Modeling of food drying processes in industrial spray dryers

Data-Driven Modeling of the Spray Drying Process. Process Monitoring and Prediction of the Particle Size in Pharmaceutical Production

Spray drying is used in the pharmaceutical industry for particle engineering of amorphous solid dispersions (ASDs). The particle size of the spray-dried (SD) powders is one of their key attributes due to its impact on the downstream processes and the drug product's functional properties. Offline and inline laser diffraction methods can be used to estimate the product's particle size; however, the final release of these ASDs is based on offline instruments. This paper presents a novel data-driven modeling approach for predicting the particle size of SD products. The model-based characterization of the process and the product's particle size, as a critical quality attribute, follows the quality by design principles. The resulting model can be used for online process monitoring, reducing the risks of out-of-specifications products and supporting their real-time release. A Tucker3 model is trained to capture and factorize the deterministic variability of the process. Subsequently, a partial least-squares regression model is calibrated to model the impact that variability in the input material properties, the process parameters, and the spray nozzle have on the products' particle size. This strategy has been calibrated and validated using large scale production data for two intermediate drug products under high sparsity of particle size data. Despite the challenges, high accuracy was obtained in predicting the median particle size (dv50) for release. The 99% confidence interval results in an error of maximum 2.5 μm, which is less than 10% of the allowed range of variation.

Production of MgAl/layered double hydroxide microspheres and investigation of the volumetric heat transfer coefficient in spray drying

Layered Double Hydroxides (LDH) are synthetic materials nanostructured in two dimensions that present positively charged layers with interspersed anions for charge and structure balancing. Being recognized as a promising material for various applications, a complete exploration of its possible attractive properties and its synthesis process is essential. However, drying, a necessary step in the process, is still little studied. This work aimed to produce MgAl-CO3/LDH microspheres and calculate the volumetric heat coefficient in spray drying, evaluating the drying air inlet temperature and the concentration of the feed paste in the dryer. LDH synthesis was carried out using the coprecipitation method, maintaining a 2:1 Mg/Al ratio. The infrared spectra presented the bands characteristic of the hydrotalcite-type material. Through XRD, it was possible to observe that the variation in drying air temperature and feed paste concentration produced LDHs with structural differences. The results obtained for the basal spacing ranged from 7.685 to 7.705 Å. Scanning electron microscopy images confirm the production of LDH microspheres, showing variation in the size of the agglomerates with changes in the feed paste concentration. The volumetric heat transfer coefficient values ranged from 4.31 to 5.36 W m-3 K-1, with only the air inlet temperature significantly influencing the process under the conditions studied.

Enhancing Antioxidant Retention through Varied Wall Material Combinations in Grape Spray Drying and Storage

The encapsulation of bioactive compounds, which spans phytochemicals, vitamins, antioxidants, and other precious substances, has risen to prominence as a crucial area of interest spanning various domains, including food, pharmaceuticals, and cosmetics. This investigation delved into the efficacy of distinct wall materials-whey protein isolate, high methoxy pectin, and gum arabic-when employed individually or in combination to encapsulate and preserve phenolic compounds and antioxidants during storage. The encapsulation process involved spray-drying bioactive compounds extracted from grapes. Over a span of 120 days, the stability of these encapsulated compounds was meticulously evaluated, encompassing assessments via different antioxidant capacity assays, phenolic content analyses, and high-performance liquid chromatography measurements. The modeling of retention kinetics during storage facilitated the comprehension of the release mechanisms. Notably, the findings underscore the pivotal role of wall materials in preserving these bioactive compounds, with each material or combination of materials exhibiting varying degrees of protective capacity. Remarkably, the synergistic blend of whey protein, pectin, and gum arabic showcased the utmost retention of bioactive compounds over this study's period. The amassed data distinctly show that an amalgamation of wall materials can indeed considerably enhance the stability of encapsulated bioactive compounds, presenting promising applications within the realms of both the food and pharmaceutical industries.

Microencapsulation of Erythrocytes Extracted from Cavia porcellus Blood in Matrices of Tara Gum and Native Potato Starch

Ferropenic anemy is the leading iron deficiency disease in the world. The aim was to encapsulate erythrocytes extracted from the blood of Cavia porcellus, in matrices of tara gum and native potato starch. For microencapsulation, solutions were prepared with 20% erythrocytes; and encapsulants at 5, 10, and 20%. The mixtures were spray-dried at 120 and 140 °C. The iron content in the erythrocytes was 3.30 mg/g and between 2.32 and 2.05 mg/g for the encapsulates (p < 0.05). The yield of the treatments varied between 47.84 and 58.73%. The moisture, water activity, and bulk density were influenced by the temperature and proportion of encapsulants. The total organic carbon in the atomized samples was around 14%. The particles had diverse reddish tonalities, which were heterogeneous in their form and size; openings on their surface were also observed by SEM. The particle size was at the nanometer level, and the zeta potential (ζ) indicated a tendency to agglomerate and precipitation the solutions. The presence of iron was observed on the surface of the atomized by SEM-EDX, and FTIR confirmed the encapsulation due to the presence of the chemical groups OH, C-O, C-H, and N-H in the atomized. On the other hand, high percentages of iron release in vitro were obtained between 88.45 and 94.71%. The treatment with the lowest proportion of encapsulants performed at 140 °C obtained the best results and could potentially be used to fortify different functional foods.

Thermodynamic Balance vs. Computational Fluid Dynamics Approach for the Outlet Temperature Estimation of a Benchtop Spray Dryer

The use of design space (DS) is a key milestone in the quality by design (QbD) of pharmaceutical processes. It should be considered from early laboratory development to industrial production, in order to support scientists with making decisions at each step of the product’s development life. Presently, there are no available data or methodologies for developing models for the implementation of design space (DS) on laboratory-scale spray dryers. Therefore, in this work, a comparison between two different modeling approaches, thermodynamics and computational fluid dynamics (CFD), to a laboratory spray dryer model have been evaluated. The models computed the outlet temperature (Tout) of the process with a new modeling strategy that includes machine learning to improve the model prediction. The model metrics calculated indicate how the thermodynamic model fits Tout data better than CFD; indeed, the error of the CFD model increases towards higher values of Tout and feed rate (FR), with a final mean absolute error of 10.43 K, compared to the 1.74 K error of the thermodynamic model. Successively, a DS of the studied spray dryer equipment has been implemented, showing how Tout is strongly affected by FR variation, which accounts for about 40 times more than the gas flow rate (Gin) in the DS. The thermodynamic model, combined with the machine learning approach here proposed, could be used as a valid tool in the QbD development of spray-dried pharmaceutical products, starting from their early laboratory stages, replacing traditional trial-and-error methodologies, preventing process errors, and helping scientists with the following scale-up.

Metal-Organic Framework Photonic Balls: Single Object Analysis for Local Thermal Probing

Due to their high porosity and chemical versatility, metal-organic frameworks (MOFs) exhibit physical properties appealing for photonic-based applications. While several MOF photonic structures have been reported, examples of applications thereof are mainly limited to chemical sensing. Herein, the range of application of photonic MOFs is extended to local thermal and photothermal sensing by integrating them into a new architecture: MOF photonic balls. Micrometric-sized photonic balls are made of monodispersed MOFs colloids that are self-assembled via spray-drying, a low-cost, green, and high-throughput method. The versatility of the process allows tuning the morphology and the composition of photonic balls made of several MOFs and composites with tailored optical properties. X-ray nanotomography and environmental hyperspectral microscopy enable analysis of single objects and their evolution in controlled atmosphere and temperature. Notably, in presence of vapors, the MOF photonic balls act as local, label-free temperature probes. Importantly, compared to other thermal probes, the temperature detection range of these materials can be adjusted "on-demand." As proof of concept, the photonic balls are used to determine local temperature profiles around a concentrated laser beam. More broadly, this work is expected to stimulate new research on the physical properties of photonic MOFs providing new possibilities for device fabrication.

Optimization of Spray-Drying Process with Response Surface Methodology (RSM) for Preparing High Quality Graphene Oxide Slurry

The “Drying-redissolution” method is promising for the industrial production of high-concentration well-dispersed graphene oxide slurry (GOS). As the potential key step in this method, the spray drying process requires a statistical investigation which guides the large-scale preparation of graphene oxide powder (GOP). This work systematically studies the effects of operating parameters, including nozzle airflow rate (439–895 L·h−1), atomization pressure (0.5–0.7 MPa), and liquid feed rate (3.0–9.0 mL·min−1), by using the response surface methodology integrated Box–Behnken design (RSM–BBD), aiming to produce GOP with high yield and easy re-dispersion. The optimized spray drying condition is predicted to be 439 L·h−1, 0.59 MPa, and 9.0 mL·min−1, at which a powder yield of 70.45% can be achieved. The experimentally obtained GOP has an average particle size of 11.65 μm and the low crumpling degree of the particle morphology results in the good re-dispersibility (97.95%) and excellent adsorption performance (244.1 mg·g−1) of GOP. The GOS prepared by the spray-dried GOP possess low viscosity and high exfoliation efficiency with a single-layer fraction up to 90.8%, exhibiting good prospects for application. This work first applied the RSM–BBD model on the spray drying process of GO, and evidenced the possibility of producing high-quality GO slurry with the “drying-redissolution” method.

Challenges associated with spray drying of lactic acid bacteria: Understanding cell viability loss

Lactic acid bacteria (LAB) cultures used in food fermentation are often dried to reduce transportation costs and facilitate handling during use. Dried LAB ferments are generally lyophilized to ensure high cell viability. Spray drying has come to the forefront as a promising technique due to its versatility and lower associated energy costs. Adverse conditions during spray drying, such as mechanical stress, dehydration, heating, and oxygen exposure, can lead to low LAB cell viability. This reduced viability has limited spray drying's industrial applications thus far. This review aims to demonstrate the operations and thermodynamic principles that govern spray drying, then correlate them to the damage suffered by LAB cells during the spray-drying process. The particularities of spray drying that might cause LAB cell death are detailed in this review, and the conclusion may enhance future studies on ways to improve cell viability.

Engineering Advances in Spray Drying for Pharmaceuticals

Spray drying is a versatile technology that has been applied widely in the chemical, food, and, most recently, pharmaceutical industries. This review focuses on engineering advances and the most significant applications of spray drying for pharmaceuticals. An in-depth view of the process and its use is provided for amorphous solid dispersions, a major, growing drug-delivery approach. Enhanced understanding of the relationship of spray-drying process parameters to final product quality attributes has made robust product development possible to address a wide range of pharmaceutical problem statements. Formulation and process optimization have leveraged the knowledge gained as the technology has matured, enabling improved process development from early feasibility screening through commercial applications. Spray drying's use for approved small-molecule oral products is highlighted, as are emerging applications specific to delivery of biologics and non-oral delivery of dry powders. Based on the changing landscape of the industry, significant future opportunities exist for pharmaceutical spray drying.

Anti-inflammatory and antixidant properties of blend formulated with compounds of Malpighia emarginata D.C (acerola) and Camellia sinensis L. (green tea) in lipopolysaccharide-stimulated RAW 264.7 macrophages

The antioxidant and anti-inflammatory properties of Malpighia emarginata D.C (acerola) and Camellia sinensis L. (green tea) have been studied, particularly as an alternative in medicinal approach for different physio pathological conditions. Here we develop an powder blend formulated with both Malpighia emarginata D.C and Camellia sinensis L. which have in the composition higher content of ascorbic acid and epigallatocathechin-3-gallate respectively. Using different conditions for microencapsulation of biocompounds, we performed the powder production through spray-drying process. After, we evaluate the antioxidant and anti-inflammatory properties of blends formulated with Malpighia emarginata D.C and Camellia sinensis L. in an in vitro model of inflammation, using LPS-stimulated RAW-264.7 macrophage cell line. We observed that co-treatment with blends was able to modulate the redox parameters in cells during the in vitro inflammatory response. Moreover, the co-treatment with blends were able to modulate inflammatory response by altering the secretion of cytokines IL-1β, IL-6, IL-10, and TNF-α. Taken together, our results demonstrate for the first time the synergistic effects antioxidant and anti-inflammatory of Malpighia emarginata D.C and Camellia sinensis L. These results warrant further use of the blend powder for use in the products to heath beneficial, principally in terms of prevention of chronic diseases.

Production of Probiotic Passion Fruit (Passiflora edulis Sims f. flavicarpa Deg.) Drink Using Lactobacillus reuteri and Microencapsulation via Spray Drying

Probiotic foods offer many benefits to human health, causing increased interest in the development of new food products that exploit such benefits. However, traditional dairy foods are being replaced by other non-dairy foods to provide additional sources of benefits provided by bioactive molecules. Therefore, the objective of the present work was to study the production process of a probiotic fruit drink and then microencapsulate the probiotic pulp to stabilize the drink further. Passion fruit pulp (Passiflora edulis Sims f. flavicarpa Deg.) was fermented with Lactobacillus reuteri under different temperature conditions in combination with different pHs to find the best fermentation conditions. Different from dairy sources, the optimal conditions for the growth of Lactobacillus reuteri in the passion fruit pulp were found to be 30 °C at pH 3.18, where phenolic compounds could also be used as a secondary metabolic pathway. Spray-drying was performed using different conditions for microencapsulation. Process yields and Lactobacillus reuteri survival showed the dependency of droplet sizes, whereas phenolic compound retention was increased when higher amounts of gelatin were used. Therefore, the development of a new food product comprising a powdered fruit pulp rich in probiotic and phenolic compounds was possible.

Optimisation of umbu juice spray drying, and physicochemical, microbiological and sensory evaluation of atomised powder

Aim: Optimum conditions of umbu juice spray drying were selected using inlet air temperature (T), feed flow rate (F) and 10-DE maltodextrin concentration (C_MD) as independent variables, and water activity, moisture content, hygroscopicity and phenolic compounds retention as responses.Methods: Powders water activity was determined with a water activity metre, moisture content and hygroscopicity gravimetrically, total phenolics spectrophotometrically, apparent and absolute density, porosity and solubility by standard methods, particle size by laser diffraction, and morphology by Scanning Electron Microscopy. Nectars sensory analysis was based on acceptance, purchase intention and multiple comparison preference tests. Powder stability was checked at 25 °C varying water activity and storage time in the ranges 0.1-0.3 and 30-90 days, respectively.Results: Powders prepared at T = 110 °C, F = 0.84 L/h, C_MD=10% and T = 140 °C, F = 0.60 L/h, C_MD=10% gave the best microparticles and sensory results. The former showed properties suitable for industrial production.Conclusion: These findings may promote umbu powder industrial exploitation.