Production Of Powders Research Articles

Techno economic analysis of the production of potato powder applying potato starch purification system in Japan

To implement the technology for producing potato powder, significant investment is required. This study evaluated the techno-economic feasibility of the dried potato powder production process, based on a scenario developed in a starch plant process in Japan. The simulation was performed with SuperPro Designer® software. The annual production volume and the unit production cost were estimated to be 15,786,585 kg and 1056 Japanese yen/kg, respectively. According to economic evaluation indicators—the gross margin, return on investment, payback time, internal rate of return, and net present value (at a 7% interest rate)—the scenario was profitable and investment worthwhile. A sensitivity analysis was conducted to evaluate the impact of the variable parameters (the purchasing price of raw potatoes, the selling price of potato powder, and labor and electricity costs) on the net present value (at the 7% interest rate). The analysis suggested that the purchasing price of raw potatoes and the selling price of potato powder had particularly large impacts on the net present value.

Safflower protein as a potential plant protein powder: optimization of extraction and spray-drying process parameters and determination of physicochemical and functional properties.

The research about sustainable and alternative plant protein sources has accelerated with the increasing need for protein. Safflower meal has a potential to be used in protein production due to its high protein content. This research aimed to produce an alternative plant-based protein powder using safflower meal. Both extraction and spray-drying parameters of safflower protein powder production were optimized using response surface methodology to achieve maximum yield. Moreover, the physicochemical and functional properties of safflower protein were determined and compared with those of commercial protein powders (soy, sunflower, pea, fava bean, and rice). The optimum extraction conditions were found to be 33.06:1 mL-1 g solvent-to-meal ratio, pH 11.00, 23.34 °C extraction temperature, and 30.86 min extraction time, which were achieved with a protein yield response of 75.21%. The highest powder yield (51.28%) was recorded for drying conditions of inlet air temperature of 160.11 °C, aspiration rate of 54.17 m3 h-1, and feed flow rate of 16.01 mL min-1. According to the amino acid profile of safflower protein, the glutamic acid content (14 475 mg (100 g)-1) was highest, while the methionine content (96 mg (100 g)-1) was lowest. Moreover, safflower protein can be regarded as a high-quality protein due to its high essential amino acid ratio (41.55%). The experiments showed that safflower protein had high solubility and good foam and emulsifying properties. Safflower protein could be a nutritional and functional protein source for the food industry. © 2024 Society of Chemical Industry.

Optimization of high-phenolic European cranberrybush juice powder production using hybrid microwave hot air-drying: a novel approach for enhanced preservation and efficiency in food processing

Optimization of high-phenolic European cranberrybush juice powder production using hybrid microwave hot air-drying: a novel approach for enhanced preservation and efficiency in food processing

Molar-scale formate production via enzymatic hydration of industrial off-gases

Decarbonizing the steel industry, a major CO2 emitter, is crucial for achieving carbon neutrality. Escaping the grip of CO combustion methods, a key contributor to CO2 discharge, is a seemingly simple yet formidable challenge on the path to industry-wide net-zero carbon emissions. Here we suggest enzymatic CO hydration (enCOH) inspired by the biological Wood‒Ljungdahl pathway, enabling efficient CO2 fixation. By employing the highly efficient, inhibitor-robust CO dehydrogenase (ChCODH2) and formate dehydrogenase (MeFDH1), we achieved spontaneous enCOH to convert industrial off-gases into formate with 100% selectivity. This process operates seamlessly under mild conditions (room temperature, neutral pH), regardless of the CO/CO2 ratio. Notably, the direct utilization of flue gas without pretreatment yielded various formate salts, including ammonium formate, at concentrations nearing two molar. Operating a 10-liter-scale immobilized enzyme reactor feeding live off-gas at a steel mill resulted in the production of high-purity formate powder after facile purification, thus demonstrating the potential for decarbonizing the steel industry.

PRODUCTION OF Ni-HARD ALLOY POWDERS BY GAS ATOMIZATION

Ni-Hard cast iron materials are frequently used in equipment where high wear resistance is required in industrial applications. Generally, Ni-Hard is produced by conventional casting techniques. In this study, it was aimed to produce Ni-Hard powders to produce Ni-Hard cast iron materials with additive manufacturing techniques. To produce spherical and fine raw materials for additive manufacturing techniques, the gas atomization technique with a close-coupled nozzle system was preferred for the production of Ni-Hard powders. Ni-Hard alloy was melted in a high-frequency 10kW induction furnace under a protective atmosphere integrated into the gas atomization system. During the atomization process, 150 °C superheating was applied to prevent the liquid metal from freezing and clogging the melt delivery tube. In terms of the continuity of the atomization process, the negative pressure (aspiration pressure) values formed at the end of the melt delivery tube at different gas pressures were measured. An aspiration pressure of -50 mbar was obtained under an atomization pressure of 35 bar. Particle size distributions, hall flow behaviour and angle of repose properties of the produced powders were determined. Finally, the characterization of the powders was carried out by scanning electron microscopy. It was determined that the powders obtained as a result of atomization exhibited a spherical morphology and a narrow size range. The Hall flow rate test result of Ni-Hard powders was measured as 22 seconds for 50 g.

Comparison of diterpenoid contents and dissolution profiles of selected Andrographis paniculata crude and extract capsules.

Andrographis paniculata (AP) has been approved by the Thai government for the treatment of mild cases of COVID-19 patients. Increasing use of AP products requires quality control to ensure efficacy and safety. At present, there is no requirement for dissolution test of AP products in the Thai Herbal Pharmacopoeia (THP). This work aimed to examine the contents and dissolution profiles of active diterpenoids, andrographolide (AP1), 14-deoxy-11,12-didehydroandrographolide (AP3), neoandrographolide (AP4), and 14-deoxyandrographolide (AP6) in AP capsules available in Thai markets. Four extract products (EXT. A-D) and three crude powder products (CRD. A-C) were tested for contents by using HPLC-DAD. Dissolution profiles of four diterpenoids were investigated in different media (pH 1.2, 4.5, 6.8, and 0.01 N HCl + SLS) with apparatus II (paddle type). The AP1 contents were 1.99%-2.90% w/w for crude capsules and 2.84%-16.27% w/w for extract capsules. In the dissolution test, the dissolution percentages of four diterpenoids from crude capsules were higher than those from extract capsules except EXT. A. AP1 in most extract products (EXT. B, C, D) was dissolved in all dissolution media at a lower percentage than the other three diterpenoids. EXT. A (aqueous extract) was the only extract capsule showing the amounts of all diterpenoids dissolved in all media >80% in 45 min. The study demonstrated that AP1 content in AP products complied with the acceptance criteria in the THP (80%-120%), and the weight variation also met the United States Pharmacopeia (USP) requirements. However, different dissolution profiles of AP products may lead to different bioavailability of diterpenoids and further affect their efficacy.

A Comparison between Powder Bed Fusion of Polyamide 12 and Aluminum Computer Numeric Control Machining: A Carbon Footprint and Energy Assessment

This study presents a comparative life cycle assessment (LCA) of two manufacturing scenarios for a camera housing: Powder Bed Fusion (PBF) using polyamide 12 (PA-12) and Computer Numeric Control (CNC) machining using aluminum, for a cradle-to-gate boundary. The selected impact categories were cumulative energy demand (CED) and global warming potential (GWP). The key findings indicate that the PA-12 PBF part outperformed the aluminum CNC machining one in terms of environmental and energy performance, showing a significant reduction of approximately 90% in equivalent carbon emissions and 84% in cumulative energy demand. Sensitivity analyses revealed that the PBF process was highly sensitive to changes in the proportion of virgin/recycled material for the printing process, variations in the life cycle inventory (LCI) data sources for PA-12 powder production, and changes in the transportation system for imported materials, as is the case for the main input in the process (PA-12 powder). Sensitivity analysis also showed less impact for the PBF camera housing even considering a lifespan of one-fifth that of the aluminum for the impact categories considered. However, it should be noted that this analysis did not include considerations for the usage and end-of-life phases, which may have significant contributions to the overall environmental impact.

Influence of microwave drying on quality parameters of foamed Nagpur Mandarin (Citrus reticulata) juice

In the world of industrial drying processes, foam mat microwave drying is a significant and valuable approach. Its advantages include increased drying effectiveness, preservation of product quality, energy and cost savings, flexibility in application, and improved safety. Development of Nagpur mandarin juice powder is tedious and time-consuming due to its bitter test and less total soluble solid, therefore the present research carried out with the process parameters for microwave drying include microwave power levels (180, 360, 540, 720, and 900 W) and drying bed thicknesses (2, 4, and 6 mm). Foamed juice is produced using soy protein isolate (2.10 %), GMS (2.75 %), CMC (1.75 %), and sugar (5.10 %), with whipping times of 8 min. Additional foaming agents include guar gum (0.45 %), soy protein isolate (3.30 %), and sugar (10 %) with whipping times of 6 min. The optimal conditions for drying Nagpur mandarin juice were determined through analysis using Design-Expert 11.0.4.1 software. These conditions include 540 W of microwave power, a drying bed thickness of 3 mm, and the use of a foaming agent comprising 2.10 % soy protein isolate, 2.75 % GMS, 1.75 % CMC, and 5.10 % sugar, with an 8-min whipping period. Under these optimized conditions, the resulting powder exhibited the following characteristics: color b value of 19.59, ΔE (change in color) of 6.24, acidity of 0.40 %, ascorbic acid content of 36.64 mg/100 g, water activity of 0.26, drying time (in minutes), and overall acceptability rating of 7.77. These findings highlight the effectiveness of the optimized process parameters in achieving desirable quality attributes for Nagpur mandarin juice powder production.

Chemo‐rheological and quantitative dispersion analysis of mass‐produced graphene‐unsaturated polyester based nanocomposites

AbstractRecent advancements in mass production of graphene powders utilize less energy‐intensive methods and milder chemicals compared to traditional lab‐scale techniques. This can influence the properties of the resulting graphene particles. This study investigates the effect of mass‐produced graphene powder on the curing and rheological properties of a resin transfer molding (RTM) grade unsaturated polyester resin. An objective dispersion quantification method was established to track the dispersion state of the nanocomposite throughout the curing process. The findings reveal that the graphene powder accelerated the curing evidenced by a shift in the peak temperature and gel point towards lower values. The sample containing 1 wt.% graphene exhibited remarkable dispersion stability with only 7.1% decrease by gelation. The resin matrix's low viscosity enhanced graphene particles mobility, while its fast‐curing nature allowed less time for agglomeration.Highlights Characterization of unsaturated polyester nanocomposites modified with an industrial‐grade graphene powder Real‐time in‐situ monitoring of graphene's dispersion state Quantification dispersion analysis for an objective dispersion assessment

Influence of temperature on the process of preparing homogenised magnesium-zinc alloy spherical powders using the relative vacuum method

The production of magnesium-zinc (Mg-Zn) alloy spherical powders is complex and expensive. As they have extensive applications in a wide variety of fields including military manufacturing, aerospace, and biomedicine, there is an urgent need to explore new production processes for Mg-Zn alloy spherical powders. In this study, 5 wt% homogenised Mg-Zn alloy spherical powder was prepared using the relative vacuum method. The effects of the insulation time, maximum temperature, and heating rate on the morphology, size distribution, and particle size of the Mg-Zn alloy spherical powder were investigated. The results indicated that the insulation time had the greatest influence on the particle size of the spherical powder, whereas the maximum temperature and heating rate had significant impacts on the alloy composition. When the insulation time was 10 min the maximum temperature was 1150 °Cand the heating rate was 15 min, the prepared Mg-Zn alloy spherical powder exhibited a full morphology without satellite particles, uniform composition, narrow size distribution, and a volume median diameter (VMD) of 17.62 μm. The research findings provide a new production process for Mg-Zn alloy spherical powders and establish a foundation for studying the specific effects of temperature on the production of Mg-Zn alloy spherical powders using the relative vacuum method.

Detection of risk areas in dairy powder processes: The development of thermophilic spore forming bacteria taking into account their growth limits

Anoxybacillus flavithermus, Geobacillus stearothermophilus and Bacillus licheniformis are the main contaminants found in dairy powders. These spore-forming thermophilic bacteria, rarely detected in raw milk, persist, and grow during the milk powder manufacturing process. Moreover, in the form of spores, these species resist and concentrate in the powders during the processes. The aim of this study was to determine the stages of the dairy powder manufacturing processes that are favorable to the growth of such contaminants. A total of 5 strains were selected for each species as a natural contaminant of dairy pipelines in order to determine the minimum and maximum growth enabling values for temperature, pH, and aw and their optimum growth rates in milk. These growth limits were combined with the environmental conditions of temperature, pH and aw encountered at each step of the manufacture of whole milk, skim milk and milk protein concentrate powders to estimate growth capacities using cardinal models and the Gamma concept. These simulations were used to theoretically calculate the population sizes reached for the different strains studied at each stage in between two successive cleaning in place procedures. This approach highlights the stages at which risk occurs for the development of spore-forming thermophilic bacterial species. During the first stages of production, i.e. pre-treatment, pasteurization, standardization and pre-heating before concentration, physico-chemical conditions encountered are suitable for the development and growth of A. flavithermus, G. stearothermophilus and B. licheniformis. During the pre-heating stage and during the first effects in the evaporators, the temperature conditions appear to be the most favorable for the growth of G. stearothermophilus. The temperatures in the evaporator during the last evaporator effects are favorable for the growth of B. licheniformis. In the evaporation stage, low water activity severely limits the development of A. flavithermus.

Effect of Plant-Based Mung Bean Products on Digestibility and Gut Microbiome Profiling Using In Vitro Fecal Fermentation.

The concept of plant-based protein consumption has been increasing recently because of the growing health consciousness among people. Mung bean is one of the most consumed legumes with a dense nutrient profile. Hence, current research is aimed to study the effect of mung bean protein-based products including mung bean snack (MBS) and textured vegetable protein (TVP) for treatment groups against the control groups, commercial ingredients group consisting of mung bean powder (MBP) and pea powder (PP) and commercial products group include commercial pea texture (cPT) and commercial textured vegetable protein (cTVP) for their proximate composition, digestibility, gut microbial profile and fatty acid metabolite profiling. The MBS and TVP samples had significantly higher digestibility of 74.43% and 73.24% than the commercial products. The protein content of TVP was 0.8 times higher than its commercial control. Gut microbiome profiling showed that all the samples shared around 162 similar genera. Post-fermentation analysis provided promising results by reflecting the growth of beneficial bacteria (Parabacteroides, Bifidobacterium and Lactobacillus) and the suppression of pathogens (Escherichia-Shigella, Dorea and Klebsiella). The dual relationship between gut microbiota and nutrient interaction proved the production of abundant short- and branched-chain fatty acids. The MBS sample was able to produce SCFAs (41.27 mM)significantly and BCFAs (2.02 mM) than the TVP sample (27.58 mM and 2.14 mM, respectively). Hence, our research outcomes proved that the mung bean protein-based products might infer numerous health benefits to the host due to enriched probiotics in the gut and the production of their corresponding metabolites.

Influence of the shape of the anode assembly inner channel on plasma flow velocity

This article considers how the shape of the inner channel in the anode assembly affects plasma flow velocity in a plasma torch. Three different shapes of the anode assembly were analyzed, all with a conical confusor part of 50 mm in length: with a diameter transition from 12 to 6 mm, from 12 to 8 mm, and from 12 to 10 mm. A computer experiment was performed using the finite element method and then validated by the subsequent full-scale experiment on a laboratory plasma unit. The obtained results were verified. The verification outcomes showed a satisfactory convergence and were consistent with the published data. A review of the existing plasma unit designs for powder production, application of functional coatings, and surface modification was carried out. The software packages implementing the finite element method to solve these problems were examined. The study yielded practical recommendations for consumers and developers of plasma equipment and identified the shapes of the anode assembly enabling both supersonic and subsonic plasma flow regimes.

Acerola byproducts microencapsulated by spray and freeze-drying: the effect of carrier agent and drying method on the production of bioactive powder

Abstract Bagasse, peels and seeds from fruits are usually discarded as byproducts. However, these byproducts contain high levels of bioactive compounds. The objective of this study was to microencapsulate bioactive compounds from acerola byproducts by spray drying (SD) and freeze-drying (FD) using maltodextrin (MD), gum arabic (GA), and whey protein isolate (WPI) as carrier agents and then evaluate their stability in a gelatin food-model system. Moisture, solubility, and hygroscopicity of the powders were 5.02–10.05 %, 78.83–92 %, and 7.64–14.76 %, respectively. The best method for obtaining phenolic compounds and flavonoids was SD/GA, which yielded 1855.11 mg GAE/100 g and 289.38 μg/g of quercetin. The best method for obtaining anthocyanins was FD/GA, which yielded 33.85 mg of cy-3-glu/100 g. Powder dried by SD/MD could be used as a natural dye. Our results show that acerola byproducts has potential for reuse, and microencapsulation is a good technique for generating stable extracts.

Characteristics of 3D Printed Functionally Graded Material for Replacement of Dissimilar Metal Weld in Nuclear Reactor

The dissimilar metal welds in the most of the reactors are connections between low alloy steel parts and stainless steel piping. There is a high possibility of primary water stress corrosion cracking (PWSCC) damage attributed to residual stress caused by the difference in material properties in the dissimilar metal weld joints. A number of accidents such as leakage of radioactive coolant due to PWSCC have been reported around the world, posing a great threat to nuclear safety. The objective of this study is to develop a technology that can fundamentally remove dissimilar metal welds by replacing the existing dissimilar metal parts with the functionally graded material (FGM) manufactured by metal 3D printing consisting of low alloy steel and austenitic stainless steel. A powder production, mixing ratio calculation, and metal 3D printing were performed to fabricate the low alloy steel-stainless steel FGM, and microstructure analysis, mechanical properties, and coefficient of thermal expansion (CTE) measurement of the FGM were performed. As a result, it is observed that CTE tended to increase as the austenite content increased in FGM. The gradual change of coefficient of thermal expansion in a FGM showed that the additive manufacturing using 3D printing was effective for preventing an abrupt change in thermal expansion properties throughout their layers.

Utilization of Ginger and Its Waste

Ginger has become the focus of research because of its oleoresin and essential oil content. First, the drying process can maintain the quality of post-harvest products and increase the shelf life of dry products. Applying heat by air, microwave, vacuum, and freeze-drying can remove up to 5% (w.b.) of the moisture content of the material. High temperatures provide a greater driving force and result in the best possible product damage. The involvement of an adsorption dryer can be an opportunity to carry out drying at low temperatures by involving a dehumidified air agent. Apart from drying, the extraction process is an essential component of the ginger isolation technique. In addition to temperature, the physical properties involved in this process are density and pressure (having relatively great difficulty in achieving the desired properties). Significant components with GC-MS and GLC tests gave different peak area results from the drying and extraction processes. However, β-phellandrene and camphene represent the presence of ginger essential oil in both methods. Then, the pulp and skin can also be reprocessed through extraction to produce ginger oil and ginger pulp. The sustainability of ginger residue through pyrolysis can produce ginger charcoal products. Meanwhile, the ginger pulp contains sugar, acid, and micro-fibrillation of cellulose (MFC) through hydrolysis. The results of research related to ginger provide opportunities for SMEs to produce post-harvest products in red ginger powder. The extraction process with polar solvents and the role of appropriate technology have encouraged independent economic activities. In addition, dregs from raw materials and by-products can be exploited for opportunities to reduce the waste generated.

Processing of reactive Ni−Al powders via the LabRAM**

AbstractReactive Ni−Al materials have been developed using a variety of methods, with high energy ball milling (HEBM) being one of the most common means for tailoring reaction behavior. Powder production limitations associated with HEBM, including the addition of process control agents, have inspired the exploration of an alternate manufacturing technique: acoustic dry milling with the Resodyn Laboratory Resonant Acoustic Mixer (LabRAM). The influence of acoustic milling time, intensity, and media size with respect to microstructure and reactive behavior of Ni−Al powders were evaluated in this work. After just 20 min of milling, a reactive composite Ni−Al microstructure was produced. Milling intensity and media size were directly proportional to the formation of more homogeneous composite powders. The reaction onset temperature was decreased to 446 °C, or ≈200 °C lower than that of unprocessed material. The method shows promise for the production of reactive powder for a host of applications.

Up-scaling a Sol-Gel Process for the Production of a Multi-Component Xerogel Powder.

A sol-gel process for the synthesis of a multi-component oxide material from the system SiO2-ZrO2-Al2O3underwent optimization and up-scaling. Initially, on a laboratory scale, components including precursors, catalysts, and additives were methodically evaluated to ensure a safe and efficient transition to larger volumes. Subsequently, the equipment for the whole setup of the sol-gel process was strategically selected. Leveraging insights from these optimizations, the process was successfully scaled-up to pilot-scale operation, conducting hydrolysis, condensation reactions, gelation, aging, and drying within a single, integrated conical dryer system for an 80 L batch. A visual test and FTIR spectroscopy were applied for process control and monitoring.

Mechanism of enhancing rehydration capacity and foaming property of spray-dried egg white powder by lactic acid fermentation

Spray-dried egg white powder has limited applicability as a raw material in food production due to its deteriorative rehydration capacity. Lactic acid fermentation is a promising technique for protein denaturation and has been widely used in the food industry. In this work, we investigated the effects of 4, 8, and 12-h lactic acid fermentation on protein structure, powder characteristics, rehydration capacity, and foaming property of spray-dried egg white powder. Results show that the fermentation treatment significantly reduced the surface hydrophobicity of egg white powder samples, while 8 and 12 h of fermentation significantly increased their zeta potential. During the 12 h of fermentation, the particle size of the powder gradually decreased from 2.59 μm to 1.69, 1.23, and 0.76 μm, respectively. Scanning electron microscope result shows the same and also indicates a concave hole structure in fermented egg white powders. These changes in protein molecules result in the significantly improved wettability, dispersibility, and solubility of the powder, thus enhancing its rehydration capacity. The foaming ability and foam stability of egg white powder also significantly improved after fermentation. Furthermore, the fermentation process altered the secondary structure, moisture content, bulk densities, flowability, and color of the powder. This work demonstrates the usefulness of lactic acid fermentation in enhancing the quality of egg white powder. The findings have significant implications for the development of better-quality egg white powder products in the food industry.

Metabolomic analysis reveals the effect of ultrasonic-microwave pretreatment on flavonoids in tribute Citrus powder

In this study, the ultrasonic-microwave pretreatment was defined as a processing technology in the production of tribute citrus powder, and it could increase the flavonoid compounds in the processing fruit powder. A total of 183 upregulated metabolites and 280 downregulated metabolites were obtained by non-targeted metabolomics, and the differential metabolites was mainly involved in the pathways of flavonoid biosynthesis, flavone and flavonol biosynthesis. A total of 8 flavonoid differential metabolites were obtained including 5 upregulated metabolites (6”-O-acetylglycitin, scutellarin, isosakuranin, rutin, and robinin), and 3 downregulated metabolites (astragalin, luteolin, and (−)-catechin gallate) by flavonoids-targeted metabolomics. The 8 flavonoid differential metabolites participated in the flavonoid biosynthesis pathways, flavone and flavonol biosynthesis pathways, and isoflavonoid biosynthesis pathways. The results provide a reference for further understanding the relationship between food processing and food components, and also lay a basis for the development of food targeted-processing technologies.