Spray-drying Process Research Articles

Preparation and characterization of lysozyme loaded liposomal dry powder inhalation using non-ionic surfactants

Delivering protein drugs through dry powder inhalation (DPI) remains a significant challenge. Liposomes offer a promising solution, providing protection for proteins from external environment and controlled release capabilities. Furthermore, the use of non-ionic surfactants plays a crucial role in protecting the activity of proteins because of how the surfactants positioning themselves at the liquid–gas interface during the spray-drying process. In this study, lysozyme-loaded liposomal DPI formulations were prepared using various non-ionic surfactants, including polysorbate 80, poloxamer 188, poloxamer 407, and sucrose stearate. Lysozyme solution and 1,2-distearoyl-sn-glycero-3-phosphatidylcholine liposomes were subjected through high-pressure homogenization to form lysozyme-loaded liposomes. Formulations of homogenized lysozyme liposomes were spray-dried and further characterized. The particle size of reconstituted liposomal lysozyme DPI was from 129.5 to 816.9 nm. The formulations showed encapsulation efficiency up to 32.5% with zeta potential value of around − 30 mV, and spherical structures were observed. The aerosol dispersion performance of the dry powder inhalers was evaluated with emitted doses reaching up to 103% and fine particle fractions up to 28.4%. Significantly higher lysozyme activity was confirmed in formulation with drug to PS 80 ratio of 1: 0.5 w/w (92.1%) compared to that of formulation containing no surfactant (59.8%). The formulation stood out as the only formulation that maintained protein activity while demonstrating good aerosol performance.

Valorization of Sour Buttermilk (A Potential Waste Stream): Conversion to Powder Employing Reverse Osmosis and Spray Drying.

Reverse osmosis (RO) is known for the economic dewatering of dairy streams without any change in phase. At the household level, surplus milk is fermented and churned to obtain butter, which is subsequently heated to obtain clarified milk fat (ghee). The production of 1 kg ghee generates 15-20 kg sour buttermilk (SBM) as a by-product that is mostly drained. This causes a loss of milk solids and environmental pollution. The processing, preservation and valorization of SBM are quite challenging because of its low total solids (TS) and pH, poor heat stability and limited shelf life. This investigation aimed to transform SBM into a novel dried dairy ingredient. SBM was thermized, filtered, defatted and concentrated at 35 ± 1 °C, employing RO up to 3.62× (12.86%). The RO concentrate was subsequently converted into sour buttermilk powder (SBMP) by employing spray drying. SBMP was further characterized for its physicochemical, reconstitution and functional properties; rheological and morphological characteristics; and amino acid and fatty acid profiling, along with FTIR and XRD spectra. SBMP was "instant soluble-3 s" and exhibited excellent emulsion stability (80.70%), water binding capacity (4.34 g/g of protein), flowability (28.36°) and antioxidant properties. In nutshell, a process was developed for the valorization of sour buttermilk to a novel dairy ingredient by employing reverse osmosis and a spray-drying process.

Electrical bridging effects of dual-carbon microsphere frameworks in Si-based composite anodes for high-performance Li-ion batteries

Herein, the successful fabrication of a high-performance Si-based composite Li-ion battery (LIB) anode, comprising a dual-carbon framework of reduced graphene oxide (r-GO) and oxidized single-walled carbon nanohorns (o-NHs), was demonstrated using a simple and scalable spray-drying process followed by heat treatment (h-s-GO/Si/NH). The r-GO nanosheets in the h-s-GO/Si/NH anode acted as a robust spherical framework that facilitated the mechanical and electrical connection between the carbon-coated Si (c-Si) nanoparticles, homogeneous dispersion of c-Si and o-NH nanoparticles, and suppression of the volume expansion and pulverization that occur during lithiation/delithiation. Additionally, the o-NH nanoparticles incorporated in the h-s-GO/Si/NH composite served as electrical bridges between the r-GO nanosheets, resulting in enhanced electrical conductivity and effortless Li-ion shuttling. The h-s-GO/Si/NH composite anode exhibited high electrochemical performance with a very high initial gravimetric charge capacity (2961 mAh g−1 at 0.1 A g−1), stable initial Coulombic efficiency (80.6% at 0.2 A g−1), and high cycling stability (983 mAh g−1 at 0.2 A g−1 after 50 cycles). This study highlights the importance of the effective design of electrically conductive three-dimensional frameworks in Si-based composite anodes, which may contribute to the development of high-performance LIB anode materials.

Preclinical Investigation of a Lipoglycopeptide Dry Powder Inhalation Therapy for the Treatment of Pulmonary MRSA Infection.

The increased prevalence of pulmonary methicillin-resistant Staphylococcus aureus (MRSA) infection in patients living with cystic fibrosis (CF) is concerning due to a correlation with reduced life expectancy and lack of available treatment options. RV94 is a next generation lipoglycopeptide designed for pulmonary delivery that preclinically demonstrated high potency against MRSA in planktonic and protected colonies and improved pulmonary clearance relative to same class molecules. Here, RV94 was formulated into a dry powder for inhalation (DPI) to investigate the localized treatment of pulmonary MRSA presented in a potentially more convenient dosage form. RV94 DPI was generated using a spray-drying process with 12.5 wt% trileucine and demonstrated aerosol characteristics (2.0 μm MMAD and 73% FPF) predictive of efficient pulmonary deposition. In vivo PK from a single dose of RV94 DPI delivered by inhalation to rats yielded lung levels (127 μg/g) much greater than the MRSA minimum inhibitory concentration (0.063 μg/mL), low systemic levels (0.1 μg/mL), and a lung t1/2 equal to 3.5 days. In a rat acute pulmonary MRSA model, a single dose of RV94 DPI delivered by inhalation either up to seven days prior to or 24 h after infection resulted in a statistically significant reduction in lung MRSA titer.

Role of Hydrophobic Attraction and Hydrophobic Nanoconfined Channels in the Spray Drying Process for Synthesizing Hollow Microspheres from Silica Sol

Role of Hydrophobic Attraction and Hydrophobic Nanoconfined Channels in the Spray Drying Process for Synthesizing Hollow Microspheres from Silica Sol

Heat and Mass Transfer in Spray Drying Processes with Convective-Radiant Energy Supply

Heat and Mass Transfer in Spray Drying Processes with Convective-Radiant Energy Supply

Production of betalain-rich Opuntia ficus-indica peel flour microparticles using spray-dryer: A holist approach

This study aimed to obtain a betalain-rich extract (BRE) from Opuntia ficus-indica peels and protect them through a holistic approach involving microencapsulation via spray-drying. To enhance the stability of the microencapsulated betalains, an antioxidant-rich extract (ARE) obtained through hydrothermal extraction from the residual material remaining after the conventional extraction of betalains was used as a stabilizer during the spray-drying process. The antioxidant activity of the ARE was evaluated by measuring its IC50 value for 2,2-Diphenyl-1-picrylhydrazyl (DPPH) of 65.8 μg/mL, its Trolox equivalent antioxidant capacity (TEAC) of 60.4 gTrolox eq./100 g, and its reducing power of 16.6 g butylated hydroxytoluene (BHT) eq./100 g. Spray-drying parameters were optimized using a Box-Behnken design to enhance the total betalain content and minimize by-product formation. The results demonstrated that the addition of the ARE significantly improved the stability of betalains during spray-drying, leading to the formation of microparticles with high betalain content and enhanced stability. The optimal conditions (0.72% starch, 1.50% BRE and 0.25% ARE) resulted in microparticles with a maximum concentration of 6.74 ± 0.09 mgBetalains/g. The predictive model exhibited high accuracy in estimating experimental values. This research provides a natural and sustainable solution for food coloring by effectively utilizing discarded Opuntia ficus-indica peel. Moreover, it offers new scientific understanding on the production of betalain-rich microparticles as a possible substitute for food coloring, with considerable benefits in terms of sustainability and high antioxidant capacity.

Bergamot juice powder with high bioactive properties: Spray-drying for the preservation of antioxidant activity and ultrasound-assisted extraction for enhanced phenolic compound extraction.

The spray-drying process yielded functional bergamot juice powder with high antioxidant activity, phenolic content, and vitamin C content. Optimal drying conditions were determined as 10% maltodextrin concentration, 146.02°C inlet temperature, and 39.99% pump rate, preserving powder's bioactive properties. Under these drying conditions, bergamot juice powder exhibited an antioxidant activity of 62.2% DPPH scavenging activity, a total phenolic content of 3862.1ppm, and a vitamin C content of 1385.9ppm. The bergamot juice powder, with a water activity of 0.2, bulk density of 0.4g/mL, tapped density of 0.5g/mL, porosity of 89.6%, hygroscopicity of 8.6%, and cohesiveness of 37.2%, is highly suitable for further processing. High-pressure liquid chromatography analysis revealed the presence of major phenolic compounds in both fresh bergamot juice and spray-dried powder, although their concentrations were lower in the powder form. The major phenolics identified in the fruit juice were naringin (197.5ppm), eriocitrin (105.9ppm), neoeriocitrin (53.4ppm), neohesperidin (68.8ppm), and naringenin (119.8ppm). However, in the powder form, the bitterness-associated compounds, naringin and neohesperidin, exhibited a significant reduction of 85.0% and 90.3%, respectively. Compared to dimethyl sulfoxide (48.4%), ethanol (37.9%), and distilled water (17.3%), ultrasound-assisted extraction with acetone solvent demonstrated the highest efficiency (61.7%) in obtaining phenolic compounds from bergamot juice powder. In conclusion, spray-drying is an effective method for obtaining functional bergamot juice powder, and ultrasound-assisted extraction can further enhance phenolic compound extraction efficiency. These findings have potential applications in the food, cosmetics, and pharmaceutical industries, with opportunities for further research in functional foods or nutraceuticals. PRACTICAL APPLICATION: Spray-drying yields functional bergamot juice powder with high bioactive properties. Optimal drying conditions can be applied in industrial settings. Ultrasound-assisted extraction enhances phenolic compound extraction efficiency. Potential applications in food, cosmetics, and pharmaceutical industries.

3D Na3MnTi(PO4)3@C microspheres anchored on MWCNTs as advanced electrodes for sodium energy storage

Herein, we introduce an efficient strategy to fabricate 3D MWCNTs-enhanced Na3MnTi(PO4)3@C (abbreviated as 3D-NMTP@C/MWCNTs) microsphere via the simple spray-drying process followed by the solid-state annealing way. In these microspheres, the Na3MnTi(PO4)3@C (abbreviated as NMTP@C) nanoparticles are anchored on 3D MWCNTs, constructing a conductive transport pathway for electron and Na+. As a result, the resulted 3D-NMTP@C/MWCNTs electrode possesses superior battery properties for sodium energy storage. It displays a high capacity of 163.7 mAh g−1 at 0.1C. Furthermore, it exhibits a reversible capacity of 100.3 mAh g−1 over 400 cycles at 10C. These results suggest that the as-synthesized 3D-NMTP@C/MWCNTs microspheres can be employed as advanced electrodes in high-property sodium energy storage.

Microencapsulation of Betaxanthin Pigments from Pitahaya (Hylocereus megalanthus) By-Products: Characterization, Food Application, Stability, and In Vitro Gastrointestinal Digestion.

The yellow pitahaya peels generated as by-products during the consumption and processing of the fresh fruit are a rich and underutilized source of betaxanthins (natural yellow-orange pigment with antioxidant activity) and mucilage (structuring material used in the spray-drying process), molecules of high interest for the food industry. In this work, the betaxanthin-rich extract (BRE) obtained from this by-product was microencapsulated by spray drying (SD) using pitahaya peel mucilage (MPP) and maltodextrin (MD) as wall materials. Both types of microencapsulates (i.e., SD-MPP and SD-MD) retained high betaxanthin content (as measured by UV-vis) and antioxidant activity (ORAC). These microencapsulates were characterized structurally (FTIR and zeta potential), morphologically (SEM and particle size/polydispersity index), and thermally (DSC/TGA). The powdered microencapsulates were incorporated into the formulation of candy gummies as a food model, which were subjected to an in vitro gastrointestinal digestion process. The characterization study (FTIR and antioxidant activity) of the microcapsules showed that the fruit peel mucilage favors the retention of betaxanthins, while the SEM analysis revealed a particle size of multimodal distribution and heterogeneous morphology. The addition of SD-MPP microcapsules in the candy gummy formulation favored the total dietary fiber content as well as the gumminess and chewiness of the food matrix; however, the inhibition of AAPH• (%) was affected. The stability of the yellow color in the gummies after 30 days of storage indicates its suitability for storage. Consequently, the microencapsulation of betaxanthins with pitahaya peel mucilage can be used as a food additive colorant in the food industry, replacing synthetic colorants, to develop products with beneficial qualities for health that can satisfy the growing demand of consumers.

Heat and Mass Transfer in Spray Drying Processes with Convective-Radiant Energy Supply

Heat and Mass Transfer in Spray Drying Processes with Convective-Radiant Energy Supply

Structure and in vitro digestion characteristics of skim goat milk protein during processing: effects of fat separation.

Although nonfat milk has been used worldwide in the industrial dairy process, little is known about the effects of fat separation during the manufacturing process on skim milk's structural and digestive properties. This study investigated the effects of the manufacturing process on the structure and in vitro digestion properties of skim goat milk, particularly emphasizing fat separation. Changes in the surface charge and hydrophobicity of milk proteins caused by fat separation resulted in oxidation and aggregation in the subsequent homogenization, heat and spray-drying processing, which affected its digestibility. Compared with separation by dish separator (DS), skim milk after tubular centrifugal separation (CS) showed a higher initial and final digestibility. The CS samples also had a lower surface hydrophobicity level and higher free sulfhydryl content, ζ-potential, and average particle size (P < 0.05). Goat milk protein after CS was more readily oxidized and aggregated during the subsequent homogenization and heat treatment, as evidenced by the higher carbonyl content and particle size. Centrifugal separation also converted more β-sheets to α-helices, thus promoting the aggregation of oxidized skim milk protein. The skim milk after CS and DS demonstrated different structural and digestive properties. Skim goat milk products after CS were more susceptible to oxidant-induced protein structural changes, resulting in higher protein digestibility. These findings provide insights into the mechanism involved in the control of gastric digestion of skim milk during manufacturing process. © 2023 Society of Chemical Industry.

Strategizing Spray Drying Process Optimization for the Manufacture of Redispersible Indomethacin Nanoparticles Using Quality-by-Design Principles

Strategizing Spray Drying Process Optimization for the Manufacture of Redispersible Indomethacin Nanoparticles Using Quality-by-Design Principles

A powdered mix of cape gooseberry-based pulp, seed, and peel: Optimization of formulation and spray-drying process

BACKGROUND: Cape gooseberry (CG) is a fruit with nutritional and sensory attributes that generate significant consumer interest. Consumption patterns of this fruit must be in line with the diversification of its value-added products to be offered to new markets. OBJECTIVE: The research aim was to optimize the encapsulants formulation and the spray-drying (SD) process for developing of a powdered mix (PMCG) of CG based pulp, seed and peel, using the response surface methodology (RSM). METHODS: A RSM was used, with a face-centered central composite experimental design (α= 1). The independent variables (IV) were gum arabic (GA) (1 – 3% w/w), maltodextrin (MD) (11,5 – 13,5% w/w), air inlet temperature (AIT) (130 – 160 °C), air outlet temperature (AOT) (75 – 85 °C), and atomizer disc speed (ADS) (18000 – 22000 rpm). The dependent variables (DV) of the PMCG were moisture, solubility, hygroscopicity, wettability (We), color coordinates L* and b*, total phenols (TP), antioxidant capacity, and yield. RESULTS: The experimental optimization presented a desirability of 68.0%, with GA and MD levels in the PMCG of 2.2 and 10.1% p/p, respectively, and process conditions of AIT = 160 °C, AOT = 77.8 °C and ADS = 21450 rpm. The IV with the most significant effect on the DV was the MD. It was observed that the increase in MD decreases the PMCG moisture content, hygroscopicity, and the content of bioactive compounds, but increases the solubility and the values of L* and b*. The SD process was an effective technology that allowed obtaining PMCG with excellent quality attributes. CONCLUSIONS: In the process, greater use was made of the structure of the CG (pulp, seed, and peel), which gave high CG solids to the PMCG obtained and allowed more effective use of the fruit and higher economic viability in the SD process.

Evaluation of the Survival of Lactobacillus fermentum K73 during the Production of High-Oleic Palm Oil Macroemulsion Powders Using Rotor-Stator Homogenizer and Spray-Drying Technique.

This study aimed to evaluate the survival of the probiotic Lactobacillus fermentum when it is encapsulated in powdered macroemulsions to develop a probiotic product with low water activity. For this purpose, the effect of the rotational speed of the rotor-stator and the spray-drying process was assessed on the microorganism survival and physical properties of probiotic high-oleic palm oil (HOPO) emulsions and powders. Two Box-Behnken experimental designs were carried out: in the first one, for the effect of the macro emulsification process, the numerical factors were the amount of HOPO, the velocity of the rotor-stator, and time, while the factors for the second one, the drying process, were the amount of HOPO, inoculum, and the inlet temperature. It was found that the droplet size (ADS) and polydispersity index (PdI) were influenced by HOPO concentration and time, ζ-potential by HOPO concentration and velocity, and creaming index (CI) by speed and time of homogenization. Additionally, HOPO concentration affected bacterial survival; the viability was between 78-99% after emulsion preparation and 83-107% after seven days. The spray-drying process showed a similar viable cell count before and after the drying process, a reduction between 0.04 and 0.8 Log10 CFUg-1; the moisture varied between 2.4% and 3.7%, values highly acceptable for probiotic products. We concluded that encapsulation of L. fermentum in powdered macroemulsions at the conditions studied is effective in obtaining a functional food from HOPO with optimal physical and probiotic properties according to national legislation (>106 CFU mL-1 or g-1).

Enhancing viability of dried lactic acid bacteria prepared by freeze drying and spray drying via heat preadaptation.

Physical injury carried by dried process was an inevitable and hostile problem which could seriously affect the quality and viability of microbial agents. In this study, heat preadaptation was successfully applied as a pretreatment to fight against the physical stresses encountered during freeze-dried and spray-dried process and develop a high activity Tetragenococcus halophilus powder. The results indicated T. halophilus cells maintained a higher viability in dried powder when cells were treated with heat preadaptation before dried process. Flow cytometry analysis illustrated that heat preadaptation contributed to maintain a high membrane integrity during dried process. Besides, glass transition temperatures of dried powder increased when cells were preheated, which further verified that higher stability was obtained in group preadaptation during shelf life. Additionally, dried powder prepared by heat shock presented a better fermentation performance, suggesting heat preadaptation may be a promising strategy to prepare bacterial powder by freeze drying or spray drying.

Graphene-Wrapped Composites of Si Nanoparticles, Carbon Nanofibers, and Pyrolytic Carbon as Anode Materials for Lithium-Ion Batteries

Silicon (Si) anode materials have received much attention on account of their unparalleled theoretical specific capacity, but they suffer from huge volumetric expansion and particle pulverization, which leads to rapid capacity fading and poor electrical conductivity as well. In this work, a quaternary silicon/carbon (Si/C) composite anode material is proposed which combines the advantages of both graphene and the three-dimensional carbon framework through rational structural design and simple synthesis methods. Nanosilicon/carbon nanofibers/pyrolytic carbon (SCC) composite particles are first synthesized by spray drying and pyrolysis, which are then wrapped by graphene nanosheets through a second spray drying and pyrolysis process to obtain the final product (SGCC). In this composite, a 3D carbon skeleton composed of carbon nanofibers and pyrolytic carbon serves as an electric conductive matrix that supports and stabilizes Si nanoparticles, while graphene nanosheets wrapped on the surface further improve the conductivity and structure stability of the composite particles, and isolate the particles from direct contact with electrolytes. Meanwhile, the rich pores of the composite particles can effectively provide space for the volume expansion of Si during lithiation. As a consequence, the as-prepared SGCC composite shows a high initial Coulomb efficiency of 84.7%, a high reversible capacity of 2150.8 mA h g–1, and a good capacity retention rate of 83.75% after 100 cycles.

Spray-Dried Animal Plasma as a Multifaceted Ingredient in Pet Food.

Plasma is a co-product from pork and beef obtained during the processing of animals for human consumption. The spray-drying process maintains the solubility of spray-dried animal plasma (SDAP) and its nutritional and functional properties, making this ingredient multifunctional in human and animal nutrition. In pet food, SDAP has been used in the production of wet foods (pates and chunks in gravy) as an emulsifying and binding agent, with the potential to replace hydrocolloids partially or totally, which have some negative implications for digestibility, fecal quality, and intestinal inflammation. From a nutritional point of view, SDAP has high digestibility and an amino acid profile compatible with high-quality ingredients, such as powdered eggs. Studies in companion animals, especially in cats, have shown that SDAP is an ingredient with high palatability. Despite the immunomodulatory, anti-inflammatory, prebiotic, and neuroprotective properties demonstrated in some animal models, there are still few publications demonstrating these effects in dogs and cats, which limits its use as a functional ingredient for these species. In this review, the potential use of SDAP in pet food, aspects related to the sustainability of this ingredient, and opportunities for studies in companion animals are discussed.

Review of the Scalable Core-Shell Synthesis Methods: The Improvements of Li-Ion Battery Electrochemistry and Cycling Stability.

The demand for lithium-ion batteries has significantly increased due to the increasing adoption of electric vehicles (EVs). However, these batteries have a limited lifespan, which needs to be improved for the long-term use needs of EVs expected to be in service for 20 years or more. In addition, the capacity of lithium-ion batteries is often insufficient for long-range travel, posing challenges for EV drivers. One approach that has gained attention is using core-shell structured cathode and anode materials. That approach can provide several benefits, such as extending the battery lifespan and improving capacity performance. This paper reviews various challenges and solutions by the core-shell strategy adopted for both cathodes and anodes. The highlight is scalable synthesis techniques, including solid phase reactions like the mechanofusion process, ball-milling, and spray-drying process, which are essential for pilot plant production. Due to continuous operation with a high production rate, compatibility with inexpensive precursors, energy and cost savings, and an environmentally friendly approach that can be carried out at atmospheric pressure and ambient temperatures. Future developments in this field may focus on optimizing core-shell materials and synthesis techniques for improved Li-ion battery performance and stability.

Staphylococcus aureus inactivation and maintenance of macronutrients of human milk by high hydrostatic pressure and spray-drying process

Los bancos de leche humana (BLH) utilizan la pasteurización y congelación, como principales métodos de conservación para la leche humana (LH). Sin embargo, su valor nutricional disminuye durante la descongelación y almacenamiento. El objetivo del presente estudio fue evaluar el efecto de las altas presiones hidrostáticas (APH) y el secado por aspersión sobre los macronutrientes, la calidad microbiológica e inactivación de Staphylococcus aureus en LH. Para ello, se realizó la cuantificación de proteínas, lípidos, carbohidratos, cenizas, bacterias lácticas, mesófilos aerobios, coliformes, mohos, levaduras y S. aureus. Los resultados mostraron que S. aureus y los grupos microbianos evaluados fueron reducidos por debajo del límite permitido por los BLH (&lt;10 UFC/mL). Mientras que las concentraciones de macronutrientes permanecieron sin cambio durante todo el proceso de conservación. El uso de fibra soluble durante el proceso de secado permitió obtener un rendimiento mayor al 99 %. El polvo mostró alta solubilidad y bajos niveles de humedad y actividad en agua; las cuales son propiedades deseables en los alimentos deshidratados. Por lo tanto, la combinación de HHP y el proceso de secado por aspersión demostró ser una alternativa que facilitar el manejo, mejora la calidad microbiana y permite la adición de oligosacáridos manteniendo el valor nutricional de la LH.