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Spray drying technique of fruit juice powder: some factors influencing the
properties of product
Phisut, N.
*Corresponding author.
Email: phisut@swu.ac.th
1298 Phisut, N./IFRJ 19(4):1297-1306
nitrogen gas. The initial liquid feeding can be a through a nozzle. The liquid which sprayed through
solution, an emulsion or a suspension (Gharasallaoui nozzle will increase the surface area of the liquid
et al., 2007). It can be used to both heat-resistant and which later will be contacted to hot air and dried into
heat sensitive products. a powder. The nozzle size may differ according to the
Spray drying involves in the complex interactions size of spray dryer. Droplet size ranges from 20 μm to
of process, apparatus and feed parameters which all 180 μm and it depends on the nozzle. Smaller spray
have an influence on the final product quality (Chegini dryer occupies smaller nozzles and reverse in the
et al., 2008). The spray drying process can produce industrial scale spray dryer. The aim of this stage is to
a good quality final product with low water activity create a maximum heat transferring surface between
and reduce the weight, resulting in easy storage and the dry air and the liquid, in order to optimize heat
transportation. The physicochemical properties of and mass transfers. The choice upon the atomizer
the final product mainly depend on inlet temperature, configuration depends on the nature and viscosity of
air flow rate, feed flow rate, atomizer speed, types of feed and desired characteristics of the dried product
carrier agent and their concentration. Spray drying is (Master, 1986; Patel et al., 2009).
often selected as it can process material very rapidly
while providing relative control of the particle size Droplet-air contact
distribution (Obon et al., 2009). The important component of spray dryer is the
chamber; here the sprayed droplet is contacted with
Spray dryer the hot air and the drying process begins. Air is heated
The spray dryer is a device used to produce dried by the heating element which situated before entering
foods. It takes a liquid stream and separates the solute the chamber to a predefined temperature depending
or suspension as a solid and the solvent into a vapor. upon the characteristics of the feed fluid. The hot air
The solid is usually collected in a drum or cyclone. is brought in contact with the spray droplets in the
The liquid input stream is sprayed through a nozzle following ways through the air distributor.
into a hot vapor stream and vaporized. The solid as 1. Co-current-Air and particles move in the same
forms as moisture contents quickly leave the droplets. direction.
A nozzle is usually used to make the droplets as 2. Counter-current-air and particles move in the
small as possible to maximize the heat transfer and opposite direction.
rate of water vaporization. The spray dryers can dry 3. Mixed flow - particles are subjected to co-current
a product very quickly compared to other methods of and counter-current phase.
drying. They also turn a solution or slurry into a dried The thermal energy of the hot air is used for
powder in a single step, which can be the advantage evaporation and the cooled air pneumatically conveys
for maximizing the profit and minimize the process the dried particles in the system. The contact time of
(Chegini and Ghobadian, 2007; Murugesan and the hot air and the spray droplets is only a few seconds,
Orsat, 2011). once the drying is achieved and the air temperature
of air drops instantaneously. The nozzle increases
Basic steps of spray drying the contact area of droplet and hot air influences
in the huge heat transfer between droplet and hot
Concentration of fruit juice air. The hot air evaporates moisture content in the
Generally, the feedstock is concentrated before droplet and changes into powder form. In co-current
introducing into the spray dryer. The concentrated process the liquid is sprayed in the same direction
juice has increased in solid contents thereby reducing as the flow of hot air through the apparatus, hot air
the amount of liquids and that must be evaporated in inlet temperature is typically 150-220oC, evaporation
the spray dryer. The feedstock in conventional large occurs instantaneously and then dry powders will be
scale spray dryer normally concentrates to 50%-60% exposed to moderate temperatures (typically 50-80oC)
before introducing to spray dryer. However, the small which limits the thermal degradations. In counter-
scale laboratory spray dryer will have more diluted current drying, the liquid is sprayed in the opposite
feedstock because it will be clogged easily if the feed direction of hot air flow for high temperature process.
have high viscosity (Chegini and Ghobadian, 2007; Thermo-sensitive products are usually restricted to in
Murugesan and Orsat, 2011). this process. However, the main advantage of this
process is considered as more economic in term of
Atomization consuming energy (Master, 1986; Gharsallaoui et
Atomization refers to the conversion of bulk al., 2007; Patel et al., 2009; Murugesan and Orsat,
liquid into a spray or mist, often by passing the liquid 2011).
Phisut, N./IFRJ 19(4):1297-1306 1299
major role in processing, handling and shelf life and Ghobadian, 2005; Finney et al., 2002; Tonon et al.,
the microstructure is related to powders functionality, 2008; Tonon et al., 2011). Walton (2000) reported, the
stability and flowability (O’hagan et al., 2005). increase of drying air temperature generally causes
the decrease in bulk, particle density and provides the
Factors influencing the properties of fruit juice greater tendency to the particles to hollow.
powder produced by spray dry technique In addition, the particle size was affected by
Spray drying is a technique widely used in the inlet temperature as reported by Tonon et al. (2011).
food industry to produce food powder due to its The use of higher inlet air temperature leads to the
effectiveness under the optimum condition (Cano- production of larger particles and causes the higher
Chuca et al., 2005; Jittanit et al., 2010). The spray swelling. The similar finding was also obtained by
drying parameters such as inlet temperature, air other authors (Chegini and Ghobadian, 2005; Nijdam
flow rate, feed flow rate, atomizer speed, types of and Langrish, 2006; Reineccius, 2001). Reineccius
carrier agent and their concentration are influencing (2001) reported, drying at higher temperatures results
as particle size, bulk density, moisture content, yield in faster drying rates, which was leading to the early
and hygroscopicity in spray dried foods (Chegini and formation of a structure and that did not allow the
Ghobadian, 2005; Chegini and Ghobadian, 2007; particles to shrink during drying. When the inlet air
Yousefi et al., 2011). The detail of all these parameters temperature is low, the particle remains more shrunk
is described below. and smaller. Nijdam and Langrish (2006) were
obtained the similar results in the production of milk
Inlet temperature powder at 120oC and 200oC. Chegini and Ghobadian
Powder properties such as moisture content, bulk (2005) also obtained comparable results in the
density, particle size, hygroscopicity and morphology production of orange juice powder. An increase of
were affected by inlet temperature. Normally, the inlet air temperature often results in a rapid formation
inlet temperature uses for spray dry technique for of dried layer at the droplet surface. This hardened
food powder is 150-220oC. Chegini and Ghobadian the skin to did not allow the moisture to exit from the
(2005) studied the effect of inlet temperature (110- droplet and its due to the increase of particle size as
190oC) on the moisture content of orange juice mentioned previously.
powder. It was found that at a constant feed flow The inlet air temperature has a role on the
rate, increasing the inlet air temperature reduced the hygroscopicity of the powder. Tonon et al. (2008)
residual moisture content. The similar observation studied the effect of inlet temperature (140, 170,
was obtained in the different fruit juice powders such 200oC) on the hygroscopicity of acai juice powder.
as watermelon juice (Quek et al., 2007), tomato juice The powders produced at higher inlet temperatures
(Goula and Adamopoulos, 2008), acai juice (Tonon were more hygroscopic due to the presence of
et al., 2008; Tonon et al., 2011) and pineapple juice moisture content in the powder. The higher drying
(Jittanit et al., 2010). Moisture content is decreased temperature is lower the moisture content and increase
with the increase of drying temperature, due to the its hygroscopicity (its capacity to absorb ambient
faster heat transfer between the product and drying moisture). This is related to the water concentration
air. At higher inlet air temperatures, there is a greater gradient between the product and the surrounding
temperature gradient between the atomized feed and air, which is great for the less moist powder. It is
drying air and it results the greatest driving force for an agreement with the spray drying of tomato pulp
water evaporation. by Goula et al. (2004). Moreover, the effect of inlet
Additionally, the inlet temperature affects the temperature on process yield of acai juice powder was
bulk density of powder. Tonon et al. (2008) studied investigated by Tonon et al. (2008). The increase of
the effect of inlet temperature (140, 170, 200oC) on inlet temperatures has given the higher process yield
the bulk density of acai juice powder and found that and it was due to the greater efficiency of heat and
the increased temperature caused the reduction in mass transfer processes occurring when higher inlet
bulk density. An increase in the inlet air temperature air temperatures were used. This is in accordance
often results in a rapid formation of dried layer on with the amaranthus betacyanin pigments by Cai &
the droplet surface and particle size and it causes the Corke (2000). On the other hand, the increase of inlet
skinning over or casehardening on the droplets at air temperature has reduced the yield and it might be
the higher temperatures. This leads to the formation caused by melting of the powder and cohesion wall
of vapor-impermeable films on the droplet surface, and therefore the amount of powder production and
followed by the formation of vapor bubbles and, yield was reduced. (Chegini and Ghobadian, 2007;
consequently the droplet expansion (Chegini and Dolinsky et al., 2000; Dolinsky, 2001).
Phisut, N./IFRJ 19(4):1297-1306 1301
inducing, the passage of spray through the drying zone Feed flow rate
and the concentration of product in the region of the The feed flow rate was negatively affected the
dryer walls and finally extent the semi-dried droplets moisture content in the acai juice powder (Tonon et
and thus re-enter the hot areas around the air disperser. al., 2008). Higher flow rates imply in a shorter contact
A lower drying air flow rate causes an increase in the time between the feed and drying air and making
product halting time in drying chamber and enforces the heat transfer less efficient and thus caused the
the circulatory effects (Goula and Adamopoulos, lower water evaporation. The higher feed flow rate
2004; Master, 1979; Oakley and Bahu, 2000). The showed a negative effect on process yield and that
increased residence time led to the greater degree was resulting the decreased heat, mass transfer and
of moisture removal. As a result, an increase of the the lower process yield. In addition, when higher
drying air flow rate, decrease the residence time of feed rates were used, a dripping inside the main
the product in the drying chamber and it leads to have chamber was observed, when the mixture was passed
higher moisture contents. In addition, the effect of straight to the chamber and that was not atomized and
drying air flow rate of powder bulk density depends finally resulting the lower process yield. Toneli et al.
on its effect on moisture content due to the sticky (2006) also verified an increase on mass production
nature of the product. The higher moisture content in rate with increasing air temperatures and decreasing
the powder leads to stick together and consequently pump speeds in the spray drying of innulin. Chegini
leaving more interspaces between them and it results and Ghobadian (2007) also revealed increasing the
the larger bulk volume. Therefore, the raise of air feed flow rate increased the wall deposit and reduced
flow rate leads to an increase of moisture content in yield. At constant atomizer speed, increasing the feed
the powder and decreased in powder bulk density. flow rate, more liquid was atomized into chamber,
Masters (1979) reported that, the increasing residual thus time of drying was reduced and finally the drying
moisture content was increased the bulk density of dry was incorrect.
product. In addition, powder solubility was influenced
by air dry flow rate. The effect of drying air flow rate Type of carrier agent
on powder solubility depends on its effect on powder The addition of high molecular weight additives
moisture content, as low moisture content seemed to the product before atomizing is widely used
to be associated with the fast dissolution. The rising as an alternative way to increase Tg of powder
of air flow rate was led to the increased of powder (Truong et al., 2005). The use of carrier agents
moisture content and decrease in powder solubility such as maltodextrins, gum Arabic, waxy starch,
(Papadakis et al., 1998). and microcrystalline cellulose, was influenced the
properties and stability of the powder. Crystalline
Atomizer speed and amorphous forms of the same material powder
Chegini and Ghobadian (2005) studied the show differences in particle size, particle shape,
effect of atomizer speed (10,000-25,000 rpm) on the bulk density, physicochemical properties, chemical
properties of an orange juice powder. The residual stability, water solubility and hygroscopicity (Yousefi
moisture content was decreased when increasing et al., 2011).
the atomizer speed. At higher atomizer speed, the The common carrier agents used for fruit
smaller droplets were produced and more moisture juices are maltodextrins and gum Arabic. Goula
was evaporated resulting from an increased contact and Adamopoulos (2008) studied the effect of
surface. This was correlated with the findings of maltodextrin addition (maltodextrin 6DE, 12DE,
Knipschildt (1986). The higher atomizer speed 21DE) on the properties of tomato powder. The result
resulted in a smaller particle size and quicker drying showed that the higher the maltodextrin dextrose
due to the larger surface area and consequently it equivalent (DE) causes higher the moisture content
prevented the ‘‘skinning’’ over the droplets. The in the powder. This probably due to the chemical
increased of atomizer speed was spread the liquid into structure of high-DE maltodextrins, which have a
thin film layer and thus caused the smaller droplet high number of ramifications with hydrophilic groups,
and particle size. Additionally, the higher atomizer and thus can easily bind to water molecules from the
speed was higher the bulk density. At the same time, ambient air during powder handling after the spray
the increased atomizer speed applied on a droplet to drying. Additionally, higher maltodextrin DE caused
spread on a larger surface has reduced the particle the increase in bulk density in the powder due to its
size and decreased the bulk density (Greenwald and stickiness. The higher maltodextrin DE was produced
King, 1981). the lower glass transition temperature and it lower the
elevation of the Tg in fruit pulp-maltodextrin mixture
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