Maltodextrin is mainly produced from corn, wheat, potato and other starches as raw materials, which are hydrolyzed and reacted under the action of acid or enzyme. In the field of food and beverage, maltodextrin is widely used as filler, thickener, carrier, etc. With the continuous improvement of people's requirements on the taste and quality of food, as well as the continuous development of the food industry, the demand for maltodextrin will maintain a steady growth. For example, the addition of maltodextrin in confectionery can improve taste and reduce costs; as a thickener in beverages can improve taste and stability, with the continuous expansion of the beverage market size, the amount of maltodextrin will also increase accordingly. In the pharmaceutical industry, maltodextrin as a pharmaceutical excipient can be used in the production of tablets, capsules, etc. With the continuous expansion of the global pharmaceutical market and the improvement of the quality and stability of drugs, its application in the pharmaceutical field is expected to further expand. In the cosmetics industry, maltodextrin can be used as an additive to improve the texture and stability of products. As consumers' concern for the quality and safety of cosmetics continues to rise, the demand for maltodextrin will also increase.
With the continuous development of China's economy, the improvement of residents' income level and the upgrading of consumption structure, the domestic demand for maltodextrin will continue to increase. At the same time, as an important global manufacturing base, China's rapid development in the food and beverage, pharmaceutical, chemical and other industries will provide a broad space for the maltodextrin market. The market demand for maltodextrin will be more diversified and refined, and maltodextrin products with different degrees of polymerization and different DE values will be more widely used. For example, maltodextrins with low DE values have lower sweetness and stronger film-forming properties, and can be used in special applications such as microencapsulation; maltodextrins with high DE values have better solubility and hygroscopicity, and are suitable for some specific food and industrial applications. In order to improve competitiveness and reduce costs, some enterprises may expand into upstream raw material cultivation or downstream application fields through industry chain extension, realizing industry chain integration and synergistic development, and enhancing enterprises' risk-resistant ability and profitability. Develop maltodextrin products with specific properties according to the needs of different application fields to meet the market demand for product diversification and refinement. With the continuous progress of science and technology, the drying technology of maltodextrin will be constantly innovated and upgraded. Jinwang Intelligent has developed a special multi-stage fluidized granulation spray dryer for maltodextrin. By optimizing the process parameters of spray drying, such as inlet air temperature, outlet air temperature, atomizer type, process flow, etc., the drying efficiency can be increased, energy consumption can be lowered, and the particle size distribution and solubility of the product can be improved. The new equipment integrates several links in the production of maltodextrin to realize continuous and integrated production, which can reduce the material loss and energy consumption in the intermediate links, have a more stable and efficient continuous production process, reduce the intermediate links in the production process and improve the stability of product quality.
Maltodextrin granulation spray dryer process flow
(1) Feed preparation: the pre-treated maltodextrin solution will be stored in the raw material tank, the raw material solution needs to be filtered and other operations to remove impurities, in order to prevent clogging of the atomizer and other equipment to ensure the stability and purity of the feed.
(2) atomization process: through the high-pressure pump or atomizer and other devices, the maltodextrin solution at a certain pressure and speed from the nozzle spray, so that the formation of a fine mist droplets. The size of the droplets produced by atomization is inversely proportional to the pressure, and the production capacity of the nozzle is proportional to the square of the pressure. The use of high-pressure pumps to pressurize the solution to a few MPa to tens of MPa, so that the solution from the tiny nozzle holes sprayed to form a high-speed rotation of the liquid film, the liquid film is then split into tiny droplets.
(3) Drying and granulation: the atomized maltodextrin droplets are then in full contact with the filtered and heated hot air, the temperature of the hot air is usually between 180 ℃ ~ 220 ℃. In a very short period of time, the water in the droplets evaporates rapidly, and the maltodextrin is solidified to form granules. Due to the action of the surface tension of the droplets, the particles formed are mostly spherical, and their particle size can be controlled by adjusting parameters such as feed rate, atomization pressure, hot air temperature and flow rate. The formation of spherical particles of powder in the drying tower gradually settling, and hot air separation.
(4) Fluidized granulation: from the fluidized bed with the hot air flow flying field upward floating fine powder and the falling wet solid fine powder in the atomization granulation area in contact with each other, through the coating, bonding and other roles to make the particles grow up gradually. The mother liquor or binder can also be made by the pressure pump and other pressure equipment were sent to the atomization nozzle, atomized coated in the surface of the fluidized particles or particles bonded to each other, after continuous fluidization, re-polymerization, drying, the particles further growth to the required particle size.
(5) Particle discharge and collection: the particles that reach the required particle size are discharged from the fluidized bed outlet into the finished product collection device. And the finer granular material together with the drying air is extracted into the dust removal system by the extractor fan connected with the upper part of the funnel shape, and separated through the cyclone separator, the exhaust air is emptied, and the powder can be collected and re-processed to improve the utilization rate of the raw material.
(6) Screening and Packaging: The particles discharged from the bottom of the drying tower may have certain uneven distribution of particle size, which needs to be screened by the screening equipment, and the finished particles that meet the required particle size can be collected and packaged and stored, while the particles that do not meet the requirements of particle size can be returned to be re-processed.
Maltodextrin granulation spray dryer performance characteristics
(1)High drying efficiency
Fast drying: it can make the water in the maltodextrin solution evaporate rapidly in a very short time, and it takes only a few seconds to tens of seconds to complete the drying process, which greatly improves the production efficiency and is suitable for large-scale industrialized production.
High-efficiency heat exchange: special design, such as hot air distributor, etc., so that the hot air can uniformly and fully contact with the atomized maltodextrin droplets, improve the heat exchange efficiency, speed up the drying speed, but also reduce energy consumption.
(2) Excellent product quality
Uniform particles: the obtained maltodextrin particles are spherical, with uniform particle size distribution, good fluidity and good solubility, which can meet the strict requirements of different industries on the quality of maltodextrin and is conducive to subsequent processing and application.
High purity: During the drying process, due to the rapid evaporation of water, the impurities and off-flavor substances in maltodextrin can also be effectively removed, thus improving the purity and quality of the product, making it more suitable for use in food, pharmaceutical and other industries that require high purity.
Retention of nutrients and performance: For heat-sensitive maltodextrin solution, spray dryer can quickly complete the drying at low temperatures, effectively retaining its nutrients and performance, reducing the nutrient loss and quality degradation caused by high temperature drying.
(3)Convenient operation control
Precise adjustment of parameters: by adjusting the parameters such as feeding speed, atomizing pressure, hot air temperature and flow rate, the particle size, bulk density, moisture content and other indicators of the product can be precisely controlled to produce maltodextrin granules of different specifications and performance requirements to meet the diversified market demand.
High degree of automation: continuous and automatic production can be realized, which reduces manual intervention and lowers labor cost, and also improves the stability of the production process and the consistency of product quality. Equipped with advanced control system, it can monitor and control the running status of the equipment in real time, realize remote operation and fault diagnosis, and facilitate production management and maintenance.
(4) The equipment is highly stable:
Reasonable structural design: its structural composition includes feeding system, atomization system, drying system, discharging and dust removal system, etc. Each system cooperates with each other and works together to ensure the stable operation of the equipment. The cone angle of the drying tower is reasonably designed, which can avoid powder adsorption in the tower wall for too long and produce coking or melting phenomenon; equipment and pipeline internal surface finish is high, no dead ends, blind holes, the corners are rounded and over-polished, which reduces the risk of material residue and clogging.
Excellent material: the part of the equipment in contact with the material is usually made of high-quality stainless steel materials, such as SUS304 or 316L, etc., which has good corrosion resistance and hygiene, and can ensure that the product is not contaminated and prolong the service life of the equipment.
(5) Good environmental performance
Effective dust treatment: Equipped with high-efficiency cyclone separator, it can fully separate and collect the tiny powder in the exhaust gas, so that the dust content in the exhaust gas can be reduced to the range that meets the environmental protection standard, which reduces the pollution of the environment and improves the utilization rate of the raw material at the same time.
Low noise operation: In the design and manufacturing process of the equipment, advanced noise reduction technology is adopted, such as increasing the noise elimination device and optimizing the structure of the equipment, etc., so that the equipment produces low noise during operation, which is in line with the relevant national standards and improves the working environment.
Optimized design of maltodextrin granulation spray dryer
(1) Optimization of feeding system
Filtration and impurity removal: add finer filtration device on the feeding pipeline to further remove impurities and particles in the maltodextrin solution to prevent clogging the atomizer and affect product quality.
Flow control: Adopt high-precision flow sensors and controllers to precisely control the feed rate, ensure the stability and continuity of the feed, and match the working condition of the atomizer and drying system to obtain stable product quality and production efficiency.
(2) Atomization system optimization
Atomizer selection and design: according to the nature of maltodextrin solution and production requirements, select the appropriate type of atomizer and optimize the design of its structure to produce more uniform droplets, improve the drying effect and uniformity of product size.
Atomization pressure adjustment: increase the adjustment range and precision of atomization pressure, and be able to flexibly adjust the atomization pressure according to different production stages and product requirements, so as to control the size and distribution of the droplets, which in turn affects the product's particle size, bulk density and other indicators.
(3) Drying system optimization
Improvement of hot air distribution system: design a more reasonable hot air distributor, so that the hot air can be more evenly distributed in the drying tower, to ensure that the atomized maltodextrin droplets are fully in contact with the hot air, to improve the heat exchange efficiency, speed up the drying speed, while reducing product quality problems due to local overheating.
Optimize the cone angle: design the cone angle of the drying tower to be less than or equal to 40°, and install the air shocker on the cone to avoid the powder adsorption in the tower wall for too long and produce the phenomenon of coking or melting.
Increase the inner wall finish: improve the equipment and pipeline internal surface finish, so that it is less than 0.2 ~ 0.3um, and connect the transition part of the dead-end, blind-hole design, the corners of the arc over-polished to reduce the material residue and the risk of clogging.
(4)Optimization of discharging and dust removal system
Improvement of discharging method: optimize the design of discharging port, adopt continuous and stable discharging method to avoid blockage and material accumulation during discharging process, and at the same time, reduce the dust generated during discharging.
Upgrading of dust removal equipment: select more efficient cyclone separator, and reasonably design its combination of methods and parameters to improve the dust collection efficiency, so that the dust content in the exhaust gas is lower, reducing the pollution of the environment, and at the same time, the collected fine powder will be recycled and utilized to improve the utilization rate of raw materials.
(5) Control system optimization
Automation control: realize the full automation control of the equipment, through the programmable logic controller PLC or distributed control system DCS, the feeding, atomization, drying, discharging and dedusting and other aspects of the fine que control and coordinated management, reduce manual intervention, improve the stability of the production process and the consistency of product quality.
Remote monitoring and diagnosis: Equipped with remote monitoring system, real-time remote monitoring and data analysis of equipment operation status is realized through network technology, which is convenient for operators to grasp the operation of the equipment in time, carry out remote operation and troubleshooting, and improve the maintenance efficiency and operation reliability of the equipment.
(6) Energy-saving design optimization
Heat recovery and utilization: design heat recovery device to recover and reuse the heat in the discharged exhaust gas for preheating the incoming cold air or other media that need to be heated, reducing energy consumption and improving energy utilization.
Frequency conversion speed control technology application: adopting frequency conversion speed control technology for fans, pumps and other power equipment, automatically adjusting the rotational speed of the equipment according to the changes in the production load, reducing the energy consumption of the equipment and realizing energy-saving operation.
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