Spray drying

Introduction to atomization and dehydration

Spray drying, also known as atomization, is a dehydration method that disperses a liquid into fine droplets in a stream of hot air to quickly obtain a powder. Widely used in the food, pharmaceutical, and chemical industries, this technique allows control over various properties of the final product such as particle size, morphology, and solubility.

Historical evolution of spray drying

Spray drying has evolved significantly since its invention in the 19th century. Initially, nozzle atomizers were used, and later, rotary atomizers were introduced. Despite an initially simple design, commercial applications were limited before the 1920s due to operational difficulties. In the 1920s, advances in dryer design made commercial exploitation viable, with the drying of emulsions as the first major application. World War II marked a turning point for this technology, spurred by the urgent need to reduce the weight of food and other substances intended for shipment. These advances expanded the range of products that could be spray-dried, paving the way for widespread use in various industrial sectors.

INNOV’IA’s expertise in atomization

INNOV’IA positions itself as a partner of choice for companies seeking to develop and produce powdered ingredients through its expertise in spray drying. Here are the main advantages of using their services:

Advanced technological expertise

INNOV’IA masters various spray drying technologies, including single and multiple effect drying, co-drying, and microencapsulation. This versatility allows the process to be adapted to the specific needs of each product.

Flexible production capacities

With eight spray drying towers of different evaporative capacities at the sites of La Rochelle, Segré-en-Anjou-Bleu, and Commentry, INNOV’IA can handle varying production volumes, from a few hundred kilograms to several tons per day

Preservation of functional properties

INNOV’IA’s process allows instantaneous water evaporation while preserving the functional properties of the active ingredient, crucial for sensitive or high-value-added ingredients.

Precise control of physical properties

INNOV’IA can meet precise specifications in terms of particle size with fine powders (50–100 µm) or microgranules (100–350 µm).

Certifications and regulatory compliance

The INNOV’IA sites and subsidiaries are FSSC22000 certified for human food, FAMI-QS certified for animal feed, and some lines comply with the requirements of GMP (part 2) for pharmaceutical products, ensuring product quality and safety.

Wide range of applications

INNOV’IA can process a wide variety of products, hydrophilic or lipophilic, making it a suitable partner for various industries, from food to pharmaceuticals.

Combination of technologies

INNOV’IA’s ability to combine different technologies such as drying, agglomeration, and encapsulation allows the creation of complex and innovative products.

Comprehensive support

INNOV’IA offers support from design to production, acting as an ally for companies developing new products.

High-performance industrial equipment

Several Innov’ia sites have benefited from measures under the France Relance plan, offering state-of-the-art industrial facilities that integrate all of Innov’ia’s business requirements: processes, safety, hygiene, quality, and flow management.

Expertise in encapsulation

INNOV’IA’s mastery of coating, prilling, and dripping technologies allows the development of controlled-release or protected products, opening possibilities for advanced applications.

By partnering with INNOV’IA, companies benefit from cutting-edge technical expertise, production flexibility, and comprehensive support to develop and produce high-quality powdered ingredients while meeting the strictest regulatory standards.

Dehydrated food products

Spray drying is widely used in the food industry to transform various liquid products into stable and easy to manage powders while preserving their nutritional and organoleptic properties.

Common applications

• Dairy products: Milk powder (including infant formulas), whey powder, milk proteins, cream powder, cheese powder.
• Egg-based products: Whole egg powder, egg white powder, egg yolk powder.
• Instant beverages: Soluble coffee, instant tea, powdered fruit juices.
• Other products: Flavorings and powdered ingredients, leavening agents, vegetable proteins, plant extracts.

Advantages

• Extended shelf life: Reducing water activity (aw) limits microbial growth and enzymatic reactions.
• Ease of handling and transport: The resulting powders are lighter and take up less volume than equivalent liquid products.
• Preservation of nutritional qualities: The rapid and low-temperature process allows retaining a large portion of vitamins and bioactive compounds.
• Control of final product properties: Particle size, bulk density, and solubility can be adjusted by modifying process parameters.

Spray drying process

1. Raw material preparation: The liquid to be dried (solution, emulsion, or suspension) is homogenized and sometimes concentrated.
2. Atomization: The liquid is dispersed into fine droplets using an atomizer (airflow, pressure, or rotary).
3. Drying: The droplets come into contact with hot air (usually between 150°C and 200°C) in the drying chamber.
4. Separation: Dry particles are separated from the drying air, usually using cyclones or filters.
5. Cooling and packaging: The product is cooled and packaged under controlled conditions to prevent moisture uptake.

Spray drying in the food industry must comply with strict hygiene and food safety standards. The equipment used must be designed to allow effective cleaning and disinfection, and the process must be controlled to guarantee the quality and safety of the final product.

Applications in the pharmaceutical industry

Spray drying plays a crucial role in the pharmaceutical industry, particularly for the development of innovative formulations and the production of active substances. This technique allows obtaining powders with controlled properties, essential for improving the bioavailability and stability of medications. In the pharmaceutical sector, the process is used for the production of active substances, plant extracts, and other compounds, strictly adhering to Good Manufacturing Practices (GMP).

Advantages

• Precise control of final product characteristics: Particle size and morphology, directly influencing the therapeutic efficacy of medications.
• Production of controlled-release formulations: Advanced drug delivery systems, opening new perspectives for treating various pathologies.

Economic analysis of the process

The cost of the spray drying process is an important aspect for industrial players to consider. Although this process offers many advantages in terms of final product quality, it also presents significant costs related to several factors:

Cost factors

• Initial investment: Spray drying equipment, notably drying towers and auxiliary systems, represents a substantial investment. The cost can vary considerably depending on production capacity and system complexity.
• Energy consumption: Spray drying is energy-intensive, mainly due to the need to heat the drying air to high temperatures (usually between 200°C and 300°C).
• Yield and product losses: The process yield can vary depending on product characteristics and operating parameters. Product losses, especially in the form of unrecovered fine particles, can impact the overall cost of the process.
• Maintenance and cleaning: Spray drying equipment requires regular maintenance and frequent cleaning, particularly in the food and pharmaceutical industries where hygiene standards are strict.
• Skilled labor: Operating a spray dryer requires trained personnel capable of controlling and adjusting process parameters to optimize product quality and energy efficiency.
• Formulation costs: In some cases, additives or encapsulating agents may be necessary to improve the properties of the final product.
• Scaling-up costs: Transitioning from laboratory scale to industrial scale can incur additional costs related to process optimization and equipment adaptation.

Cost optimization strategies

• Improving energy efficiency: Using heat recovery systems or optimizing drying parameters to reduce energy consumption.
• Increasing yield: Optimizing the design of the drying chamber and particle recovery systems to minimize product losses.
• Automation: Using advanced control systems to improve process efficiency and reduce labor needs.
• Production flexibility: Using versatile equipment to process different types of products, thus increasing facility utilization rates.

The cost of spray drying must be weighed against the added value it brings to the final product, particularly in terms of quality, stability, and ease of use. In many cases, the advantages in terms of preservation, transport, and handling of powdered products can offset the higher production costs.

FAQ