NZ767414B2 - Method and apparatus for manufacture of dry powders - Google Patents
Method and apparatus for manufacture of dry powders Download PDFInfo
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- NZ767414B2 NZ767414B2 NZ767414A NZ76741418A NZ767414B2 NZ 767414 B2 NZ767414 B2 NZ 767414B2 NZ 767414 A NZ767414 A NZ 767414A NZ 76741418 A NZ76741418 A NZ 76741418A NZ 767414 B2 NZ767414 B2 NZ 767414B2
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- New Zealand
- Prior art keywords
- product
- sugar
- gas
- mixture
- rich product
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 16
- 239000000843 powder Substances 0.000 title description 3
- 235000000346 sugar Nutrition 0.000 claims abstract description 95
- CURLTUGMZLYLDI-UHFFFAOYSA-N carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 claims abstract description 43
- 229910002092 carbon dioxide Inorganic materials 0.000 claims abstract description 43
- 239000001569 carbon dioxide Substances 0.000 claims abstract description 43
- 239000000203 mixture Substances 0.000 claims abstract description 36
- 239000007788 liquid Substances 0.000 claims abstract description 27
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 23
- 239000007787 solid Substances 0.000 claims abstract description 20
- 150000008163 sugars Chemical class 0.000 claims abstract description 15
- 238000007872 degassing Methods 0.000 claims abstract description 14
- 238000001035 drying Methods 0.000 claims abstract description 13
- 238000002156 mixing Methods 0.000 claims abstract description 13
- GQPLMRYTRLFLPF-UHFFFAOYSA-N nitrous Oxide Chemical compound [O-][N+]#N GQPLMRYTRLFLPF-UHFFFAOYSA-N 0.000 claims abstract description 10
- BVKZGUZCCUSVTD-UHFFFAOYSA-N Carbonic acid Chemical compound OC(O)=O BVKZGUZCCUSVTD-UHFFFAOYSA-N 0.000 claims abstract description 6
- 239000001272 nitrous oxide Substances 0.000 claims abstract description 5
- GRYLNZFGIOXLOG-UHFFFAOYSA-N nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 claims abstract 3
- 239000007789 gas Substances 0.000 claims description 56
- 240000000111 Saccharum officinarum Species 0.000 claims description 20
- 235000007201 Saccharum officinarum Nutrition 0.000 claims description 20
- 239000003570 air Substances 0.000 claims description 6
- 229940029983 VITAMINS Drugs 0.000 claims description 5
- 229940021016 Vitamin IV solution additives Drugs 0.000 claims description 5
- 229910052500 inorganic mineral Inorganic materials 0.000 claims description 5
- 239000011707 mineral Substances 0.000 claims description 5
- 235000013343 vitamin Nutrition 0.000 claims description 5
- 239000011782 vitamin Substances 0.000 claims description 5
- 229930003231 vitamins Natural products 0.000 claims description 5
- 235000019749 Dry matter Nutrition 0.000 claims description 4
- 240000006245 Dichrostachys cinerea Species 0.000 claims description 3
- 235000019568 aromas Nutrition 0.000 claims description 3
- 235000010755 mineral Nutrition 0.000 claims description 2
- 239000001301 oxygen Substances 0.000 claims description 2
- 229910052760 oxygen Inorganic materials 0.000 claims description 2
- MYMOFIZGZYHOMD-UHFFFAOYSA-N oxygen Chemical compound O=O MYMOFIZGZYHOMD-UHFFFAOYSA-N 0.000 claims description 2
- 235000008476 powdered milk Nutrition 0.000 claims description 2
- 239000000796 flavoring agent Substances 0.000 claims 1
- 239000000047 product Substances 0.000 abstract description 145
- 239000000284 extract Substances 0.000 abstract description 10
- 238000000034 method Methods 0.000 abstract description 10
- 239000005913 Maltodextrin Substances 0.000 abstract description 7
- 229920002774 Maltodextrin Polymers 0.000 abstract description 7
- 229940035034 maltodextrin Drugs 0.000 abstract description 7
- GUBGYTABKSRVRQ-UUNJERMWSA-N Lactose Natural products O([C@@H]1[C@H](O)[C@H](O)[C@H](O)O[C@@H]1CO)[C@H]1[C@@H](O)[C@@H](O)[C@H](O)[C@H](CO)O1 GUBGYTABKSRVRQ-UUNJERMWSA-N 0.000 abstract description 6
- 239000008101 lactose Substances 0.000 abstract description 6
- GUBGYTABKSRVRQ-XLOQQCSPSA-N lactose Chemical compound O[C@@H]1[C@@H](O)[C@@H](O)[C@@H](CO)O[C@H]1O[C@@H]1[C@@H](CO)O[C@H](O)[C@H](O)[C@H]1O GUBGYTABKSRVRQ-XLOQQCSPSA-N 0.000 abstract description 6
- 239000012467 final product Substances 0.000 abstract description 4
- 238000009835 boiling Methods 0.000 abstract description 3
- 150000001875 compounds Chemical class 0.000 abstract description 3
- 238000010438 heat treatment Methods 0.000 abstract description 3
- 230000001737 promoting Effects 0.000 abstract description 3
- 239000005445 natural product Substances 0.000 abstract description 2
- 229930014626 natural products Natural products 0.000 abstract description 2
- 230000000930 thermomechanical Effects 0.000 description 24
- 238000005273 aeration Methods 0.000 description 13
- 238000001704 evaporation Methods 0.000 description 10
- 238000002347 injection Methods 0.000 description 10
- 239000007924 injection Substances 0.000 description 10
- 230000000694 effects Effects 0.000 description 7
- 239000000243 solution Substances 0.000 description 7
- BJHIKXHVCXFQLS-UYFOZJQFSA-N Fructose Natural products OC[C@@H](O)[C@@H](O)[C@H](O)C(=O)CO BJHIKXHVCXFQLS-UYFOZJQFSA-N 0.000 description 6
- 230000005484 gravity Effects 0.000 description 6
- 239000011521 glass Substances 0.000 description 5
- 239000000654 additive Substances 0.000 description 4
- LRHPLDYGYMQRHN-UHFFFAOYSA-N n-butanol Chemical group CCCCO LRHPLDYGYMQRHN-UHFFFAOYSA-N 0.000 description 4
- 239000002245 particle Substances 0.000 description 4
- 229940057070 sugarcane extract Drugs 0.000 description 4
- 239000006188 syrup Substances 0.000 description 4
- 235000020357 syrup Nutrition 0.000 description 4
- 239000005715 Fructose Substances 0.000 description 3
- 239000012141 concentrate Substances 0.000 description 3
- 235000008504 concentrate Nutrition 0.000 description 3
- 238000001816 cooling Methods 0.000 description 3
- 239000011552 falling film Substances 0.000 description 3
- 239000007921 spray Substances 0.000 description 3
- 230000000996 additive Effects 0.000 description 2
- XKRFYHLGVUSROY-UHFFFAOYSA-N argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- 239000007795 chemical reaction product Substances 0.000 description 2
- 238000010924 continuous production Methods 0.000 description 2
- 230000003247 decreasing Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 235000013399 edible fruits Nutrition 0.000 description 2
- 235000012907 honey Nutrition 0.000 description 2
- 239000004615 ingredient Substances 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- -1 sugar cane Natural products 0.000 description 2
- 235000013311 vegetables Nutrition 0.000 description 2
- 240000002254 Ananas comosus Species 0.000 description 1
- 235000007119 Ananas comosus Nutrition 0.000 description 1
- 235000004936 Bromus mango Nutrition 0.000 description 1
- CZMRCDWAGMRECN-UGDNZRGBSA-N D-sucrose Chemical compound O[C@H]1[C@H](O)[C@@H](CO)O[C@@]1(CO)O[C@@H]1[C@H](O)[C@@H](O)[C@H](O)[C@@H](CO)O1 CZMRCDWAGMRECN-UGDNZRGBSA-N 0.000 description 1
- 239000005977 Ethylene Substances 0.000 description 1
- 229940068517 FRUIT EXTRACTS Drugs 0.000 description 1
- 240000007228 Mangifera indica Species 0.000 description 1
- 235000014826 Mangifera indica Nutrition 0.000 description 1
- 240000008790 Musa x paradisiaca Species 0.000 description 1
- 235000018290 Musa x paradisiaca Nutrition 0.000 description 1
- 235000009184 Spondias indica Nutrition 0.000 description 1
- CZMRCDWAGMRECN-GDQSFJPYSA-N Sucrose Natural products O([C@@H]1[C@H](O)[C@@H](O)[C@H](O)[C@H](CO)O1)[C@@]1(CO)[C@H](O)[C@@H](O)[C@@H](CO)O1 CZMRCDWAGMRECN-GDQSFJPYSA-N 0.000 description 1
- 239000012080 ambient air Substances 0.000 description 1
- 230000000111 anti-oxidant Effects 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 235000006708 antioxidants Nutrition 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 239000008122 artificial sweetener Substances 0.000 description 1
- 235000021311 artificial sweeteners Nutrition 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- UGFAIRIUMAVXCW-UHFFFAOYSA-N carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 1
- 229910002091 carbon monoxide Inorganic materials 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 229910052803 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 238000006297 dehydration reaction Methods 0.000 description 1
- 230000001419 dependent Effects 0.000 description 1
- 239000002274 desiccant Substances 0.000 description 1
- 230000001627 detrimental Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- OTMSDBZUPAUEDD-UHFFFAOYSA-N ethane Chemical compound CC OTMSDBZUPAUEDD-UHFFFAOYSA-N 0.000 description 1
- VGGSQFUCUMXWEO-UHFFFAOYSA-N ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 1
- 230000001747 exhibiting Effects 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 235000013305 food Nutrition 0.000 description 1
- 235000015203 fruit juice Nutrition 0.000 description 1
- 239000001307 helium Substances 0.000 description 1
- 229910052734 helium Inorganic materials 0.000 description 1
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium(0) Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 125000004435 hydrogen atoms Chemical class [H]* 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 239000012263 liquid product Substances 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- PWHULOQIROXLJO-UHFFFAOYSA-N manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 239000011572 manganese Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 239000012528 membrane Substances 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000006011 modification reaction Methods 0.000 description 1
- 235000021096 natural sweeteners Nutrition 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- ABLZXFCXXLZCGV-UHFFFAOYSA-N phosphorous acid Chemical compound OP(O)=O ABLZXFCXXLZCGV-UHFFFAOYSA-N 0.000 description 1
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 1
- 239000011591 potassium Substances 0.000 description 1
- 229910052700 potassium Inorganic materials 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 238000010008 shearing Methods 0.000 description 1
- 239000005720 sucrose Substances 0.000 description 1
- 235000019155 vitamin A Nutrition 0.000 description 1
- 239000011719 vitamin A Substances 0.000 description 1
- 235000010374 vitamin B1 Nutrition 0.000 description 1
- 239000011691 vitamin B1 Substances 0.000 description 1
- 235000019164 vitamin B2 Nutrition 0.000 description 1
- 239000011716 vitamin B2 Substances 0.000 description 1
- 235000019160 vitamin B3 Nutrition 0.000 description 1
- 239000011708 vitamin B3 Substances 0.000 description 1
- 235000009492 vitamin B5 Nutrition 0.000 description 1
- 239000011675 vitamin B5 Substances 0.000 description 1
- 235000019158 vitamin B6 Nutrition 0.000 description 1
- 239000011726 vitamin B6 Substances 0.000 description 1
- 235000019154 vitamin C Nutrition 0.000 description 1
- 239000011718 vitamin C Substances 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
Abstract
High sugar concentration liquids extracted from natural products contain an abundance of health promoting compounds. However, current techniques for converting these extracts from their liquid form into dry powdered products involving heating or boiling techniques that removes or destroys these components. An alternative technique involves adding lactose or maltodextrin before drying. However, this typically results in products where the maltodextrin or lactose component exceeds 50% of the final product. The present application attempts to solve these problems by providing a method of production of a homogeneous powdered product from a starting product in a liquid state, the starting product having sugars as at least 60% of its total solids, the method comprising: in the absence of air: pressurizing the starting product to a pressure greater than 1 bar and less than 15 bar; injecting a gas into the starting product to form a mixture in which the starting product is substantially saturated by the gas; and degassing the mixture into a continuous stream of transport gas at a temperature of 50°C or greater of such that, on contact with the transport gas, water from the mixture evaporates to leave the homogeneous powdered product; wherein the gas comprises at least one of: carbon dioxide, or nitrous oxide, or a mixture thereof in a quantity sufficient to form a mixture comprising carbonic acid and/or nitric acid; and wherein before or during the mixing of the gas and the starting product, the starting product is cooled below 30°C, but not less than 5°C. onents. An alternative technique involves adding lactose or maltodextrin before drying. However, this typically results in products where the maltodextrin or lactose component exceeds 50% of the final product. The present application attempts to solve these problems by providing a method of production of a homogeneous powdered product from a starting product in a liquid state, the starting product having sugars as at least 60% of its total solids, the method comprising: in the absence of air: pressurizing the starting product to a pressure greater than 1 bar and less than 15 bar; injecting a gas into the starting product to form a mixture in which the starting product is substantially saturated by the gas; and degassing the mixture into a continuous stream of transport gas at a temperature of 50°C or greater of such that, on contact with the transport gas, water from the mixture evaporates to leave the homogeneous powdered product; wherein the gas comprises at least one of: carbon dioxide, or nitrous oxide, or a mixture thereof in a quantity sufficient to form a mixture comprising carbonic acid and/or nitric acid; and wherein before or during the mixing of the gas and the starting product, the starting product is cooled below 30°C, but not less than 5°C.
Description
Method and apparatus for manufacture of dry powders
Cross-reference to related applications
This application claims priority from Australian provisional patent application
number 2017901770 filed 12 May 2017, the contents of which is incorporated by
reference in its entirety.
Technical Field
The present disclosure relates to a method and apparatus for manufacturing
dry powders from high sugar concentration, low glass transition liquids.
Background
High sugar concentration, low glass transition (T ) liquids extracted from
natural products, such as sugar cane, vegetables and fruits contain an abundance of
vitamins and minerals including calcium, chromium, cobalt, copper, magnesium,
manganese, phosphorous, potassium and zinc. Some of these extracts also contain iron
and vitamins A, C, B1, B2, B3, B5 and B6 alongside a high concentration of
phytonutrients, antioxidants and other health-promoting compounds.
A common techniques for converting some of these extracts from their liquid
form into dry powdered products involves dehydration by boiling, which results in a
dry, crystalline sugar rich product. However, this boiling process leads to removal or
destruction of components in these extracts that have been found to have positive health
benefits when consumed.
In an attempt to maintain health promoting compounds when drying, attempts
have been made to spray dry high sugar, low T extracts using conventional spray
dryers known in the art. These conventional techniques involve heating a liquid extract
to a temperature at which water in the liquid is converted to steam when it is sprayed
into the dryer. Not only is this heating detrimental to the end product, but it also causes
problems in the dryer due to the high sugar concentration and low T of product being
dried. The temperature in conventional dryers is so high that sugar crystals form on the
dryer walls due to their high temperature. This has led manufacturers to add high T
sugars, such as lactose or maltodextrin, to the liquid extract before drying in order to
raise the overall T of the mixture to the point at which it can be dried successfully
without melting on impact with the spray dryer walls. The amount of maltodextrin
required to achieve drying of a mixture can exceed 50% of the final product. In
addition, the final powdered product can only be dried to around 50% total solids using
such processes.
There is a need for a cost effective method for the production of a powdered
liquid extract, the end
product with high total solids from a high sugar content, low T
product maintaining some or all of the health promoting components found in its
original liquid form.
Any discussion of documents, acts, materials, devices, articles or the like
which has been included in the present specification is not to be taken as an admission
that any or all of these matters form part of the prior art base or were common general
knowledge in the field relevant to the present disclosure as it existed before the priority
date of each of the appended claims.
Summary
According to an aspect of the disclosure, there is provided a method of
production of a homogeneous powdered product from a starting product in a liquid
state, the starting product having sugars as at least 60% of its total solids, the method
comprising: in the absence of air: pressurizing the starting product to a pressure greater
than 1 bar; injecting a gas into the starting product to form a mixture in which the
starting product is substantially saturated by the gas; and degassing the mixture into a
continuous stream of transport gas such that, on contact with the transport gas, water
from the mixture evaporates to leave the homogeneous powdered product. In some
embodiments, in order to achieve substantial saturation, the rate of injection of gas by
volume based on the dry mass of the starting product may be greater than 10 normal
−1 −1
litres per kilogram per minute (nl·kg ·mn ), the volume of gas being expressed under
normal temperature and pressure conditions.
According to another aspect of the disclosure, there is provided a method of
production of a homogeneous powdered product from a starting product in a liquid
state, the sugar cane extract having a viscosity greater than 300 centipoise and having
sugars as at least 85% of its total solids, the method comprising: in the absence of air:
pressurizing the sugar cane extract to a pressure greater than 4 bar; injecting carbon
dioxide into the starting product to form a mixture in which the starting product is
substantially saturated by the carbon dioxide so as to form a solution comprising
carbonic acid and the starting product; and degassing the mixture into a continuous
stream of transport gas such that, on contact with the transport gas, water from the
mixture evaporates to leave the homogeneous powdered product. The rate of injection
of carbon dioxide by volume based on the dry mass of the starting product is
−1 −1
prefereably greater than 10 nl·kg ·mn , the volume of gas being expressed under
normal temperature and pressure conditions.
According to another aspect of the disclosure, there is provided an apparatus
for the production of a homogeneous powdered product from a starting product in a
liquid state, the starting product having sugars as at least 60% of its total solids, the
apparatus comprising: a thermomechanical treatment device configured to mix a gas
with the starting product to form a mixture in which the starting product is substantially
saturated by the gas; and a degassing device configured to degas the mixture into a
continuous stream of transport gas such that, on contact with the transport gas, water
from the mixture evaporates to leave the homogeneous powdered product. The rate of
injection of gas by volume based on the dry mass of the starting product is preferably
−1 −1
greater than 10 nl·kg ·mn , the volume of gas being expressed under normal
temperature and pressure conditions.
According to another aspect of the disclosure, there is provided a method of
production of a homogeneous powdered product from a starting product in a liquid
state, the starting product having sugars as at least 60% of its total solids, the method
comprising: in the absence of air: pressurizing the starting product to a pressure greater
than 1 bar; injecting a gas into the starting product to form a mixture comprising carbon
dioxide in a quantity in excess of 35 grams per 100 grams of water in the starting
product; and degassing the mixture into a continuous stream of transport gas such that,
on contact with the transport gas, water from the mixture evaporates to leave the
homogeneous powdered product.
According to another aspect of the disclosure, there is provided an apparatus
for the production of a homogeneous powdered product from a starting product in a
liquid state, the starting product having sugars as at least 60% of its total solids, the
apparatus comprising: a mixing device configured to mix a gas with the starting
product to form a mixture comprising carbon dioxide in a quantity in excess of 35
grams per 100 grams of water in the starting product, the starting product is
substantially saturated by the gas; and a degassing device configured to degas the
mixture into a continuous stream of transport gas such that, on contact with the
transport gas, water from the mixture evaporates to leave the homogeneous powdered
product.
Throughout this specification the word "comprise", or variations such as
"comprises" or "comprising", will be understood to imply the inclusion of a stated
element, integer or step, or group of elements, integers or steps, but not the exclusion of
any other element, integer or step, or group of elements, integers or steps.
Brief Description of Drawings
Figure 1 is a flow diagram of depicting a method of drying a sugar based
product according to an embodiment of the present disclosure;
Figure 2 is an image taken by a scanning electron microscope showing a
product formed using a method according to an embodiment of the disclosure; and
Figure 3 is an image taken by a scanning electron microscope showing a
product formed using a method according to an embodiment of the disclosure.
Description of Embodiments
Embodiments of the present disclosure relate to methods for the continuous
production of a powdered product from a sugar rich product in liquid form. In
particular, the methods described herein relate predominantly to the production of dry
powdered products from aqueous solutions having more than 90% of their total solids
(TS) made up of sugars and having a glass-liquid transition (T ) less than 60°C.
Examples of naturally occurring products having the above properties include but are
not limited to sugar cane extract (juice and syrup), honey, fruit extracts (e.g. such as
mango, pineapple, and banana juice and concentrate), vegetable extracts (juice and
concentrate) and natural and artificial sweeteners.
Particular embodiments of the present disclosure will be described with
reference to a generic sugar based product. It will be appreciated, however, that
methods described herein may be used to produce a dry powdered product from many
natural and artificial aqueous products having high sugar content and low T , such as
those listed above.
Methods described herein with reference to Figures 1 to 3 allow for the
continuous production of a powdered product from a product in the liquid state. During
a first step, a sugar rich product in its liquid form is transformed into a viscous state, for
example by evaporation. The sugar rich product in its viscous state then undergoes a
drying step which includes thermomechanical treatment and aeration.
Figure 1 is a flow diagram 100 depicting a process for converting a sugar rich
product in a liquid state into a sugar rich product in a powdered form. In a first
concentration step 102, the sugar rich product in the liquid state, typically having a brix
concentration of between 8 °Bx and 30 °Bx, is treated to obtain a sugar rich product in
a viscous state having a brix concentration of over 50 °Bx and preferably between 70
°Bx and 80 °Bx. The temperature for evaporation is chosen so as limit damage to the
liquid product whilst still achieving the required evaporation. In examples, the
evaporator may operates at between 40 and 45°C, between 45 and 50°C, between 55
and 60°C, between 60 and 65°C, or between 65 and 70°C. To reduce the temperature
of evaporation of water during evaporation, evaporation may be performed under
vacuum.
In some embodiments, an evaporator, such as a falling film evaporator (and
preferably a multi-effect falling film evaporator) may be used. In which case, there
may be a temperature gradient over the effects of the evaporator. For example, a three
effect falling film evaporator might operate at a temperature of around 70°C in its first
effect, around 60°C in its second effect, and around 50°C in its third effect.
In some embodiments, vapour captured from the evaporator may be used in
the production of an essence from the sugar rich product. Alternatively or additionally,
vapour may be captured from the evaporator and mixed with the viscous sugar rich
syrup in a later production step, as will be described in more detail below.
In other embodiments, the sugar rich product may be concentrated using
techniques other than evaporation. For example, the sugar rich product may be
concentrated using a membrane technology as is known in the art.
The concentrated (viscous) sugar rich product can then be subjected to at least
one thermomechanical treatment step 104 to obtain a mixture of the concentrated sugar
rich product and a gas such as carbon dioxide. The thermomechanical treatment step is
preferably carried out in a thermomechanical treatment device, such as an extruder.
The extruder may comprise two or more co-rotating, co-penetrating screws as is known
in the art. Other examples of thermomechanical treatment devices include mixers such
as paddle mixers or screw mixers, as well as blenders, kneaders and pumps.
The thermomechanical treatment device comprises a zone for simultaneous
introduction, on the one hand, of the sugar rich product in a viscous state originating
from the evaporation (or other concentration) step as described above and, on the other
hand, a predetermined proportion of carbon dioxide and/or a predetermined proportion
of liquid or powdered additives such as liquid extract aromas and other ingredients.
Other ingredients may include powdered milk, vitamins, minerals and other additives.
In addition to the above, the vapours captured in the evaporator may be mixed
with the sugar rich product at this point to capture volatile aromas otherwise lost during
evaporation. It will be appreciated that any additive mixed with the sugar rich product
should be able to withstand the pH and concentration of the sugar rich product.
The use of the extruder as a thermomechanical treatment device enables
continuous treatment of injected sugar rich product. Thermal mechanical
plasticisation/mixing may be carried out on the viscous sugar rich product, which in
turn allows for, the mixing, blending, shearing and cooling (all at controlled pressure
and temperature) of the viscous sugar rich product with carbon dioxide and/or any other
additive described above.
In some embodiments, the thermomechanical treatment step is performed
under pressure in excess of 5 bar and preferably no more than 15 bar. However, the
pressure at which the thermomechanical treatment step is performed is dependent on
several equipment parameters, including but not limited to pipe length, nozzle back
pressures, etc.
The thermomechanical step is preferably performed at a low temperature, for
example, less than 30°C or more preferably below 15°C. Decreasing the temperature
of the sugar rich product increases the amount of and speed at which carbon dioxide
can dissolve into the aqueous sugar rich product. Injection of carbon dioxide at this
stage also decreases the viscosity of the sugar rich product so that the solution can more
easily exit the thermomechanical treatment device. On the other hand, decreasing the
temperature also increases the viscosity of the sugar rich product. Accordingly,
preferably, the temperature is not lowered below 5°C.
The resulting product of the thermomechanical treatment step 104 is a viscous
sugar rich product having a brix concentration of between 60 °Bx and 90 °Bx.
This viscous sugar rich product can be transferred directly and continuously,
without being exposed to the atmosphere, to an aeration device where it is aerated at
step 106. The aeration device may comprise a device comprising a plurality of agitator
blades configured to cut the sugar rich product with carbon dioxide to form the foam.
Alternatively, a helical mixer may be used to introduce the sugar cane product to the
carbon dioxide (or other gas at atmospheric conditions).
During the aeration step 106 the sugar rich product is mixed with a high
volume of carbon dioxide (or other gas at atmospheric conditions) at an amount
sufficient to substantially saturate the sugar rich product so as to form a solution
comprising carbonic acid and at least some of the sugar rich product. To achieve
saturation using carbon dioxide, the amount of carbon dioxide injected during the
thermoelectric treatment step 104 and the aeration step 106, is preferably greater than
−1 −1
nl·kg ·mn of gas being expressed under normal temperature and pressure
conditions based on the dry mass the sugar cane product input at the thermomechanical
treatment step. In some embodiments, the amount of carbon dioxide injected is greater
−1 −1 −1 −1 −1 −1
than 20 nl·kg ·mn , or greater than 25 nl·kg ·mn or greater than 30 nl·kg ·mn ,
−1 −1 −1 −1
or greater than 35 nl·kg ·mn , or greater than 40 nl·kg ·mn , or greater than 45
−1 −1 −1 −1
nl·kg ·mn , or greater than 50 nl·kg ·mn . In some embodiments, the amount of
carbon dioxide injected is greater than 35g per 100 g of water present in the viscous
sugar rich product is used. The amount of carbon dioxide (or other gas at atmospheric
conditions) required to achieve saturation will depend on the amount of water in the
viscous sugar rich product and the temperature and pressure in the thermomechanical
treatment device. In some embodiments, during injection of the carbon dioxide at any
of the amounts of levels described above, the sugar rich product is held at a temperature
of 30 degrees or lower, preferably 15 degrees C or lower. In some embodiments,
during injection of the carbon dioxide at any of the amounts of levels described above,
the sugar rich product is held a at a pressure of 5 bar or greater.
Subsequent to the aeration step106, a degassing step 108 is carried out.
During the degassing step 108, the aerated sugar rich product is submitted to a sudden
drop in pressure. This drop in pressure causes the separation of carbonic acid into
carbon dioxide and water and the near instantaneous evaporation of the water contained
therein, leaving behind a powdered sugar rich product consisting of homogenous solid
particles of the sugar rich product.
The pressure may be reduced to atmospheric pressure or to a vacuum in order
to achieve the requisite degassing.
Simultaneous to or shortly after the degassing step 108, the sugar rich product
may be dried at step 110. In some embodiments, the aerated sugar rich product may be
output from the aeration device via one or more nozzles into a stream of transport gas.
The transport gas may be selected from one or more of air, oxygen, or carbon dioxide,
and is preferably at a temperature greater than 50°C.
The transport gas is configured to transport the aerated sugar rich product into
a drying device. The drying device may be in the form of one or more of a fluidized-
bed dryer, an atomizing tower, a counter-current vertical dryer, and a conveyer dryer.
In some embodiments, after drying, the sugar cane product has a concentration
of dry matter in excess of 96% and preferably 98% or more.
Whilst it is preferable to add carbon dioxide (or other gas at atmospheric
pressure) during the thermomechanical treatment step 104 as described above, in some
embodiments, carbon dioxide may only be added during the aeration step 106. In other
embodiments, all of the carbon dioxide may be injected during the thermomechanical
treatment step 104. The carbon dioxide may be introduced at any stage as a solid,
liquid or gas under pressure, so long as the sugar rich product is aerated to the point at
which the product is saturated by the gas as described above.
Whilst in embodiments described above, the sugar rich product is mixed with
carbon dioxide, in other embodiments, other gases having similar characteristics to
carbon dioxide may be used in addition to or in place of carbon dioxide. Such gases
preferably exhibit good solubility in water. Further, such solubility is preferably
improved with reduced temperature so that the sugar rich product can be maintained at
a low temperature during the thermomechanical treatment step 104 and/or the aeration
step 106. An example of a gas exhibiting these characteristics is nitrous oxide.
Another example is butanol, although butanol is not suitable for use in the production
of food grade products. Other examples include argon, ethylene, ethane, carbon
monoxide, hydrogen, helium, and nitrogen. Two or more of these gases may be used in
combination in the processes described herein.
Where nitrous oxide is mixed with the sugar rich product, amounts in the
excess of 55 ml per 100 ml of water are preferably used in order to achieve saturation.
It will be appreciated that different sugar rich products may have different
glass transition temperatures due to the different sugars contained therein. For
example, the sugar contained in sugar cane extract (juice or concentrate) is
approximately 95% sucrose, which has a T of around 54°C. In contrast, the sugars in
fruit juices tend to consist of more than 50% fructose, which has a lower T of
approximately 26°C. Other sugars such as maltodextrin and lactose, which are often
added to sugar rich products to increase the glass transition temperature, have a T In
the region of 100°C.
Because of this, the Tg of a sugar rich product affects its behaviour when
being dried. For example, sugar cane syrup, which has a relatively high glass transition
can be injected into the dryer at relatively high percentage total solids (>70%) without
the risk of the sugar cane juice sticking to the walls of the dryer.
In contrast, honey and fruit based sugar products with high levels of fructose,
and thus a relatively low Tg compared with that of sugar cane syrup, may crystalize on
the walls of the dryer as they are heated by the transport gas and drying gas circulating
the dryer. Accordingly, preferably when processing sugar rich products containing a
large amounts of low T sugars, such as fructose, the walls and other surfaces of the
dryer may be cooled, for example, using a cooling jacket. The surfaces of the dryer
should not be cooled excessively, however, as such cooling may cause any gaseous
water present in the dryer to condense on the walls. Condensate on the walls of the
dryer may itself lead to sugar particles crystallising on the walls of the dryer.
To this end, it is also preferable to maintain the relative humidity within the
dryer as low as possible to maximise the percentage total solids of the final powdered
product. Preferably the relative humidity of the exhaust from the dryer is maintained
below 12%. This may be achieved by ensuring that gas entering the dryer has a water
of gas entering the dryer. In some geographic locations,
content of less than 3 g/m
ambient air may exhibit these characteristics. However, in other jurisdictions, a
desiccant may be provided at the gas (e.g. air) input of the dryer so as remove water
from the gas as it enters the dryer.
Examples
In the following examples, a homogeneous sugar rich product was formed
from a sugar cane product extracted from sugar cane using the method described in
Australian provisional patent application number 2017901576 and International patent
application number , the contents of each of which are hereby
incorporated by reference in their entirety.
Concentrated sugar cane juice (Version 1)
In the following example, a viscous sugar cane solution having a specific
gravity of 1.4 after concentration at step 102 and before thermomechanical treatment at
step 104 was aerated with carbon dioxide such that after aeration at step 106, its
specific gravity was reduced to below 0.4. The specifics of processing of the sugar
cane solution are as follows.
Starting product:
Total Solids (TS) 70%
Specific gravity: 0.4
Amount of gas injected:
greater than 10 nl·kg−1·mn−1 of carbon dioxide being expressed under
normal temperature and pressure conditions and based on the dry mass of starting
product input at the thermomechanical treatment step.
Thermomechanical processing:
pressure greater than 5 bar;
optional mixing with vitamins/minerals;
injection of carbon dioxide;
temperature of the product: below 15° C.
Aeration:
injection of carbon dioxide;
temperature of the product: below 15° C.
Degassing:
nozzle pressure: > 4 bar;
inlet of dryer: > 80°C
Resulting product (as shown in Figures 2 and 3):
homogeneous;
smaller than 50 μm;
concentration of dry matter greater than 96%.
Using a scanning electron microscope, the Applicant took measurements of
the resulting powdered sugar cane product in order to determine the characteristics of
the internal structure obtained by the method described above. Images acquired by the
scanning electron microscope are shown in Figures 2 and 3 at 50μm and 10μm
respectively. It can be seen that the powdered product has a solid internal structure
comprising substantially homogenous balls. This is shown more clearly in Figure 3
which depicts a single particle of the sugar cane product. The resulting product shows
extremely limited porosity and further demonstrates that each particle is made up of
solid sugar components.
The final product had a water activity of 0.11 at the output of the drying step
110.
Concentrated sugar cane juice (Version 2)
In the following example, a viscous sugar cane solution having a specific
gravity of 1.4 after concentration at step 102 and before thermomechanical treatment at
step 104 was aerated with carbon dioxide such that after aeration at step 106, its
specific gravity was reduced to below 0.5. The specifics of processing of the sugar
cane solution are as follows.
Starting product:
Total Solids (TS) 70%
Specific gravity: 0.5
Amount of gas injected:
greater than 10 nl·kg−1·mn−1 of carbon dioxide being expressed under
normal temperature and pressure conditions and based on the dry mass of starting
product input at the thermomechanical treatment step.
Thermomechanical processing:
pressure greater than 5 bar;
optional mixing with vitamins/minerals;
injection of carbon dioxide;
temperature of the product: below 15° C.
Aeration:
injection of carbon dioxide;
temperature of the product: below 15° C.
Degassing:
nozzle pressure: > 4 bar;
inlet of dryer: > 80°C
Resulting product (as shown in Figures 2 and 3):
homogeneous;
smaller than 50 μm;
concentration of dry matter greater than 96%.
The water activity of the powdered sugar cane product output from the dryer
was found to be at approximately 0.3.
It will be appreciated by persons skilled in the art that numerous variations
and/or modifications may be made to the above-described embodiments, without
departing from the broad general scope of the present disclosure. The present
embodiments are, therefore, to be considered in all respects as illustrative and not
restrictive.
Claims (10)
1. A method of production of a homogeneous powdered product from a sugar-rich product in a liquid state, the sugar-rich product having sugars as at least 60% of its total solids, the method comprising: in the absence of air, pressurizing the sugar-rich product to a pressure greater than 1 bar and less than 15 bar and mixing the sugar-rich product with a gas to form a mixture in which the sugar-rich product is substantially saturated by the gas; and degassing the mixture into a continuous stream of transport gas at a temperature of 50°C or greater such that, on contact with the transport gas, water from the mixture evaporates to leave the homogeneous powdered product, wherein the gas comprises at least one of: carbon dioxide; or nitrous oxide, or a mixture thereof, in a quantity sufficient to form a mixture comprising carbonic acid and/or nitric acid, and wherein before or during the mixing of the gas and the sugar-rich product, the sugar-rich product is cooled to less than 30°C, but not below 5°C.
2. The method of claim 1, wherein the amount of gas mixed with the sugar-rich product by volume based on the dry mass of the sugar-rich product is between 10 normal −1 −1 −1 −1 Lkg mn and 50 normal Lkg mn .
3. The method of claim 1, wherein, before or during the mixing of the gas and the sugar-rich product, the sugar-rich product is cooled below 15°C.
4. The method of claim 2, wherein the sugar-rich product is concentrated sugar cane juice.
5. The method of claim 1, wherein the transport gas comprises one or more of air, oxygen, and carbon dioxide.
6. The method of claim 4, further comprising: before or during the mixing of the gas and the sugar-rich product, mixing the sugar-rich product with at least one additional product selected from the group consisting of powdered milk, vitamins, minerals, flavourings and aromas.
7. The method of claim 1, wherein the mixture is degassed to atmospheric pressure or to a vacuum.
8. The method of claim 7, wherein the mixture is degassed into a drying device selected from the group consisting of a fluidized-bed dryer, an atomizing tower, a counter-current vertical dryer, and a conveyor dryer.
9. The method of claim 4, wherein the dry matter concentration of the homogeneous powdered product is greater than 96%.
10. The method of claim 9, wherein: the sugar-rich product is a concentrated sugar cane juice with a viscosity greater than 300 centipoise and sugars as at least 85% of its total solids; the sugar-rich product is pressurised to a pressure greater than 4 bar; the gas is carbon dioxide; and the amount of carbon dioxide injected by volume based on the dry mass of the starting −1 −1 −1 −1 product is between 10 normal Lkg mn and 50 normal Lkg mn .
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/AU2018/050436 WO2019213685A1 (en) | 2018-05-10 | 2018-05-10 | Method and apparatus for manufacture of dry powders |
Publications (2)
Publication Number | Publication Date |
---|---|
NZ767414A NZ767414A (en) | 2021-10-29 |
NZ767414B2 true NZ767414B2 (en) | 2022-02-01 |
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