Common Challenges in Spray Drying Flavors

Spray drying is a proven method for producing consistent powdered flavors with extended shelf life while maintaining product integrity. However, this process poses several engineering challenges, affecting efficiency, yield, and product quality.  

In this article, Dahmes will address the common challenges and offer solutions for achieving significant optimal results for flavor drying.  

1. Flavor Quality and Consistency  

One challenge in flavor drying is preserving the flavor profile when exposed to high heat. The heat-sensitive flavor components that give products their distinctive taste and smell are easily damaged, resulting in a less flavorful final product.  

Dahmes Solution: Dahmes uses a high-pressure feed system designed to introduce a liquid product into the drying system. The pump delivers the product to the atomizing nozzle lance which atomizes the product to the drying chamber. Dahmes uses a balance tank to maintain product flow to the pump to maintain consistent product dispersion.  

The DDD-C technology, combined with an advanced two-stage drying solution, helps customers maintain a flavorful product while minimizing degradation. 

The first stage allows the product to endure a lower inlet temperature, while during the second stage, the internal fluid bed achieves final drying targets at a much lower temperature. This process enhances flavor preservation and ensures overall product consistency. 

2. Yield Loss 

Traditional spray drying systems use cyclones and wet scrubbers. When drying flavors, these components often result in significant product loss and shutdowns due to clogged ducts.  

Dahmes Solution: One of the most significant innovations in the Dahmes Spraying Drying systems is the removal of cyclones and wet scrubbers. The DDD-C is a tall form drying chamber surrounded by a baghouse. By eliminating those components, manufacturers can retain more of their product while significantly reducing waste and keeping the dryer footprint to a minimum.  

3. Cross-Contamination & Downtime Between Batches 

Flavor production facilities often handle multiple SKUs, making it critical to prevent allergen contamination and have an efficient cleaning process.  

Dahmes Solution: The Dahmes Bag-In-Place (BIP) CIP integration ensures that cleaning between runs is thorough and efficient, without the need to change filter bags. This reduces downtime and prevents no allergen cross-contamination, essential for any flavor drying system.  

4. Energy Efficiency and Process Optimization  

Spray drying is an energy-intensive process, requiring significant heat input for air heating and moisture evaporation.  

Dahmes Solution: The DDD-C requires lower airflow and pressure drop than comparable alternatives, reducing horsepower and lowering operating costs. Unlike off-the-shelf solutions, Dahmes can create systems that fit your required throughput.