steel towers with a concurrent flow of hot ak and atomized extract droplets are utilized for this purpose. Atomization, through pressure nozzles, is controUed based on selection of the nozzles, properties of the extract, pressures used, bulk density, and capacity requkements. Low inlet ak temperatures (200—280°C) are preferred for best flavor quaHty. The spray towers must be provided with adequate dust coUection systems such as cyclones or bag filters. The dried particles are coUected from the conical bottom of the spray drier through a rotary valve and conveyed to bulk storage bins or packaging lines. Processors may screen the dry product to... 

Spray-dried extract The solutions containing the drug extracts, which are sprayed through a nozzle, sink in the form of fine droplets in the current of warm air, losing their moisture and reaching the separator as dry and hollow pellets of extract which can be recognized with a hand lens. The spray-... 

Methods of fixing the volatile aroma and flavor compounds separately from the instant coffee powder have been developed. The volatile mixture can be mixed with aqueous gelatin or gum arabic and spray dried. The oily droplets of the flavor and aroma compounds are coated with gelatin or gum arabic in a dry lattice. This powder can be mixed in with instant coffee powder and is relatively stable in the presence of air. Emulsification with sugar is also a highly effective way of trapping and preserving coffee volatiles, but is of limited use for instant coffees. 

In precipitation reactions, powder characteristics depend on the speed of the nucleation of particles and their growth due to the mass flow to the surfaces. In freeze drying and spray drying, powder characteristics primarily depend on the size of droplets, which in turn is determined by the parameters of a nozzle and characteristics of the flow of a carrier gas. Both these methods enable one to obtain powders with very high surface area. 

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