Ppt

1. NANO SPRAY DRYING OF
FOOD INGREDIENTS:
MATERIALS, PROCESSING
AND APPLICATIONS
1
CHRISTY TOJI
ROLL NO: 17
AJC20FT019
S7 FOOD TECHNOLOGY
GUIDE: Dr. SUNNICHAN V GEORGE

2. CONTENT
1. INTRODUCTION
2. CONVENTIONAL SPRAY DRYING VS NANO SPRAY DRYING
3. FUNDAMENTALS OF NANO SPRAY DRYING TECHNOLOGY
4. APPLICATION OF NANO SPRAY DRYING FOR FOOD INGREDIENTS
5. CHALLENGES WITH NANO SPRAY DRYING
6. CONCLUSION
7. REFERENCES
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3. INTRODUCTION
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 Nowadays, there is a growing trend in the consumption of bioactive food ingredients and their use in the
production of functional foods.
 Bioactive components are sensitive to various factors so encapsulation technology has been emerged as a
promising solution to achieve these goals.
 Spray drying is one of the most common and popular techniques for the encapsulation and drying of food
ingredients.
 With the emergence of nanotechnology scientists have focused on the development of nano-based materials in
the food industry.
 The problem with conventional spray drying is the limited possibility of obtaining powder nanoparticles as the
cyclone separating units can not result in collecting those very small particles.
 Nano spray dryer has been designed successfully to address this issue.

4. CONVENTIONAL SPRAY DRYER
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ATOMIZATION OF LIQUID FEED
DROPLET HOT AIR CONTACT
EVAPORATION OF DROPLET
WATER
RECOVERY OF POWDER
https://images.app.goo.gl/RVmNBuftdE8oJN7b8

5.  Spray drying is the most prevalent method to produce flowable powders of encapsulated micro- and nano-
capsule for food ingredients.
 The contact time between dried material and hot air is very short (a few seconds), which makes it possible
to dehydrate thermosensitive materials.
 Heat-sensitive materials can be dried and protected using this method, because of the rapid evaporation
cooling.
 The size and size distribution of particles produced by conventional spray dryers is typically from several
μm to several hundred μm.
 The yield of product in traditional laboratory spray driers is usually around 50%–70%, depending on
particle separation efficiency and the tendency to build product depositions at the spray chamber walls.
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BENEFITS OF SPRAY DRYING FOR THE ENCAPSULATION OF FOOD INGREDIENTS

6. ADVANTAGES
 Fast conversion
of liquid into
powder
 Possible low
thermal degradation
 High thermal
efficiency
 Easy scaling up
DISADVANTAGES
 Low drying yield
 Difficult control of
particle size and
distribution
 The need for
optimization
 Not possible to
obtain nano
particles
ADVANTAGES AND DRAWBACKS OF CONVENTIONAL SPRAY DRYING
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7. MODIFICATION IN SPRAY DRYING ADVANTAGES DRAWBACKS
Dehumidified air spray drying Reduction of drying temperature,
reduce stickiness of sugar-rich materials.
Additional equipment required for air
dehumidification.
Vacuum spray drying Reduction of drying temperature.
Minimizing oxidative stress. Powder
collection more efficient.
Additional equipment required for low-
pressure maintenance, High processing
cost.
Ultrasonic spray drying Production of droplets of small and
uniform size, Reduction of drying
chamber dimensions, Reduced risk of
nozzle clogging.
Limitation to fluids of low viscosity.
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8. NANO SPRAY DRYING
 Ability to produce nanoparticles and submicron particles with a
uniform distribution.
 Büchi Nano Spray Dryer B-90 system is the only commercial NSD
system currently available.
 Encapsulated particles produced by conventional spray drying have size
above micrometer range and hence they have got lower absorption rate,
solubility, controlled release, imprecise targeting and bioavailability of
core compound is low as compared to nanoparticles.
 NSD can improve process yield compared to standard spray drying,
since the powder collection is independent of particle mass.
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MICROENCAPSULATION NANOENCAPSULATION
Protection of bioactive compounds Reducing particle size and creating narrow particle
distribution
Controlling release profile Higher surface area
Masking of undesirable flavors Enhanced delivery of bioactive protection
Improving flow properties Improving the bioavailability
Increasing shelf life Enhancement of physical stability and long shelf
life
Product enrichment with specific nutrients Better precision targeting and passing through
minute body fenestration
FUNCTIONALITY OF MICRO AND NANO ENCAPSULATION

10.  Carrier materials should be able to stabilize the feed emulsion, reduce stickiness during drying, protect the
core materials, and have desirable taste, availability, and cost.
 Commonly used carriers for spray drying encapsulation include maltodextrins, gum Arabic, Proteins (whey
proteins, caseinates, and gelatine), polysaccharides (chitosan, pectin, alginate).
 Growing trend to develop new carriers from food industry by-products with additional health-promoting
properties, aligning with "clean label" and "zero waste" trends.
 NUTRIOSE® of prebiotic characteristic was applied for the production of honey powder, zein from corn
meal used for encapsulating tomato oleoresin.
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WALL MATERIALS, PARTICLE MORPHOLOGY, PARTICLE SIZE RANGE

11.  Difference in atomization causes the variations in
particle morphology, size, and size distribution.
 The shape and surface properties of the particles also
depend on the raw material, drying temperature, type
of wall material.
 The ratio of core material to carrier material impacts
particle size distribution, while inlet temperature also
influence particle size and distribution.
 Surfactants or other compounds may need to be added
to the feed solution to alter morphology, reduce
particle size, and improve uniformity.
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WALL MATERIALS, PARTICLE MORPHOLOGY, PARTICLE SIZE RANGE

12. NANO SPRAY DRYING
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Dryer design has been rearranged in Büchi’s Nano Spray Dryer B-90
system.
Droplet generation in an NSD is based on the vibration mesh
technology.
Electrostatic particle collector used for collecting the dried
powders.
Gentle laminar flow heating system as drying medium.
Generate particle size ranging from 300 nm to 5 µm for milligram
sample quantities at high yields and with minimal activity loss.
https://images.app.goo.gl/bRmpzY2DMGf4pAwg7

13. PROCESS STEPS OF NANO SPRAY DRYING TECHNOLOGY
Heating of the
drying gas
Droplet formation
by atomization of
the liquid supply
Drying of the
droplets in the
drying gas and
formation of dry
particles
Particle separation
and collection of
the dry particles
from the drying gas.
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14. DROPLET GENERATION
DROPLET
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https://images.app.goo.gl/2wVXrvBKfE33oeny5

15. DROPLET GENERATION
DROPLET
 Piezoelectric actuator vibrates a thin spray mesh with laser-drilled holes.
 Ultrasonic frequency vibration (adjustable from 80 to 140 kHz) deforms the mesh,
charges holes with fluid, and pushes it into the drying chamber.
 Around 100 million droplets per second are produced at approximately
100 kHz oscillation frequency with 1,000 active holes.
 Droplet size uniformity depends on uniformity of holes.
 Nano spray Dryer B-90 had spray meshes with
4.0, 5.5, and 7.0 μm holes.
 Droplet size influenced by mesh size, sample concentration,
and fluid properties like viscosity and surface tension.
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https://images.app.goo.gl/4mBk861mbdmZSR337

16. DRYING OF DROPLETS
 The upper heating unit in the NSD have a porous metal
surface, creating a laminar flow of drying gas to gently dry
the sprayed droplets and prevent turbulence.
 A compact porous disc fixed with an electrical heating coil
rapidly heats up the drying air to desired temperature.
 Confirms laminar flow of drying air in drying chamber to
prevent unrestrained spray formation and particle loss on
the inner surface of drying chamber.
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https://www.researchgate.net/figure/Compact-heater-unit-at-the-top-of-
the-Nano-Spray-Dryer-B-90-consisting-of-an-electrical_fig5_337007067

17. DRYING OF DROPLETS
 Gas Residence Time: About 3–6 seconds in a short setup and 7–15
seconds in a tall setup.
 Outlet temperature is determined by inlet temperature, drying gas
flow rate, feed flow rate, and solid concentration.
 To achieve low residual moisture in the final product,
a high inlet temperature is used, and the temperature
difference between inlet and outlet is minimized.
 Low outlet temperatures help maintain the stability and activity
of heat-sensitive bioactive food ingredients.
 Due to the intense evaporative cooling effect, the temperature of
the particles is close to the gas temperature at the outlet.
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https://www.researchgate.net/figure/Schematic-
image-of-Nano-Spray-Dryer-B-90_fig10_230618274

18. ELECTROSTATIC PARTICLE SEPERATION
 The Nano Spray Dryer uses an electrostatic particle
collector for efficient separation.
 The collector consists of a stainless steel cylinder
(anode) and a star-shaped counter electrode
(cathode).
 A high voltage of about 17 kV is applied, charging
particles and directing them to the inner wall of the
collecting electrode.
 Submicron particles are captured with over 99%
efficiency for small powder batches.
 After the process, particles are gently removed with
a scraper, filled into airtight glass vials, and stored
under controlled conditions.
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https://images.app.goo.gl/hBMSsjoF3HGH19L57

19. KEY DIFFERENCE BETWEEN TRADITIONAL AND NANO SPRAY DYYER IN LABORATORY SCALE
CHARACTERISTICS TRADITIONAL SPRAY DRYER NANO SPRAY DRYER (NSD)
Drying gas flow regime Turbulent Laminar
Particle separation technology Cyclone Electrostatic particle collector
Drying temperature Up to 220 ◦C Up to 120 ◦C
Sample viscosity <300 cps <10 cps
Droplet size/distribution 5–100 μm, broader 3–15 μm, narrow
Key spray technologies Two fluid nozzle Piezoelectric driven vibrating mesh
atomizer
Dried particle size 2–25 μm 200 nm – 5.0 μm
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20. INFLUENCE OF PROCESS PARAMETERS AND FORMULATION VARIABLES
- strong increasing influence
- strong decreasing influence
- weak increasing influence
- weak decreasing influence
(-) minimal or no influence
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21. APPLICATION OF NANO SPRAY DRYING FOR FOOD INGREDIENTS
PHENOLIC COMPOUNDS
VITAMINS AND MINERALS
CAROTENOIDS
FATTY ACID AND FUNCTIONAL OIL
ESSENTIAL OILS AND FLAVOURS
PROTEINS AND PEPTIDES
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Type of
Ingredients
Wall materials/
Stabilizer
Food
Ingredients
Particle
diameter(nm)
Production
yield (%)
Encapsulation
efficiency(%)
References
Carotenoids Maltodextrin Paprika
oleoresin
500-1000 63.46 98.5 Díaz et al.
(2019)
Vitamin Arabic gum,
polyvinyl alcohol
Vitamin E
acetate
625–801 70–90 ND Li et al. (2010)
Functional oils Maltodextrin sunflower oil 548–5570 41–90 ND (Büchi
Labortechnik
AG 2017e)

23. Type of
Ingredients
Wall materials/
Stabilizer
Food
Ingredients
Particle
diameter(nm)
Production
yield (%)
Encapsulation
efficiency(%)
References
PHENOLIC
COMPOUNDS
Chitosan CURCUMIN 346 - 499.5 ND ND O’Toole et al.
(2012)
CMC
(carboxymethylcell
ulose)
SOY
ISOFLAVONE
EXTRACT
303 - 1857 61.2 – 87.1 78 - 89 Del Gaudio et
al. (2017c)
Maltodextrin crocins and
picrocrocin
1500–4200 71–87 54–82 Kyriakoudi and
Tsimidou
(2018)
Proteins Trehalose В-
galactosidase
1000–5000 60–90 ND Bürki et al.
(2011)
Other
compounds
NA NaCl 517–933 ND NA
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24. CHALLENGES WITH NANO SPRAY DRYING
CHALLENGES IN NSD TECHNOLOGY FOR FOOD INGREDIENT PRODUCTION
• Limited scalability of the technology.
• Low productivity.
• Manual powder collection from the electrostatic precipitator
Future directions in NSD technology:
• Development of an automated powder separator system.
• Facilitating continuous operation.
• Focus on scaling up the process from lab to pilot and industrial scales.
• Increasing the production capacity, potentially by using multiple atomizers.
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25. • Spray drying encapsulation is commonly used for natural food ingredients.
• Resulting powders have good shelf-life and are used for fortification in various food
products.
• Nanotechnology has emerged in the food industry for nanoencapsulated ingredients and
materials.
• Conventional spray dryers produce particles >1 μm due to limitations in particle collection
and droplet size.
• Nano spray dryers use ultrasonic atomizers and electrostatic separation for precise
nanoparticle production.
• Challenges: Limited availability of nano spray dryers in research centers and small-scale
equipment.
• Future: Research and development needed; pilot-scale and industrial-scale nano spray
dryers may become available soon.
CONCLUSION
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REFERENCE
 Jafari, S. M., Arpagaus, C., Cerqueira, M. A., & Samborska, K. (2021). Nano spray drying of food ingredients;
materials, processing and applications. Trends in Food Science & Technology, 109, 632-646.
 Chopde, S., Datir, R., Deshmukh, G., Dhotre, A., & Patil, M. (2020). Nanoparticle formation by nanospray drying & its
application in nanoencapsulation of food bioactive ingredients. Journal of Agriculture and Food Research, 2, 100085.
 Sivamma, M. E., & Snehitha, R. (2021). Atomization techniques in spray drying: A Review. The Pharma Innovation
Journal, 10(5), 454-461.
 Heng, D., Lee, S. H., Ng, W. K., & Tan, R. B. (2011). The nano spray dryer B-90. Expert opinion on drug delivery, 8(7),
965-972.

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