Instant Tea Polyphenol is an instant drink extracted and made from tea with various health benefits. It has a strong antioxidant capacity, which can scavenge excess free radicals in the body and reduce the damage caused by free radicals to cells, thus slowing down the aging process. For example, for people who face electronic devices such as computers and cell phones for a long time, drinking instant tea polyphenols can to a certain extent resist the free radical damage produced by radiation. It can reduce the total cholesterol and triglyceride content in the blood, regulate blood lipids, reduce the risk of atherosclerosis, and thus play a preventive role in coronary heart disease, myocardial infarction and other cardiovascular diseases. With the continuous improvement of people's health consciousness, the demand for natural, healthy food and health care products continues to increase, instant tea polyphenols as a natural extract with a variety of health benefits, its market demand is expected to further expand.
The application of instant tea polyphenols in food, beverage, health care products, cosmetics, medicine and other fields is expanding, and the demand for its production equipment will also increase accordingly. With the continuous improvement of relevant industry standards and quality requirements, enterprises will also put forward higher requirements on the performance and quality of production equipment. Jiangsu Longxin produces instant tea polyphenol agglomerated granulation spray drying tower, which has significant advantages in improving production efficiency, reducing energy consumption, ensuring product quality, etc., attracting user enterprises to update and invest in the equipment, thus promoting the growth of the market scale. The new drying tower adopts advanced control system and energy-saving technology, which can realize automatic production and efficient use of energy, reduce production costs and improve the economic benefits of enterprises.
Instant tea polyphenol agglomeration spray drying tower working principle
(1) material atomization: first, the pre-treated tea polyphenol solution is transported to the top of the spray drying tower through the feeding device. Under the action of the atomizer at the top of the tower, the material solution is dispersed into extremely small droplets. There are generally two types of atomizers: centrifugal atomizers and pressure atomizers. Centrifugal atomizer rely on high-speed rotation of the disc or impeller generated by the centrifugal force, the material will be thrown out of the formation of droplets, the atomization effect is good, the droplet size is uniform, but the equipment structure is relatively complex, the power consumption is larger; pressure atomizer with the help of high-pressure pumps or diaphragm pumps pressure, so that the material through the nozzle atomized into droplets, this way of structure is simple, easy to operate, but the effect of atomization by the viscosity of the liquid and the pressure fluctuations. Slightly larger impact.
(2) hot air drying: at the same time, the dry hot air filtered through the air filter and heated by the heater, into the top or bottom of the drying tower. Hot air and atomized tea polyphenol droplets in the drying tower in full contact and heat exchange. As the surface area of the droplets is very large, after contacting with the hot air, the water in them evaporates rapidly in an instant, and the tea polyphenols are rapidly dried into fine granular substances. Usually at a temperature of 100 ℃ ~ 150 ℃, 1 ~ 3 seconds to evaporate 95% ~ 98% of the water, drying speed is extremely fast, this process can be well preserved the active ingredients of tea polyphenols and nutritional functions, especially suitable for drying tea polyphenols such heat-sensitive materials.
(3) Attachment granulation: In the drying process, the dried tea polyphenol particles will enter the attachment granulation device. Common attachment granulation device such as fluidized bed attacher, vibrating fluidized bed attacher, etc., will make part of the fine tea polyphenol particles in the airflow or vibration under the action of mutual collision, bonding, and gradually form larger particles of attachment. By controlling the relevant parameters of the agglomerated granulation device, such as air velocity, vibration frequency, etc., the size and tightness of the agglomerated particles can be adjusted to improve the product's fluidity, solubility and mixing properties, so as to make it more in line with the quality of instant tea polyphenols.
(4) Finished product discharge: after drying and agglomerated granulation, the finished instant tea polyphenol particles are discharged from the bottom of the drying tower under the effect of gravity, and then further collected and separated by cyclone separator and other equipment to get pure instant tea polyphenol products. The exhaust gas containing a small amount of water and dust is discharged by the fan, and after corresponding treatment, it meets the standard to meet the requirements of environmental protection.
Instant tea polyphenol agglomerated spray drying tower performance characteristics
(1)High drying efficiency
Rapid drying: the material liquid is atomized to form a large number of tiny droplets, greatly increasing the contact area with the hot air, in the hot air stream, can instantly evaporate 95% to 98% of the water, drying time is only a few seconds, can be completed in a short period of time drying process, high production efficiency.
Continuous production: the equipment can realize continuous operation, can uninterruptedly feed, dry and discharge, suitable for large-scale industrialized production, effectively improve production capacity and output.
(2) Good product quality
Uniform particles: the atomizer can evenly disperse the material into tiny droplets, ensuring that the particles obtained after drying have uniform particle size, high consistency and stability of the product, which is conducive to improving the quality and market competitiveness of the product.
Good solubility and fluidity: the dried tea polyphenol particles have good solubility and fluidity, can be quickly dissolved in water, convenient to use, and not easy to caking during storage and transportation.
Retention of active ingredients: the drying process is completed in a shorter period of time, and is carried out at lower temperatures, which can effectively retain the active ingredients and nutritional functions of tea polyphenols, zui degree of its antioxidant, antibacterial and other health effects, especially suitable for drying of tea polyphenols such as heat-sensitive materials.
(3)Strong controllability of production process
Convenient adjustment of parameters: by changing the operating conditions, such as feeding speed, hot air temperature, atomizer speed, etc., the particle size, bulk density, moisture content of the product can be adjusted and controlled within a certain range to meet the requirements of different users of product quality, product quality is controllable.
High degree of automation: the equipment operation is simple and stable, easy to realize automated operation, reducing manual intervention, reducing labor intensity and production costs, while also improving the stability of the production process and the consistency of product quality.
(4) Energy saving and environmental protection
High energy utilization: drying under the condition of lower exhaust temperature, compared with the traditional spray drying equipment, energy utilization can be increased by 10%~15%, reducing energy consumption and production costs, and also reducing thermal pollution to the environment.
Tail gas treatment environmental protection: the equipment is usually equipped with efficient dust removal devices, such as cyclone separator, bag filter, wet dust collector, etc., the exhaust gas containing a small amount of water and dust treatment, so that it meets the standards of discharge, reducing the pollution of dust on the environment, to meet the requirements of environmental protection.
(5)Compact structure of equipment
Small footprint: the structural design of the drying tower is relatively compact, and the required equipment installation space is relatively small, which can largely reduce the construction cost of the drying tower workshop and save the plant space and investment costs.
Low maintenance cost: the structure of the equipment is simple, the number of parts is relatively small, and the daily maintenance and repair work is more convenient, which reduces the maintenance cost and repair workload of the equipment and is conducive to improving the service life and operational reliability of the equipment.
Improvement and optimization of spray drying tower for instant tea polyphenol agglomerated granulation
(1) Product quality optimization
Refined particle control: By improving the atomizer design and optimizing the drying process parameters, etc., to achieve a more refined control of the particle size of tea polyphenol particles, particle size distribution, particle shape, etc., to produce instant tea polyphenol products with better solubility, mobility and stability, and to satisfy the higher requirements of different users for product quality.
Enhanced retention of active ingredients: research and development of milder and more efficient drying technology and process to reduce the loss of active ingredients in the drying process of tea polyphenols, zui to a large extent to retain its antioxidant, antibacterial, health care and other functional properties, to improve the added value of the product and market competitiveness.
(2) Multi-functional integration development
Integration of multiple processes: organic integration of extraction, concentration, drying, polymerization granulation and other production processes, to achieve full-flow automated production, reduce the transfer of materials between different equipment and processing time, reduce the risk of contamination in the production process, improve production efficiency and product quality and stability.
Composite function equipment research and development: the development of drying tower equipment with composite functions, such as spray drying and freeze drying, vacuum drying and other drying technologies, or in the drying tower at the same time to achieve drying, granulation, coating and other functions to meet the diverse needs of different users of the product to expand the scope of application of the equipment.
(3) Optimization of atomization system
Research and development of new type of atomizer: explore and develop more efficient and accurate atomizer. For example, research and design a combination of centrifugal force and ultrasonic vibration of the composite atomizer, the use of centrifugal force to make the initial dispersion of the material liquid, and then with the help of ultrasonic vibration to further refine the droplets, so as to obtain a smaller particle size and distribution of the droplets of a more uniform, which helps to improve the drying efficiency and consistency of product quality.
Intelligent control of atomization parameters: Introducing advanced sensor technology and automatic control system, real-time monitoring of liquid flow, viscosity, temperature and other parameters, and according to these parameters, automatically adjust the speed of the atomizer, pressure and other working parameters. Through precise intelligent regulation and control, it ensures stable and optimized atomization effect under different working conditions, and reduces product quality fluctuation due to manual operation error or working condition change.
(4) Improvement of drying and agglomeration process
Application of multi-stage drying technology: The design adopts multi-stage drying process, i.e., according to the characteristics of different stages in the drying process, different drying areas with different temperatures, humidity and air velocity are set up respectively. For example, in the initial drying stage, the hot air with higher temperature and flow rate is used to quickly remove most of the moisture, and in the later drying stage, the temperature and flow rate are reduced to avoid over-drying and loss of heat-sensitive components, and at the same time, it is conducive to the precise control of the agglomeration granulation process to improve the particle morphology and stability of the product's quality.
Strengthen the effect of agglomeration granulation: improve the internal structure of the agglomeration granulation device and the distribution of airflow, such as optimizing the design of the fluidized bed's air distribution plate, so that the airflow is more evenly distributed in the bed, and the fluidized state of the particles is more stable, thus promoting the collision and bonding between the particles in a more adequate and orderly manner. At the same time, research and development of a new type of binder or co-polymerizer addition system, according to the product demand for fine control of the amount of binder added and added position, to further enhance the effect of polymerization granulation, improve the strength of the product particles and solubility.
(5) Intelligent control and monitoring
Establishment of big data analysis platform: In the process of equipment operation, a large number of process parameters, product quality data and equipment operation status data are collected, and a big data analysis platform is established. Through the deep mining and analysis of these data, a data model is established to predict equipment failures, optimize process parameters, and guide the development of production plans, etc., so as to realize intelligent production management and decision-making support, and improve production efficiency and product quality stability.
Remote monitoring and fault diagnosis system integration: install advanced sensors and communication modules to realize the remote monitoring function of the equipment. Operators can view the running status, process parameters and product quality data of the equipment anytime and anywhere through cell phones, computers and other terminal devices, and receive equipment failure alarm information. At the same time, the integrated fault diagnosis system, using artificial intelligence algorithms to analyze the fault data, quickly and accurately diagnose the cause of the fault and provide the appropriate solutions to reduce equipment downtime and maintenance costs.
(6) Improvement of equipment material and manufacturing process
Application of high-performance materials: Adopt more corrosion-resistant, high-temperature-resistant and abrasion-resistant new materials to manufacture the key components of the drying tower, such as titanium alloy, Hastelloy, ceramic materials, etc., to improve the service life and reliability of the equipment, and to reduce the maintenance cost of the equipment.
Advanced manufacturing process promotion: introduce advanced manufacturing process and processing technology, such as laser cutting, CNC machining, 3D printing, etc., to improve the manufacturing precision and quality of the equipment, shorten the manufacturing cycle of the equipment, reduce the manufacturing cost of the equipment, and at the same time, facilitate the personalized customization and upgrading of the equipment.
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