Improving Your Products With Our Spray Drying Technologies

Steve Stewart
Technical Development Manager, Powder Systems

Examples of Source Oils vs Protein and Fat Contents

Chart Source Oils vs Fat and Protein Content [Click to view larger]

Above is a quick reference chart of a few of the various fats and oils that we use, in addition to different levels of fat and protein. This is just an example of a few of the many various oils in our product portfolio.

What is Spray Drying?

Spray Drying is an art that transforms a fluid body into a powder form using an atomization process inside a heated chamber. Atomization is a term used to describe the reduction of the wet slurry into small individual droplets. With sufficient retention time inside the spray dryer chamber, the water evaporation continues until the desired moisture content is obtained. Many factors are considered with respect to setting up a drying process– not only the final target moisture, but also color, flavor, friability and particle size, bulk density and flow properties. Powder quality is very important in a beverage application, for example, with regards to the ability of the powder to properly sink and disperse when the powder is reconstituted in water.

How Important is Powder Formulation on the Dryer?

While the fundamentals of spray drying may seem simple, considerable planning goes into the formulation of the line of SensoryEffects Powders. The powder formula can impact the design of the drying conditions, for example a low density verses a high density powder, a low fat verses a high fat powder, a low protein verses a high protein product. The scientist must also consider if the powder will be used in a dry mix or in a hot or cold beverage application and the ability of the emulsified powder to maintain product integrity in a targeted pH environment. For beverages, it is important to consider if foaming characteristics will be included in the design of the product. For whipped toppings, the scientist must determine hydration rates, relative particle size and the ability of the powder to provide necessary overrun and withstand syneresis. The formulation must also be considered when designing the slurry feed, atomizer nozzle type and configuration, air supply system, heating conditions, and fluid bed transport to the packaging area.

What Determines Dryer Conditions?

Prior to introducing a powder formulation in a plant environment, it is important for the Research and Development Team to conduct pilot plant trials. The pilot plant study will assist in establishing the spray dryer conditions, for example the target slurry solids, inlet and outlet temperatures, drying rates, percent free fat, target moisture and bulk density. The powder can then be tested for performance attributes in a finished product application. SensoryEffects has a full scale pilot plant in Defiance, Ohio that includes wet blending, dry blending, homogenization and spray drying capabilities for production of small scale samples for customer evaluation prior to scale up to production.

What Are SensoryEffects Drying Capabilities?

Spray Dryer in Defiance, OHSensoryEffects has spray drying capabilities at multiple locations, including Reading, PA, Marshfield, WI, Defiance, OH, Bridgeton, MO, and Sleepy Eye, MN. The unique design of each of these dryers is a valuable asset when allocating a formula to a specific dryer location. Options of dryer design such as a modified box type dryer, tall form, or filtermat can be considered when technology transferring the product from pilot plant to full scale production. Not only does SensoryEffects have spray drying capability options, but also has a state-of-the-art production agglomeration unit recently installed in Defiance, Ohio. (Read more on our agglomeration capabilities) Also located in Defiance is a pilot plant agglomerator designed to assist in the product development experimental design. Read more on our Powder Systems technology

What are Your Spray Drying Needs?

Please contact your SensoryEffects Account Rep to partner with you in your product development efforts. Our sales team will communicate your needs to our Technical Staff in order to assist in the design of a powder for your customized application.

Steve Stewart

Steve Stewart

Technical Development Manager  Powder Systems
419.782.5010
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