Low temperature spray drying of carrier-free compositions

1. A spray drying process for drying a spray dryable liquid composition to a spray dried powder, wherein the spray dryable liquid composition contains no carrier, the process comprising:

providing the spray dryable liquid composition at a solids concentration not exceeding 80% by weight, based on total weight of the spray dryable liquid composition, and at a viscosity in a range of from 50 to 28,000 mPa-s;

atomizing the spray dryable liquid composition to generate an atomized spray of liquid particles of the spray dryable liquid composition into a spray drying chamber;

applying an electrohydrodynamic charge to at least one of the spray dryable liquid composition and the atomized spray of liquid particles, for electrohydrodynamic spray drying of the spray dryable liquid composition;

flowing a stream of drying fluid at a temperature not exceeding 100° C. into the spray drying chamber for flow through the spray drying chamber, to contact the spray of liquid particles therein for drying of the liquid particles to form the spray dried powder; and

discharging from the spray drying chamber effluent drying fluid and the spray dried powder dried by contact with the drying fluid in the spray drying chamber.

2. The process of claim 1 , wherein the electrohydrodynamic charge is applied to the spray dryable liquid composition.

3. The process of claim 1 , wherein the electrohydrodynamic charge is applied to the atomized spray of liquid particles.

4. The process of claim 1 , wherein the electrohydrodynamic charge is applied to the spray dryable liquid composition and to the atomized spray of liquid particles.

5. The process of claim 1 , wherein the electrohydrodynamic charge is in a range of from 0.25 to 80 kV.

6. The process of claim 1 , wherein the electrohydrodynamic charge is in a range of from 0.5 to 75 kV.

7. The process of claim 1 , wherein the electrohydrodynamic charge is in a range of from 5 to 60 kV.

8. The process of claim 1 , wherein the electrohydrodynamic charge is in a range of from 10 to 50 kV.

9. The process of claim 1 , wherein in said atomizing, the spray dryable liquid composition is sprayed through an electrohydrodynamic nozzle operatively coupled with a voltage source arranged to apply a cyclically switched voltage to the nozzle, for said applying an electrohydrodynamic charge to at least one of the spray dryable liquid composition and the atomized spray of liquid particles, for electrohydrodynamic spray drying of the spray dryable liquid composition.

10. The process of claim 1 , wherein said atomizing is conducted with an atomizer including an external electrode and a grounded nozzle.

11. The process of claim 1 , wherein said applying an electrohydrodynamic charge comprises electron beam irradiation of the atomized spray of liquid particles.

12. The process of claim 1 , wherein said atomizing is carried out so that the atomized spray of liquid particles of the spray dryable liquid composition comprise droplets of the spray dryable liquid composition having a droplet size in a range of from 10 to 300 μm.

13. The process of claim 1 , wherein the viscosity of the spray dryable liquid composition is in a range of from 50 to 5000 mPa-sec.

14. The process of claim 1 , further comprising generating localized turbulence at multiple loci in the spray drying chamber, to enhance drying of the spray dryable liquid composition in the spray drying chamber.

15. The process of claim 14 , wherein the localized turbulence is generated by injection of secondary drying fluid into the spray drying chamber.

16. The process of claim 1 , wherein the spray dryable liquid composition has a solids concentration in a range of from 50% to 70% by weight, based on total weight of the spray dryable liquid composition.

17. The process of claim 1 , wherein the spray dryable liquid composition comprises at least one product material selected from the group consisting of food materials, beverage materials, fragrance materials, pigment materials, flavor materials, pharmaceutical materials, therapeutic materials, medication materials, homeopathic materials, biological materials, probiotic materials, construction materials, formulating materials, and mixtures, blends, composites, and combinations of two or more different materials of the foregoing.

18. The process of claim 1 , wherein the spray dryable liquid composition comprises at least one product material selected from the group consisting of apple juice, tea, coffee, pear juice, amino acids, fruit purees, pectin, beef broths, gelatin, pharmaceutical products, beet juice, grape juice, pineapple juice, betacyclodextran, lime juice, skim milk, carrageenan, liquid egg, sugars, cheese whey, beers, low alcohol beer, vegetable juices, chicken broth, mango juice, whey protein, citrus juice, orange juice, and whole milk.

19. The process of claim 1 , wherein the temperature of the stream of drying fluid flowed into the spray drying chamber is below at least one of 100° C., 99° C., 98° C., 95° C., 90° C., 85° C., 80° C., 75° C., 70° C., 65° C., 60° C., 55° C., 50° C., 45° C., 40° C., 30° C., 25° C., 22° C., 20° C., 18° C., 16° C., 15° C., 14° C., 13° C., 12° C., 11° C., and 10° C., and said temperature is above freezing point of the liquid in the spray dryable liquid composition.

20. The process of claim 1 , wherein the stream of drying fluid flowed into the spray drying chamber has a relative humidity in a range in which the lower end point of the range is any one of 10 −4 %, 10 −3 %, 10 −2 %, 10 −1 %, 1%, 1.5%, or 2%, and in which the upper end point of the range is greater than the lower end point of the range, and is any one of 35%, 30%, 20%, 15%, 12%, 10%, 8%, 6%, 5%, 4%, 3%, 2.5%, 2%, 1.8%, 1.6%, 1.5%, 1.4%, 1.3%, 1.2%, 1.1%, 1.0%, 0.9%, 0.8%, 0.7%, 0.6%, 0.5%, 0.4%, 0.3%, 0.2%, 0.1%, 0.05%, 0.02%, 0.01%, or 0.05%.