Powder
Engineering.

Challenge Preserving flavor compounds and heat-sensitive active ingredients through the drying process while meeting quality requirements for homogeneity, stability, solubility, and sustained release.

Approach Carrier material selection and encapsulation design protect core actives. Dehumidified air and low inlet temperature profiles prevent Maillard reaction and thermal denaturation. Particle size and moisture are controlled via atomization system selection.

Challenge Spray drying of fish sauce, soy sauce, and plant extracts common in Southeast Asian food processing — controlling hygroscopicity, caking, and flavor loss at low drying temperatures.

Approach Dehumidified air introduced into the process gas and powder recovery line maintains consistent moisture content. Powder conveying temperature is optimized to prevent caking. Inert gas can be used for oxidation-sensitive materials.

Challenge Scaling from lab to semi-industrial production while maintaining consistent particle size distribution, powder flowability, and solubility across batches — critical for nutraceutical and cosmetic grade output.

Approach Process parameters established at R&D scale (SB39/TR80) are transferred to semi-industrial scale (P260/P400) using validated scale-up protocols. Analytical measurements confirm PSD, bulk density, and reconstitution performance at each stage.

Challenge Maintaining high viable bacteria rate through the spray drying process — bacteria must survive thermal and mechanical stress while achieving stable, efficient commercial production.

Approach Inlet temperature controlled at 130–180°C with outlet at 60–90°C for gentle drying. Atomization method selected based on both droplet size and bacterial sensitivity to physical contact. Process gas dehumidification further protects viability. Viable count confirmed by analytical measurement post-drying.

Challenge Powderizing high-value microalgae (Euglena, Spirulina, Pavlova) containing heat-sensitive compounds — fucoxanthin, EPA, DHA — while preserving functional activity and achieving commercial-scale output.

Approach Low-temperature spray drying with dehumidified process gas protects bioactive compounds. Closed-cycle systems using inert gas are available for oxidation-sensitive strains. PSD and surface morphology validated by SEM and laser diffraction analysis.

Challenge Converting sensitive biological actives — bacteriophage, enzyme preparations, postbiotics — into stable dry powder form without compromising biological activity or potency.

Approach Protective excipient systems and carefully controlled inlet/outlet temperatures preserve activity. Where spray drying is unsuitable, freeze granulation provides heat-free particle formation with no binder requirement and perfect compositional homogeneity.

Challenge Manufacturing amorphous solid dispersions for poorly soluble APIs — requiring organic solvent systems, precise thermal control, and regulatory-compliant process documentation.

Approach Closed-cycle spray dryers using nitrogen as process gas handle organic solvents safely. Spray drying produces spherical, amorphous particles with sharp PSD — proven scalable for DDS, DPI, and solid dispersion formulations. GMP-compatible design with full validation support (DQ/IQ/OQ/PQ).

Challenge Converting concentrated liquid botanical extracts — herbal medicine, plant protein hydrolysates, vitamin C, polyphenols — into stable, free-flowing powders with controlled dissolution and preserved bioactivity.

Approach Carrier selection (maltodextrin, modified starch, gum arabic) protects core actives during atomization. Low-temperature drying profiles minimise degradation. Encapsulation prevents oxidation during storage. SEM and PSD analysis confirm particle quality against specification.

Challenge Producing spray-dried feed additives — plasma protein, fish hydrolysate, probiotic premix — at commercial scale with consistent particle characteristics, bulk density, and palability.

Approach P260/P400 semi-industrial to industrial spray dryers handle high-volume feed production. Rotary and two-fluid atomization selected based on feed viscosity. Dehumidified air systems maintain powder quality through the recovery line. GMP-ready facility supports certified production.

Challenge Producing catalyst support powders with precise pore structure, surface area, and particle size distribution — where composition homogeneity and morphology directly determine catalytic performance.

Approach Spray drying of slurry-based catalyst precursors produces spherical granules with controlled PSD and pore distribution. Multi-method characterization (laser diffraction, image analysis, SEM, powder rheometer) validates each batch against performance specifications.

Challenge Producing ceramic and electronic material powders — zirconia, alumina, yttrium oxide, indium oxide — with perfect compositional homogeneity, spherical morphology, and no binder segregation for sintering performance.

Approach Freeze granulation produces spherical granules by spraying slurry into liquid nitrogen — eliminating segregation and binder migration. No heat, no binder required. Resulting granules show excellent dispersibility and sintering behaviour. Spray drying is available for less heat-sensitive formulations.

Challenge Powderizing synthetic resins — thermoplastic and thermosetting — into spherical particles with controlled size distribution and flowability, avoiding the irregular shapes and thermal denaturation caused by grinding.

Approach Technology selection depends on resin type and Tg/Tm. Spray drying uses precise heat balance calculations for thermoplastics. Spray cooling solidifies lipid or wax-based systems without thermal degradation. Freeze granulation handles heat-sensitive polymers with binder-free homogeneous granules.