Spray Drying Modelling using Advanced Vaporization Approach

The final particle moisture content of ceramic slurry spray drying affects the processing, product quality, and process energy consumption. While the real-time moisture content determination is very difficult for spray drying process due to nonlinear, severe lag, interference factors, and complexity of the systems, the high temperature, high humidity drying environment and short drying process. In current work, an improved moth optimization (IMFO) algorithm combined with backpropagation neural network (BPNN) was proposed to predict the moisture content of ceramic slurry particles during spray drying. The performance of the model is trained and tested. Results demonstrate that IMFO has better convergence ability and speed compared to other algorithms such as particle swarm optimization (PSO) and gravitational search algorithm (GSA). The IMFO-BPNN model achieves a MAE of 0.0293, RMSE of 0.0383, and R2 value of 0.9113, outperforming the prediction performance of BPNN and MFO-BPNN models. The absolute error rate of the IMFO-BPNN model (0–5%) is lower compared to BPNN (5–10%) and MFO-BPNN model (>10%), showcasing superior accuracy in predicting moisture content. This mathematical model established in the study provides an efficient, accurate, and nondestructive method for predicting the drying endpoint of ceramic slurry spray drying.

Abstract. This article describes how the moisture content of baled woody biomass varied during long-term open-air storage under conditions in the Pacific Northwest region of the United States. Large rectangular bales of forest and urban biomass were produced beginning in August 2015 and periodically until June 2016. Weights were measured approximately monthly until the entire lot of bales was ground into fuel in December 2016. Because it was impractical to non-destructively obtain moisture content samples during the study, final moisture content was measured from the ground material. Estimated temporal moisture contents were back-calculated from the final dry weight and moisture content of bales. All bales dried considerably during the spring and summer months, achieving a minimum moisture content in the early fall of 15 to 29% (wb). Minimum early fall moisture content had no correlation with the initial moisture content at time of baling. The ending moisture content in December 2016 ranged from 44% to 57% (wb), with a mean moisture content of 53% (wb). Ending moisture content had no correlation with initial moisture content at the time of baling, but appeared to be related to the amount of fine versus coarse woody material in the bales. Bales of forest and urban woody biomass proved to be structurally stable during long-term storage to enable handling and final transport to a centralized grinding location. Keywords: Density, Logging, Baling, Bioenergy, Biofuel, Bundling, Forest operations, Forestry, MC, Seasonality, Transport, Woody biomass.

Ambewela MILCO (Highland) Spray Dried Milk Factory produces milk powder under the brand name of “Highland Milk Powder” among five factories belongs to MILCO Company. Moisture content of the final milk powder can hold up to 3.00%. Newly upgraded powder plant produces milk powder with moisture percentage under 2.75%. Spray Drying Inlet Temperature and Fluid Bed Dryer Inlet Temperatures are the main variables that can be controlled in the main process of milk powder production. A study was conducted to find out the possible temperature ranges of both Spray Drying Inlet and Fluid Bed Dryer Inlet in order to select the most suitable temperature range which produces good quality milk powder with acceptable bulk density value (0.56 kg/m3), scorched particles grade (“A” grade) and moisture content value closer to the 3.00%. A trial experiment was conducted to find out the suitable temperature ratio of both Spray Drying Inlet temperature and Fluid Bed Dryer Inlet Temperatures by considering bulk density, scorched particles and moisture content. Possible Spray Dryer Inlet temperatures were 175°C, 176°C, 177°C, 178°C, 179°C, 180°C and 181°C. Possible Fluid Bed Inlet Temperatures were 55°C, 60°C, 65°C, 70°C, 75°C, and 80°C. Based on the trial experiment, T1 (SPI: 175°C, FBD: 75°C), T2 (SDI: 176°C, FBD: 70°C), T3 (SDI: 177°C, FBD: 65°C), T4 (SDI: 178°C, FBD: 60°C), T5 (SDI: 179°C, FBD: 55°C) selected as treatments. Final moisture content, bulk density; scorched particles level and fat levels were taken into consideration for the quality parameters of milk powder. Fat level of the final milk powder indicated that there was no any significant difference (p>0.05) between treatments. Spray Dryer Inlet Temperatures of 177°C, 178°C and Fluid Bed Dryer Inlet Temperatures of 65°C, 60°C ( T3 and T4) produced acceptable bulk density levels and moisture content levels of 0.562 kg/m3, 0.556 kg/m3 and 2.895%, 2.911% respectively. There was no any significant difference (p>0.05) between treatments.

RESUMO A secagem por micro-ondas em um futuro próximo irá desempenhar importante papel na industrialização da madeira, pois dela depende a melhora da estabilidade dimensional e aumento da resistência mecânica, dentre outras. O objetivo deste trabalho foi avaliar a secagem da madeira de louro preto utilizando o processo por micro-ondas e sua influência na formação de rachaduras, no tempo de secagem e na umidade final. Foi utilizado o programa desenvolvido para a madeira de mogno em função da semelhança entre os valores de suas densidades básicas. Foram realizadas 3 secagens, tendo a secagem S1 com umidade inicial média acima do PSF após 2 h 25 min chegado aos 13,99% de umidade final média. As secagens S2 e S3 com umidade inicial média abaixo do PSF depois de 2 h 08 min e 2 h 02 min apresentaram 14% e 14,62% de umidade final média, respectivamente. As secagens foram consideradas rápidas, e a diferença de umidade inicial das amostras mostrou que sofreram influência dos tratamentos na formação dos defeitos de rachaduras de topo e de superfície. A secagem S2 mostrou-se mais propensa em apresentar rachaduras de superfície do que rachaduras de topo, enquanto as rachaduras internas não se formaram em nenhuma das secagens realizadas.

The objective of the present research was to simulate and evaluate the performance of spray dryers using MATLAB software. The assessments regarding energy consumption and thermal efficiency were performed. Simulations were conducted to identify the effect of the following parameters' influence on energy consumption: (1) the initial liquid feed moisture content, which ranged from 0.5 kg to 0.9 kg water/kg product, (2) the final moisture content, which ranged from 0.05 kg to 0.3 kg water/kg solid, and (3) the feed flow, ranging from 1 to 10 kg/s. It was found that energy consumption increased with increasing moisture content and feed flow rate and with decreasing final moisture content. The results indicated that the thermal efficiency of the process does not change when process parameters are varied. PRACTICAL APPLICATIONSDrying is a process in which food water activity is reduced by water removal to minimize deterioration caused by enzymatic and microbiological reactions and to prevent physical and chemical modification of products. Dried products are used mainly as convenience foods and have long storage life at normal temperatures. Spray drying is a commonly used method of drying a liquid feed through a hot gas in the production of powders. This technique is widely used in food and pharmaceutical manufacturing and presents low operating cost and short contact time. Nowadays, the development of new products has used encapsulating agent, with good emulsifying capacity and low viscosity in aqueous solution, in microencapsulation by spray drying. This wide application of spray drying in research of new product increases the need of engineers to understand energy calculation with mass and heat balance concerning spray‐drying process.

<abstract> <bold><sc>Abstract.</sc></bold> Physical properties of frozen commercial cranberries were measured, including diameters, mass, sugar content, moisture content, and color. Density was calculated to be 0.89 g mL^-1, and the moisture content averaged 87.0%. The effect of blanching on convective drying was investigated by dividing the cranberries into three size ranges and then subjecting them to convective drying after blanching in boiling water. Three blanching times (60, 120, and 180 s) were used, along with a control of no blanching. In a second set of experiments, cranberries were blanched prior to osmotic dehydration. The osmotic solution was either 50 or 65 °Brix at a temperature of 50°C or 60°C. Samples were removed hourly, and mass and moisture contents were measured. The convective drying experiments indicated that blanching affected the subsequent drying rate, with a longer blanching time resulting in a faster drying rate. Results from the osmotic dehydration study indicated that blanching had a significant effect on the final dry basis moisture content of the berries compared to non-blanched controls. The actual mass of water removed from the cranberries did not differ between the blanched and non-blanched cranberries. Rather, the significant difference in the final moisture content was attributed to increased solid matter content due to the infusion of the sugar solution. Non-blanched cranberries had an average solids content increase of 41%, whereas blanched cranberries had an increase of 254%.

HighlightsElevated SARAdjusted levels led to temperature increases during RF treatment, resulting in significant reductions in paddy rice moisture content (MC) to 13.1% wet basis (w.b.) for non-tempered and 14.0% w.b. for samples tempered for 4 h at 60°C (Control: Initial MC = 20.4% w.b.; MRY = 69.64%; HRY = 66.56%).MC gradients and structural changes within rice kernels contributed to fissures and decreased milling yields. However, tempering effectively mitigated fissures and improved milling yields.The optimal SARAdjusted for drying high mc rice while preserving milling yields is 1.33 × 106 J (Tempered: Final MC = 16.6%; Milled Rice Yield (MRY) = 72.58%; Head Rice Yield (HRY) = 68.49%. Non-tempered: Final MC: 15.8%; MRY = 70.51%; HRY = 41.16%.)Further controlled low-temperature drying at 40°C to 50°C is needed to achieve 13.5% w.b. MC for safe storage.Abstract. Efficient drying methods like radiofrequency (RF) are vital for preserving high-moisture paddy rice quality and maximizing milling yields (Milled Rice Yield [MRY] and Head Rice Yield [HRY], impacting market value and consumer preferences). This study explored the influence of RF exposure parameters and RF drying stages on fissure formation and milling yields in high MC paddy rice kernels. The objectives were to: 1. Investigate the impact of RF exposure parameters (SAR, SARAdjusted, E, EEff, and S) on rice milling yields (MRY and HRY). 2. Evaluate using X-ray imaging the effect of SARAdjusted levels on rice kernel internal structure and its relationship with fissure formation. 3. Using X-ray imaging, evaluate how RF drying steps (RF drying, tempering, and cooling) influence rice kernel internal structure and fissure formation. This study employed a pilot-scale parallel-plate RF heating system (6 kW, 27.12 MHz) with a 105 mm product-to-emitter gap size to achieve one-pass drying of high-moisture long-grain paddy rice (cv. XL-753) from 20.4% wet basis (w.b.) to =13.5% w.b. moisture content (MC) for safe long-term storage. After RF drying, half of the paddy rice samples were tempered at 60°C for 4 h, then conditioned to 13.5% w.b. in an equilibrium MC (EMC) chamber. SAR and S were notably high at 2,224.95 W/kg and 300,000 W/m2 (equivalent to 6,000 W/kg). E was calculated at 46.82 V/m. Higher SARAdjusted levels led to increased temperatures and more significant reductions in MC. Tempering promoted uniform moisture distribution with increased humidity and heating, leading to a slightly higher final MC. Increased SARAdjusted levels induced MC gradients, weakening kernel integrity and inducing fissures, primarily after RF drying and cooling/equilibrating in an EMC chamber. Tempering improved moisture distribution, reduced fissuring, and boosted milling yields. As SARAdjusted rose from 0.80 to 1.87 × 106 J, non-tempered samples saw MRY drop from 71.67% to 60.91% and HRY from 68.04% to 4.53%. Tempered samples followed a similar trend but maintained higher MRY (71.58% to 70.80%) and HRY (69.22% to 47.38%) at the same SARAdjusted levels. The optimal SARAdjusted level for drying high MC rice while preserving milling yields is 1.33 × 106 J with tempering. At this SARAdjusted level, tempered samples achieved a final MC of 16.6%, with MRY at 72.58% and HRY at 68.49%. Non-tempered samples had a final MC of 15.8% w.b., MRY of 70.51%, and HRY of 41.16% (Control MRY = 69.64%; HRY = 66.56%). Further controlled low-temperature drying at 40°C to 50°C is needed to achieve 13.5% w.b. MC for safe storage. Keywords: Cereal drying, Dielectric heating, Drying, Electromagnetic radiation, Grain drying, Milling yields, Radiofrequency, Rice drying, Rice quality.

In the present study, double-toned milk was inoculated with Streptococcus thermophilus, Lactobacillus delbrueckii subsp. bulgaricus, and Bifidobacterium bifidum, to result in a curd which was further subjected to homogenization and spray drying. Various process parameters like inlet temperature (140–160°C), the flow rate of feed (10–20 ml/min), and compressed air (2–4 kg/cm2) were varied to obtain the best-operating conditions for the maximum viable count in the probiotic cultured buttermilk powder. The yields of the powder ranged between 58.4% and 71.5%. An inlet temperature of 150°C, feed flow rate of 15 ml/min and compressed air of 3 kg/cm2 were the optimum process parameters obtained by response surface methodology for maximum survival of starter culture and probiotic bacteria Bifidobacterium bifidum. The powder stored at 4 ± 1°C showed superior qualities to that stored at 27 ± 1°C. While moisture content, aw, solubility and density showed an increase, hygroscopicity exhibited a decline during storage. The final moisture content, hygroscopicity, aw, solubility index, and bulk density of buttermilk powder stored at 4 ± 1°C and 27 ± 1°C were 5.93, 13.73, 0.293, 59.78, 0.71, and 6.27, 12.31, 0.301, 60.12, 0.93 respectively. The viable counts of Streptococcus thermophilus, Lactobacillus delbrueckii subsp. bulgaricus and Bifidobacterium bifidum in BMP were 8.07 ± 0.21, 7.68 ± 0.17, 6.01 ± 0.18 at 4 ± 1°C and 5.73 ± 0.17, 5.57 ± 0.14, 4.14 ± 0.20 at 27 ± 1°C after 4 weeks of storage. Practical applications Probiotics have gained tremendous attention in recent times. However, the viability of probiotics during rigorous food processing and handling steps remains a matter of concern. Spray drying results in a powder that can be easily handled, stored, and reconstituted in beverages. A probiotic cultured buttermilk powder was obtained by optimizing the inlet temperature, feed flow rate, and compressed air while spray drying. Buttermilk is a valuable by-product usually lost in waste streams during the manufacturing of butter. This study attempts to valorize buttermilk by developing a spray dried probiotic buttermilk powder and evaluate its shelf-life under refrigerated storage and ambient conditions, which would be of great help to the industry.

SummaryEffect of microwave power on moisture content, moisture ratio, drying rate, drying time and effective moisture diffusivity (Deff) of bamboo shoot was investigated using microwave drying. To study the effect of microwave power on drying, bamboo shoot samples (250 g) were dried at different power levels ranging from 140 to 350 W. To determine the kinetic parameters, drying data were fitted to various models based on the ratios of differences between initial and final moisture contents and equilibrium moisture content. Among the models proposed, Wang and Singh model gave a better fit for all drying conditions used. By increasing microwave output power, the Deff values increased from 4.153 × 10−10 to 22.835 × 10−10 m2 s−1. A third‐order polynomial relationship was found to correlate the Deff with moisture content. Further scope of this research work would include the effect of certain factors (shrinkage, case hardening, distortion of product and shape of bamboo shoot samples as an infinite slab) of practical significance to improve the model.

Prediction of lycopene degradation during a drying process of tomato pulp

This study aimed to develop the solid astaxanthin-encapsulated self-microemulsifying delivery system (S-AST SMEDS) spray-dried particles and investigate the effect of materials in formulations on product characteristics. The optimized liquid AST SMEDS incorporated with a polymeric precipitation inhibitor (PI) was solidified with a solid carrier by spray drying. Physicochemical properties of S-AST SMEDS spray-dried powders including morphology, particle size and distribution, flowability, solid-state characters, moisture content, yield, loading capacity of AST, and reconstitution properties were examined. Polymeric PIs seemed to have an impact on particles' size, surface smoothness, and flowability while solid carriers had an effect on the particles' moisture content and droplet size of microemulsions obtained after reconstitution. The amount of AST encapsulated in S-SMEDS powder was influenced by both polymer and solid carriers. Dissolution and short-term stability of S-AST SMEDS were also studied. Our developed spray-dried solid SMEDS particles helped enhance AST dissolution rate.

As enterprise operations become more complex and financial data volumes grow rapidly, traditional methods for detecting financial anomalies are increasingly inadequate for management needs. This study proposes a new model for financial anomaly detection and early warning. The model is based on a hybrid algorithm that combines LightGBM and Support Vector Machine (SVM). It uses a layered structure. The first layer employs SVM to classify financial data and generate probability distributions of abnormal behavior. The second layer applies LightGBM to analyze these results along with key financial features. This enhances the model's efficiency and accuracy in identifying anomalies. The model is tested using a public financial dataset, which includes enterprise financial statements from the past 5 years. Evaluation metrics include accuracy, recall, F1 score, and AUC. Results show that the LightGBM‐SVM model performs significantly better than traditional and single algorithms. Specifically, the model achieves an accuracy of 93.2%, a recall of 95.4%, and an AUC exceeding 98.2%. The model's parameters are optimized to handle large‐scale data efficiently. It also demonstrates high sensitivity and strong generalization in detecting anomalies. Based on these findings, the study designs a complete financial anomaly detection and early warning system. The system includes modules for data preprocessing, feature extraction, model training and detection, and real‐time alerts. It can clean and standardize historical financial data, extract relevant features, and generate real‐time warnings based on the model's output. This provides an intelligent and efficient solution for enterprise financial management. The system proves highly applicable in real‐world scenarios. It improves the accuracy of anomaly detection and significantly lowers the cost of manual reviews. Future research may further improve the model's computational efficiency and explore its use in other domains.

Spray drying is a removal of moisture from liquid feed by breaking into droplets in a hot medium to convert into powder form. In order to ensure the product quality is at the desired specification, a good control system and good understanding on the dynamic behavior should be considered. The aims of this study are to develop empirical model of spray drying process and improve the process by implementation of PI controller. A nozzle atomizer spray dryer, Lab-Plant SD 05 Laboratory Scale Spray Dryer was used. The liquid feed was Sunquick Concentrated Orange Juice and DE 10–15 maltodextrin as the drying agent. The effects of inlet air temperature and maltodextrin concentration on final moisture content and outlet air temperature were investigated. From investigation, the effect of inlet air temperature on moisture content and outlet air temperature was greater than maltodextrin concentration. Thus, inlet air temperature was selected as manipulated variable. For modeling, the model obtained can be represented as first order process with time delay (FOPTD). In order to improve the process, the model obtained was used in simulation studies to determine the suitable tuning method by PI controller. The PI controllers were tuned by direct synthesis, min IAE method and Cohen-coon. From the observation, direct synthesis method is the most suitable tuning method for PI controller in spray drying process.

Thin-layer drying characteristics and modelling of mint leaves undergoing microwave treatment

The effect of microwave-drying technique on moisture content, moisture ratio, drying rate, drying time and effective moisture diffusivity of basil leaves (Ocimum Basillium L.) were investigated. By increasing the microwave output powers (180–900 W) and the sample amounts (25–100 g), the drying time decreased from 28 to 6.5 min and increased from 16 to 44 min, respectively. To determine the kinetic parameters, the drying data were fitted to various models based on the ratios of the differences between the initial and final moisture contents and equilibrium moisture content versus drying time. Among the models proposed, the semi-empirical logarithmic model gave a better fit for all drying conditions applied. The activation energy was calculated using an exponential expression based on Arrhenius equation. The relationship between the drying rate constant and effective moisture diffusivity was also estimated and gave a linear relationship. PRACTICAL APPLICATIONS Drying, in general, means removal of water from the material. The purpose of drying food products is to allow longer periods of storage with minimized packaging requirements, reduce shipping weights and preserve seasonal plants and make them available to consumers during the whole year. Besides these advantages, some important changes take place, as structural and physicochemical modifications that affect the final product quality during dehydration. Microwave drying is an alternative method because of its uniform energy and high thermal conductivity to the inner sides of the material, space utilization, sanitation, energy savings, precise process control and fast startup and shutdown conditions. In the present study, drying kinetics of basil were investigated in a microwave oven at various microwave output powers and sample amounts. Drying time decreased considerably with increased microwave output power and with decreased sample amount of basil as well by using microwave-drying technique.