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Vacuum drying

vacuum drying cabinets and belt drier

Franco Ferrari
Manager Drying Division
BUCHER Drying Technology

Process
y Vacuum drying
Applications
y Food
y Pharma & Cosmetic
y Chemicals
Proporties
y gently drying
y close and hygienic
y preservation of active substances
y low specific energy consumption

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VTS Basic Flow Sheet

Drying Technology r2_0404 Page 3


VTS GMP Pharma research UK

VTS 0,25 m2 SS Halar lined , electr. controller + line printer


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VTS GMP Pharma research UK

VTS 1 m2 Hastelloy , PLC and Touch Screen


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VTS GMP Pharma production USA

VTS 3 m2 ( SS Halar lined )

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VTS GMP Pharma production

VTS 24 m2 SS 316 L
VTS 8 m2 ( Hastelloy) for USA elecropolished for DE

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VTS GMP Pharma production

VTS 30 m2 ( SS + Säkaphen lined )


Heating plates Hastelloy) for CH

VTS 52 m2 SS 316 L for CH

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VTS for fruits / vegetables (USA )

VTS 60 m2 ( SS 316 )
with electro heating, condenser
and chiller

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Differents drier types ( selection )

Drum drier Thin film drier

Spray drier

Rotary mixer drier Double cone drier

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Spray drier

Is spray drying a gentle process ?

No, because the product can be


damaged by :

y spraying
y spraying under high pressure

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Solution for sticky products

What happens to adhesive products


during spray drying?
y Sticking to the walls
y Production loss

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Vacuum belt drier

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Vacuum belt drier solution

Drying in the vacuum belt


drier is a gentle process :

y product resting on the belts


y no mechanical stress
y no problem with adhesive
products during drying

Drying Technology r2_0404 Page 14


Switching variants of the belts

Belts connected in parallel Belts connected in series


( for liquid or pasty products ) ( for free flowing granules or powders )

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Drying of liquid or pasty products

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Drying of liquid or pasty products

Vacuum plant
swivel feed dryer belt drive

product crusher
PRODUCT
INLET
liquid or pasty

product breaker

heating heating heating cooling


zone 1 zone 2 zone 3 zone 4

feed pump Vacuum plant


product mill discharge system

PRODUCT
OUTPUT

Drying Technology r2_0404 Page 17


Drying profile

Zone 1

evaporation rate heating plates temperature


product temperature evaporation temperature
limit product temperature

Zone 3

Vacuum belt drying


typical process profile

Drying Technology r2_0404 Page 18


Temperature profile

Product temperature
Product = pure Anthocyanin 60 % DS / no carrier
50,0
Z1 heating 100 °C Z2 heating 90 °C Z3 heating 80 °C Z4 cooling 25 °C
45,0

vacuum 15 mbar
40,0
Temperature ( °C )

Drying time 60 min


35,0

30,0

25,0

20,0

15,0
0,0 10,0 20,0 30,0 40,0 50,0 60,0
Zime ( min )

Drying Technology r2_0404 Page 19


Product behaviour : Zone 1

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Product behaviour: zones 2 and 3

Zone 2

Zone 3
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Product behaviour : zones 4

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Product behaviour : feeding

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Product behaviour : at belt end

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Advantages of vacuum belt drying
Gentle drying
y low drying temperatures( optimized temperature profile )
y suitable as continuous operated vacuum freeze drier

y drying to low residual moisture with no mechanical stress on product


y aroma retention or improvement ( Maillard reactions => reaction flavors)
y no oxidation of the product ( no change in taste )

High quality products even for difficult applications


y vacuum foam drying for excellent instant properties
y suitable for hygroscopic end products
y suitable for sticky or high viscous produtcs
y best technology to dry natural products without adding a filler
y continuous product quality
y short and defined residence time in the drier

Drying Technology r2_0404 Page 25


Advantages of vacuum belt drying (2 )

Economic and ecological


y minimum energy requirement
y environment-friendly
y closed system, hygienic operating conditions
y no risk of product contamination
y minimal product losses

Further advantages
y fully automatic production
y fully automatic CIP cleaning
y integrated cooling on the last zone
y coarse milling under vacuum
y optimal setting of different operating parameters

Drying Technology r2_0404 Page 26


Vacuum cabinet <=> Vacuum belt drier

Comparison of BUCHER Drying Vacuum cabinet Continuous


systems DryCab Vacuum belt drier
DryVac, DryBand, DryLab
Wet products low viscosity to solids pumpable liquids, free-flowing
solids
Vacuum / pressure variable ( Profile ) constant
( including freeze drying )
Temperature ( inkl. Kühlung ) variable ( Profile ) selectable for each zone
Product foaming slow immediately after feeding
( difficult to control ) (controlled via temperature,
vacuum and nozzle type )
Product crusher external integrated
Contamination danger moderate to high none
( open system ) ( closed system )
Moisture absorption risk moderate to high none to low
( open system ) ( closed system )
Operating costs ( handling ) high very slight
Cleaning costs moderate to low low ( CIP cleaning )
( optional CIP cleaning )
Energy costs moderate low
Operating mode manual ( loading ) and automatic automatic
control of the process parameters

Drying Technology r2_0404 Page 27


Vacuum cabinet <=> Vacuum belt drier

Comparison of BUCHER Drying Vacuum cabinet Continuous


systems DryCab Vacuum belt drier
DryVac, DryBand, DryLab
Wet products low viscosity to solids pumpable liquids, free-flowing
solids
Vacuum / pressure variable ( Profile ) constant
( including freeze drying )
Temperature ( inkl. Kühlung ) variable ( Profile ) selectable for each zone
Product foaming slow immediately after feeding
( difficult to control ) (controlled via temperature,
vacuum and nozzle type )
Product crusher external integrated
Contamination danger moderate to high none
( open system ) ( closed system )
Moisture absorption risk moderate to high none to low
( open system ) ( closed system )
Operating costs ( handling ) high very slight
Cleaning costs moderate to low low ( CIP cleaning )
( optional CIP cleaning )
Energy costs moderate low
Operating mode manual ( loading ) and automatic automatic
control of the process parameters

Drying Technology r2_0404 Page 28


Vacuum cabinet <=> Vacuum belt drier

Comparison of BUCHER Drying Vacuum cabinet Continuous


systems DryCab Vacuum belt drier
DryVac, DryBand, DryLab
Wet products low viscosity to solids pumpable liquids, free-flowing
solids
Vacuum / pressure variable ( Profile ) constant
( including freeze drying )
Temperature ( inkl. Kühlung ) variable ( Profile ) selectable for each zone
Product foaming slow immediately after feeding
( difficult to control ) (controlled via temperature,
vacuum and nozzle type )
Product crusher external integrated
Contamination danger moderate to high none
( open system ) ( closed system )
Moisture absorption risk moderate to high none to low
( open system ) ( closed system )
Operating costs ( handling ) high very slight
Cleaning costs moderate to low low ( CIP cleaning )
( optional CIP cleaning )
Energy costs moderate low
Operating mode manual ( loading ) and automatic automatic
control of the process parameters

Drying Technology r2_0404 Page 29


Vacuum cabinet <=> Vacuum belt drier

Comparison of BUCHER Drying Vacuum cabinet Continuous


systems DryCab Vacuum belt drier
DryVac, DryBand, DryLab
Wet products low viscosity to solids pumpable liquids, free-flowing
solids
Vacuum / pressure variable ( Profile ) constant
( including freeze drying )
Temperature ( inkl. Kühlung ) variable ( Profile ) selectable for each zone
Product foaming slow immediately after feeding
( difficult to control ) (controlled via temperature,
vacuum and nozzle type )
Product crusher external integrated
Contamination danger moderate to high none
( open system ) ( closed system )
Moisture absorption risk moderate to high none to low
( open system ) ( closed system )
Operating costs ( handling ) high very slight
Cleaning costs moderate to low low ( CIP cleaning )
( optional CIP cleaning )
Energy costs moderate low
Operating mode manual ( loading ) and automatic automatic
control of the process parameters

Drying Technology r2_0404 Page 30


Vacuum cabinet <=> Vacuum belt drier

Comparison of BUCHER Drying Vacuum cabinet Continuous


systems DryCab Vacuum belt drier
DryVac, DryBand, DryLab
Wet products low viscosity to solids pumpable liquids, free-flowing
solids
Vacuum / pressure variable ( Profile ) constant
( including freeze drying )
Temperature ( inkl. Kühlung ) variable ( Profile ) selectable for each zone
Product foaming slow immediately after feeding
( difficult to control ) (controlled via temperature,
vacuum and nozzle type )
Product crusher external integrated
Contamination danger moderate to high none
( open system ) ( closed system )
Moisture absorption risk moderate to high none to low
( open system ) ( closed system )
Operating costs ( handling ) high very slight
Cleaning costs moderate to low low ( CIP cleaning )
( optional CIP cleaning )
Energy costs moderate low
Operating mode manual ( loading ) and automatic automatic
control of the process parameters

Drying Technology r2_0404 Page 31


Vacuum cabinet <=> Vacuum belt drier

Comparison of BUCHER Drying Vacuum cabinet Continuous


systems DryCab Vacuum belt drier
DryVac, DryBand, DryLab
Wet products low viscosity to solids pumpable liquids, free-flowing
solids
Vacuum / pressure variable ( Profile ) constant
( including freeze drying )
Temperature ( inkl. Kühlung ) variable ( Profile ) selectable for each zone
Product foaming slow immediately after feeding
( difficult to control ) (controlled via temperature,
vacuum and nozzle type )
Product crusher external integrated
Contamination danger moderate to high none
( open system ) ( closed system )
Moisture absorption risk moderate to high none to low
( open system ) ( closed system )
Operating costs ( handling ) high very slight
Cleaning costs moderate to low low ( CIP cleaning )
( optional CIP cleaning )
Energy costs moderate low
Operating mode manual ( loading ) and automatic automatic
control of the process parameters

Drying Technology r2_0404 Page 32


Cocoa drinks <=> Malted drinks

DRY INGREDIENTS LIQUID INGREDIENTS

Cocoa Vitamins and


Sugar Milk powder Malt extract Fat
powder Minerals

DRY MIXING
Sugar syrup ( ribbon blender HM-T )
Water
Lecithin

WET MIXING
AGGLOMERISATION (ribbon blender HM-N)

FINAL DRYING VACUUM DRYING


( fluid bed FT, FK ) ( VTS, VBT )

SIEVING
MILLING
( vibrating sieve SS )

INSTANT COCOA INSTANT MALTED


DRINK DRINK

Drying Technology r2_0404 Page 33


Raw ingredients for malted drinks
Ingredients 1 2 3 4 5 6 7 8 9 10 11 12 13 14
malt malt extract X X X X X X X X X X X X X X
date extract X
honey X X X
glucose syrup X X X
sugar glucose powder (X) X X
can sugar X X
sugar (X) X X X X X X X
fructose x X X X X X
cocoa cocoa powder ( low fat ) X X X X X X X X X X X X X
1 to 14
egg egg powder X X X differents
butter (X) X X malted drink
fat palm oil X X products
vegetable fat X X
yeast X X
wheat flour X X X X X
protein lecithin X X X X X X X X
soja or millet flour X X X
soja protein X
milk (X) X
condensed milk X
milk milk powder X X
skimmed milk powder X X X X X X X X X X X
whey powder X
flavors vanillin X X X X X X X
salt and minerals X X X X X X X X X X X X X
minerals
sodium bicarbonate X (X) X
Vitamin A X X X X X X X na na X X X
Vitamin B1,B2, B6 X X X X X X X na na X X X
vitamins
Vitamin Niacin X X X X na na X X
Vitamin D X X X X X X X na na X X

Drying Technology r2_0404 Page 34


Process flow diagram

Vacuum
Vacuum
drier
drier

M
VACUUM BELT DRIER

wet mixer dry product


Heating Cooling
Auxiliary heating Heating Cooling
Auxiliary heating Zones 1 to 4 Zone 5
dry blender Zones 1 to 4 Zone 5

CA

Vacuum discharge
Vacuum discharge
system
system pneumatic conveying
vitamins
mineral salts
sugar cocoa milk powder
malt extract palm oil

dry blender
premix
Malted breakfast drink plant

dry ingredients liquid ingredients

Drying Technology r2_0404 Page 35


Vacuum belt drier typical applications

Food industry
y breakfast drinks based on malt
extract
y chocolate crumb (ground mass)

Drying Technology r2_0404 Page 36


Vacuum belt drier typical applications

Food industry
y breakfast drinks based on malt
extract
y chocolate crumb (ground mass)
y instant soup / seasoning powders
y reaction flavors , yeast / HVP

Drying Technology r2_0404 Page 37


Vacuum belt drier typical applications

Food industry
y breakfast drinks based on malt
extract
y chocolate crumb ( ground mass )
y instant soup / seasoning powders
y reaction flavors , yeast / HVP
y fruit- and vegetable powders

Drying Technology r2_0404 Page 38


Vacuum belt drier typical applications

Food industry
y breakfast drinks based on malt
extract
y chocolate crumb (ground mass )
y instant soup / seasoning powders
y reaction flavors , yeast / HVP
y fruit- and vegetable powders
y bakery products ( premix )

Drying Technology r2_0404 Page 39


Vacuum belt drier typical applications

Food industry
y breakfast drinks based on malt
extract
y chocolate crumb (ground mass )
y instant soup / seasoning powders
y reaction flavors , yeast / HVP
y fruit- and vegetable powders
y bakery products ( premix )

Pharmaceutical industry
y plant extract powders
y active substances
Drying Technology r2_0404 Page 40
Vacuum belt drier operating parameters

Compared with other types of driers the vacuum belt drier offers
the most possibilities to influence the drying process.

The following parameters can be optimized :


y feed rate / specific load
y product foaming at feed nozzles
y belt speed ( = residence time )
y vacuum
y heating / cooling temperature ( 4 to 6 values )

The last zone can be executed as cooling zone, especially for


processing of thermoplastic products.

Drying Technology r2_0404 Page 41


Vacuum belt drier operating vacuum

Vacuum Boiling point


VACUUM FREEZE DRIER mbar abs °C
coffee 0,5 -27
fruits 1 -20
3 -10
6 0
fruit , vegetable Phytoextracts 10 7
Instant soups powders Active substances 15 13
meat extract 20 17,5
25 21
30 24
VACUUM BELT DRIER malted drinks 35 27
40 29
50 33
70 40
100 46

Drying Technology r2_0404 Page 42


products and processing parameters

product feed conc.. final conc heating cooling vacuum drying time output dry
xE (% TS) xA (% TS) T (° C ) T (° C ) p ( mbar ) ( min ) ( kg / h m2 )
Malted drinks
Malted drink ( product A ) 80 97 -- 98 130 --140 50 -- 60 30 -- 40 35 -- 40 4 -- 5
Malted drink ( product B ) 82 -- 83 98 140 -- 150 30 35 -- 40 35 -- 40 6 -- 8
Chocolate crumb 85 -- 90 98 -- 99 120 -- 130 120 15 -- 20 50 -- 60 14 -- 16
Fruit juice / Sweeters
Berries juice ( no carrier ) 65 -- 70 98 80 -- 100 20 10 -- 15 60 1 -- 1.5
Glucose sirup 65 -- 70 97 -- 98 100 -- 130 30 15 -- 20 40 -- 60 2.5 -- 3.5
Orange powder ( no carrier ) 60 98 -- 99 80 -- 90 20 10 -- 15 60 1.5 -- 2
Plant extracts
Herbal extract 70 -- 75 97 - 98 80 -- 110 20 20 -- 30 50 -- 60 2 -- 3
Tea extract 60 97 -- 98 80 -- 90 20 10 -- 15 60 -- 90 1.5 -- 2
Plant proteines
Instant soup light 80 -- 85 98 -- 99 90 -- 110 30 20 30 -- 40 4 -- 5
Instant soup dark( raction flavors) 80 -- 85 98 -- 99 130 -- 140 30 -- 40 20 -- 30 30 -- 40 6 -- 8
Soup mass with granules 80 -- 85 98 -- 99 120 -- 140 30 20 40 -- 50 4 -- 8
Yeast extract 75 -- 80 97 -- 98 80 -- 100 20 -- 30 15 60 1.5 -- 2.5
Animal proteines
Roast juice 85 98 80 -- 100 20 -- 25 15 -- 20 40 -- 50 4 -- 6
Chicken bouillon 50 -- 75 97 -- 98 80 -- 110 20 20 60 -- 80 1 -- 3.5
Meat flavors 70 -- 80 97 -- 98 120 -- 140 20 20 30 -- 40 2 -- 3
Pharmaceuticals
Herbal medicine 70 98 70 -- 80 20 10 -- 20 60 1 --1.5
Stomach extract 40 98 90 -- 120 20 10 -- 15 60 1
Vitamine C 85 -- 90 98 50 -- 70 50 15 90 4 -- 6

Drying Technology r2_0404 Page 43


products and processing parameters

product feed conc.. final conc heating cooling vacuum drying time output dry
xE (% TS) xA (% TS) T (° C ) T (° C ) p ( mbar ) ( min ) ( kg / h m2 )
Malted drinks
Malted drink ( product A ) 80 97 -- 98 130 --140 50 -- 60 30 -- 40 35 -- 40 4 -- 5
Malted drink ( product B ) 82 -- 83 98 140 -- 150 30 35 -- 40 35 -- 40 6 -- 8
Chocolate crumb 85 -- 90 98 -- 99 120 -- 130 120 15 -- 20 50 -- 60 14 -- 16
Fruit juice / Sweeters
Berries juice ( no carrier ) 65 -- 70 98 80 -- 100 20 10 -- 15 60 1 -- 1.5
Glucose sirup 65 -- 70 97 -- 98 100 -- 130 30 15 -- 20 40 -- 60 2.5 -- 3.5
Orange powder ( no carrier ) 60 98 -- 99 80 -- 90 20 10 -- 15 60 1.5 -- 2
Plant extracts
Herbal extract 70 -- 75 97 - 98 80 -- 110 20 20 -- 30 50 -- 60 2 -- 3
Tea extract 60 97 -- 98 80 -- 90 20 10 -- 15 60 -- 90 1.5 -- 2
Plant proteines
Instant soup light 80 -- 85 98 -- 99 90 -- 110 30 20 30 -- 40 4 -- 5
Instant soup dark( raction flavors) 80 -- 85 98 -- 99 130 -- 140 30 -- 40 20 -- 30 30 -- 40 6 -- 8
Soup mass with granules 80 -- 85 98 -- 99 120 -- 140 30 20 40 -- 50 4 -- 8
Yeast extract 75 -- 80 97 -- 98 80 -- 100 20 -- 30 15 60 1.5 -- 2.5
Animal proteines
Roast juice 85 98 80 -- 100 20 -- 25 15 -- 20 40 -- 50 4 -- 6
Chicken bouillon 50 -- 75 97 -- 98 80 -- 110 20 20 60 -- 80 1 -- 3.5
Meat flavors 70 -- 80 97 -- 98 120 -- 140 20 20 30 -- 40 2 -- 3
Pharmaceuticals
Herbal medicine 70 98 70 -- 80 20 10 -- 20 60 1 --1.5
Stomach extract 40 98 90 -- 120 20 10 -- 15 60 1
Vitamine C 85 -- 90 98 50 -- 70 50 15 90 4 -- 6

Drying Technology r2_0404 Page 44


products and processing parameters

product feed conc.. final conc heating cooling vacuum drying time output dry
xE (% TS) xA (% TS) T (° C ) T (° C ) p ( mbar ) ( min ) ( kg / h m2 )
Malted drinks
Malted drink ( product A ) 80 97 -- 98 130 --140 50 -- 60 30 -- 40 35 -- 40 4 -- 5
Malted drink ( product B ) 82 -- 83 98 140 -- 150 30 35 -- 40 35 -- 40 6 -- 8
Chocolate crumb 85 -- 90 98 -- 99 120 -- 130 120 15 -- 20 50 -- 60 14 -- 16
Fruit juice / Sweeters
Berries juice ( no carrier ) 65 -- 70 98 80 -- 100 20 10 -- 15 60 1 -- 1.5
Glucose sirup 65 -- 70 97 -- 98 100 -- 130 30 15 -- 20 40 -- 60 2.5 -- 3.5
Orange powder ( no carrier ) 60 98 -- 99 80 -- 90 20 10 -- 15 60 1.5 -- 2
Plant extracts
Herbal extract 70 -- 75 97 - 98 80 -- 110 20 20 -- 30 50 -- 60 2 -- 3
Tea extract 60 97 -- 98 80 -- 90 20 10 -- 15 60 -- 90 1.5 -- 2
Plant proteines
Instant soup light 80 -- 85 98 -- 99 90 -- 110 30 20 30 -- 40 4 -- 5
Instant soup dark( raction flavors) 80 -- 85 98 -- 99 130 -- 140 30 -- 40 20 -- 30 30 -- 40 6 -- 8
Soup mass with granules 80 -- 85 98 -- 99 120 -- 140 30 20 40 -- 50 4 -- 8
Yeast extract 75 -- 80 97 -- 98 80 -- 100 20 -- 30 15 60 1.5 -- 2.5
Animal proteines
Roast juice 85 98 80 -- 100 20 -- 25 15 -- 20 40 -- 50 4 -- 6
Chicken bouillon 50 -- 75 97 -- 98 80 -- 110 20 20 60 -- 80 1 -- 3.5
Meat flavors 70 -- 80 97 -- 98 120 -- 140 20 20 30 -- 40 2 -- 3
Pharmaceuticals
Herbal medicine 70 98 70 -- 80 20 10 -- 20 60 1 --1.5
Stomach extract 40 98 90 -- 120 20 10 -- 15 60 1
Vitamine C 85 -- 90 98 50 -- 70 50 15 90 4 -- 6

Drying Technology r2_0404 Page 45


products and processing parameters

product feed conc.. final conc heating cooling vacuum drying time output dry
xE (% TS) xA (% TS) T (° C ) T (° C ) p ( mbar ) ( min ) ( kg / h m2 )
Malted drinks
Malted drink ( product A ) 80 97 -- 98 130 --140 50 -- 60 30 -- 40 35 -- 40 4 -- 5
Malted drink ( product B ) 82 -- 83 98 140 -- 150 30 35 -- 40 35 -- 40 6 -- 8
Chocolate crumb 85 -- 90 98 -- 99 120 -- 130 120 15 -- 20 50 -- 60 14 -- 16
Fruit juice / Sweeters
Berries juice ( no carrier ) 65 -- 70 98 80 -- 100 20 10 -- 15 60 1 -- 1.5
Glucose sirup 65 -- 70 97 -- 98 100 -- 130 30 15 -- 20 40 -- 60 2.5 -- 3.5
Orange powder ( no carrier ) 60 98 -- 99 80 -- 90 20 10 -- 15 60 1.5 -- 2
Plant extracts
Herbal extract 70 -- 75 97 - 98 80 -- 110 20 20 -- 30 50 -- 60 2 -- 3
Tea extract 60 97 -- 98 80 -- 90 20 10 -- 15 60 -- 90 1.5 -- 2
Plant proteines
Instant soup light 80 -- 85 98 -- 99 90 -- 110 30 20 30 -- 40 4 -- 5
Instant soup dark( raction flavors) 80 -- 85 98 -- 99 130 -- 140 30 -- 40 20 -- 30 30 -- 40 6 -- 8
Soup mass with granules 80 -- 85 98 -- 99 120 -- 140 30 20 40 -- 50 4 -- 8
Yeast extract 75 -- 80 97 -- 98 80 -- 100 20 -- 30 15 60 1.5 -- 2.5
Animal proteines
Roast juice 85 98 80 -- 100 20 -- 25 15 -- 20 40 -- 50 4 -- 6
Chicken bouillon 50 -- 75 97 -- 98 80 -- 110 20 20 60 -- 80 1 -- 3.5
Meat flavors 70 -- 80 97 -- 98 120 -- 140 20 20 30 -- 40 2 -- 3
Pharmaceuticals
Herbal medicine 70 98 70 -- 80 20 10 -- 20 60 1 --1.5
Stomach extract 40 98 90 -- 120 20 10 -- 15 60 1
Vitamine C 85 -- 90 98 50 -- 70 50 15 90 4 -- 6

Drying Technology r2_0404 Page 46


products and processing parameters

product feed conc.. final conc heating cooling vacuum drying time output dry
xE (% TS) xA (% TS) T (° C ) T (° C ) p ( mbar ) ( min ) ( kg / h m2 )
Malted drinks
Malted drink ( product A ) 80 97 -- 98 130 --140 50 -- 60 30 -- 40 35 -- 40 4 -- 5
Malted drink ( product B ) 82 -- 83 98 140 -- 150 30 35 -- 40 35 -- 40 6 -- 8
Chocolate crumb 85 -- 90 98 -- 99 120 -- 130 120 15 -- 20 50 -- 60 14 -- 16
Fruit juice / Sweeters
Berries juice ( no carrier ) 65 -- 70 98 80 -- 100 20 10 -- 15 60 1 -- 1.5
Glucose sirup 65 -- 70 97 -- 98 100 -- 130 30 15 -- 20 40 -- 60 2.5 -- 3.5
Orange powder ( no carrier ) 60 98 -- 99 80 -- 90 20 10 -- 15 60 1.5 -- 2
Plant extracts
Herbal extract 70 -- 75 97 - 98 80 -- 110 20 20 -- 30 50 -- 60 2 -- 3
Tea extract 60 97 -- 98 80 -- 90 20 10 -- 15 60 -- 90 1.5 -- 2
Plant proteines
Instant soup light 80 -- 85 98 -- 99 90 -- 110 30 20 30 -- 40 4 -- 5
Instant soup dark( raction flavors) 80 -- 85 98 -- 99 130 -- 140 30 -- 40 20 -- 30 30 -- 40 6 -- 8
Soup mass with granules 80 -- 85 98 -- 99 120 -- 140 30 20 40 -- 50 4 -- 8
Yeast extract 75 -- 80 97 -- 98 80 -- 100 20 -- 30 15 60 1.5 -- 2.5
Animal proteines
Roast juice 85 98 80 -- 100 20 -- 25 15 -- 20 40 -- 50 4 -- 6
Chicken bouillon 50 -- 75 97 -- 98 80 -- 110 20 20 60 -- 80 1 -- 3.5
Meat flavors 70 -- 80 97 -- 98 120 -- 140 20 20 30 -- 40 2 -- 3
Pharmaceuticals
Herbal medicine 70 98 70 -- 80 20 10 -- 20 60 1 --1.5
Stomach extract 40 98 90 -- 120 20 10 -- 15 60 1
Vitamine C 85 -- 90 98 50 -- 70 50 15 90 4 -- 6

Drying Technology r2_0404 Page 47


products and processing parameters

product feed conc.. final conc heating cooling vacuum drying time output dry
xE (% TS) xA (% TS) T (° C ) T (° C ) p ( mbar ) ( min ) ( kg / h m2 )
Malted drinks
Malted drink ( product A ) 80 97 -- 98 130 --140 50 -- 60 30 -- 40 35 -- 40 4 -- 5
Malted drink ( product B ) 82 -- 83 98 140 -- 150 30 35 -- 40 35 -- 40 6 -- 8
Chocolate crumb 85 -- 90 98 -- 99 120 -- 130 120 15 -- 20 50 -- 60 14 -- 16
Fruit juice / Sweeters
Berries juice ( no carrier ) 65 -- 70 98 80 -- 100 20 10 -- 15 60 1 -- 1.5
Glucose sirup 65 -- 70 97 -- 98 100 -- 130 30 15 -- 20 40 -- 60 2.5 -- 3.5
Orange powder ( no carrier ) 60 98 -- 99 80 -- 90 20 10 -- 15 60 1.5 -- 2
Plant extracts
Herbal extract 70 -- 75 97 - 98 80 -- 110 20 20 -- 30 50 -- 60 2 -- 3
Tea extract 60 97 -- 98 80 -- 90 20 10 -- 15 60 -- 90 1.5 -- 2
Plant proteines
Instant soup light 80 -- 85 98 -- 99 90 -- 110 30 20 30 -- 40 4 -- 5
Instant soup dark( raction flavors) 80 -- 85 98 -- 99 130 -- 140 30 -- 40 20 -- 30 30 -- 40 6 -- 8
Soup mass with granules 80 -- 85 98 -- 99 120 -- 140 30 20 40 -- 50 4 -- 8
Yeast extract 75 -- 80 97 -- 98 80 -- 100 20 -- 30 15 60 1.5 -- 2.5
Animal proteines
Roast juice 85 98 80 -- 100 20 -- 25 15 -- 20 40 -- 50 4 -- 6
Chicken bouillon 50 -- 75 97 -- 98 80 -- 110 20 20 60 -- 80 1 -- 3.5
Meat flavors 70 -- 80 97 -- 98 120 -- 140 20 20 30 -- 40 2 -- 3
Pharmaceuticals
Herbal medicine 70 98 70 -- 80 20 10 -- 20 60 1 --1.5
Stomach extract 40 98 90 -- 120 20 10 -- 15 60 1
Vitamine C 85 -- 90 98 50 -- 70 50 15 90 4 -- 6

Drying Technology r2_0404 Page 48


Fruits- and vegetables powder

pure with added filler pure With added filler


Product 100 % Product
% filler in powder 100 % % filler in powder
pineapple X bis 40 huckleberries (X) bis 40
apple ( clear juice) (X) 40 - 60 rapsberries ( juice ) X 20 - 60
apple ( puree) X honey O 20 - 30
apricot ( puree) X bis 20 black currants (juice ) X 20 - 60
apricot ( juice) O 40 - 60 carrot ( juice ) X
banana ( puree ) O bis 20 mandarins X 40 - 60
pear ( clear juice ) (X) 40 - 60 orange X 20 - 60
blackberries O 20 - 60 passion fruit O 40 - 60
cranberry ( juice ) (X) 20 - 60 peach ( juice ) O bis 40
strawberries ( puree ) X 20 - 40 red beet X 20 - 40
strawberries ( juice ) X 20 - 60 Sour cherries O 40 - 60
grapefruit O 20 - 60 tomato O 40 - 60
rose hip X lemon (X) 60 - 80

X = possible
( X ) = possible but hard cake and not instant
O = not possibel
with added filler => max value is approx equivalent to spray dried products

Drying Technology r2_0404 Page 49


Instant products

= immediately soluble
( in cold or warm liquid )
Instant
= good wettability

Not all vacuum belt drier products are instant products

Products with good foaming during drying are mostly instant products
foaming = volume increase up to 10 x / surface increase up to 400 x

Products with a high content of fruit sugar or inverted sugar often don't form
a stable foam carpet and are not instant products without a special
additional treatment.

Drying Technology r2_0404 Page 50


Instant products
Good foaming = instant properties

Carrot powder

Red beet powder


Drying Technology r2_0404 Page 51
Instant products

Compact structure / no foaming = not instant

Tea extract with invert sugar

Drying Technology r2_0404 Page 52


Vacuum belt drier for solid products

Drying Technology r2_0404 Page 53


Vacuum belt drier for solid products

Drying Technology r2_0404 Page 54


Vacuum Puffing Process SDT

Puffing Process steps


y pre drying in air belt drier

y Puffing
raw material washing sorting pealing +
y pressurize + heating reception
remove skin
y immediate expansion 1- 6 bar P = Atm.
appr 20 % RF
y + strong evaporation
y + breaking of the cell walls
y + strong volume increase Air belt drier Antyoxidant treatement cutting

y final drying in vacuum 50-100 15 mbar


mbar appr 2 % RF
y cooling in vacuum
BUCHER
y + fixed puffed structure
SDT-Process
y + crispy quality
SDT - puffing Vacuum belt drier packing

Drying Technology r2_0404 Page 55


Puffing and drying of apple chunks

Apples chunks air belt dried Apple chunks after puffing and
( approx 25 % moisture ) vacuum drying
( < 3 % moisture and crispy )

Drying Technology r2_0404 Page 56


New products
nuts and sugar
y free flowing granules
y free flowing powders
y lump size products

crispy apple rings

crispy apple bars crispy apple cubes grapes

Drying Technology r2_0404 Page 57


Freeze drying on vacuum belt drier

Freeze drying = very gentle process


y Sublimation at approx - 20 °C
y no product damages
y preservation of the solid structure
y good reconstitution (water adsorption )

Freezing drying in the vacuum belt drier


has in additional advantages:

y faster ( coffee in mono layer 5 to 10 x faster )


y continuous operation
y stronger flavor retention
y best flavors with ZEODRATATION technology

Drying Technology r2_0404 Page 58


Vacuum freeze dried products
y coffee
y vegetable and fruits
y aromatic herbs
y meat, mushroom
y medicinal herbs
y cheese, proteins

Drying Technology r2_0404 Page 59


Vacuum freeze belt drier FVBD

THERMAL COMPRESSOR
Condensation
system
y + Investment
PRODUCT IN
frozen product
y + no refrigerant
vacuum
feed system
Belt drive y - steam consumption
COLD ROOM Vacuum
0,5 to 1 mbar

Heating Heating Cooling


Zone 1 Zone 2 Zone 3

Vacuum
discharge system

PRODUCT
OUT

Drying Technology r2_0404 Page 60


Vacuum freeze belt drier FVBD

THERMAL COMPRESSOR
Condensation
system

PRODUCT IN
frozen product
ICE CONDENSER
vacuum
feed system
Belt drive y - Investment
COLD ROOM Vacuum
0,5 to 1 mbar
y - refrigerant up to - 40°C
y - energy consumption

Heating Heating Cooling


Zone 1 Zone 2 Zone 3

Vacuum
discharge system

PRODUCT
OUT

Drying Technology r2_0404 Page 61


Continuous vacuum belt freeze drier
KAFFEEKONZENTRAT
GRANULAT Kunde :
BUCHER
GW Projekt : Gefriertrockner
Zeichn. Nr. GRUNDFLIESSBILD ( PFD )
10023 Gefriervakuumbandtrockner
S Fer 17.6.2001 für Kaffee

S
Heizung Zone 1

Band 1 = Zone 1

Band 2 = Zone 2

Band 3 = Zone 3

S
Heizung Zone 2

S S S

S
GW GW GW
S
Heizung Zone 3

KAFFEE PULVER
S
Begleitheizung

Drying Technology r2_0404 Page 62


Vacuum belt freeze drier for coffee
M
M
KAFFEE KONZENTRAT

Zone 2 Zone 1
BRECHER
GEFRIERBAND

SIEB

MUEHLEN

SIEB

Einschleusung

GEFRIERVAKUUMBANDTROCKNER
Recycling "feinkorn" M

Eiskondensatoren
Vakuumgruppen
Kunde :
BUCHER Projekt : Gefriertrockner Ausschleusung
Zeichn. Nr. GRUNDFLIESSBILD ( PFD )
10021 Gefriertrockneranlage
Fer 17.6.2001
S
für Kaffee
Heizaggregate KAFFEE PULVER
SIEB

Drying Technology r2_0404 Page 63


Vacuum freeze belt drier FVBD

THERMAL COMPRESSOR
Condensation
system

PRODUCT IN
frozen product ICE CONDENSER
vacuum
Belt drive
feed system

COLD ROOM Vacuum ZEODRATION


0,5 to 1 mbar
y + product quality
y + no refrigerant
y + energy recovery

Heating Heating Cooling


Zone 1 Zone 2 Zone 3

Vacuum
discharge system

PRODUCT
OUT

Drying Technology r2_0404 Page 64


Zeolite

ZEOLITE is a form of crystallised clay that is greedy of water vapour and has a
pore diameter of 4 Angströms. This means that only the water molecule (3Å) is
trapped. Larger molecules, such as those flavourings and colourings, are preserved
within the product.

Pore
=4Å

FEATURES :
y Zeolite Adsorption capacity : up to 30% of its own weight.
y Specific surface : around 300m2 per gram
y Regeneration temperature: 250°C.
y Residual water: from 1 to 3%.
y Exothermic reaction on adsorption

Drying Technology r2_0404 Page 65


Zeolite Reactor

Exothermic reaction
WATER
EVAPORATION

Drying Chamber Reactors


Energy Recovery
Fluid loop fluid loop

HEAT EXCHANGER
Drying Technology r2_0404 Page 66
ZEODRATION

HEATING REGENERATION

COOLING
COOLING

COOLING
WATER
REGENERATION
VACUUM SKID
UTILITIES

PROCESS
VACUUM SKID

Drying Technology r2_0404 Page 67


ZEODRATATION partial pressure
All condensable products (water and others volatiles) are trapped with others process.
With Zeodration, only the water is trapped.
The partial pressure of « others volatiles » is more important with Zeodration than the
others system. So, the partial pressure of the steam water is less important with
Zeodration system.

Zeodration evaporate more water per unit of time than the others process.
Pressure

Water partial pressure curb (zeodration)


Water partial pressure curb (other process)

Total pressure curb

Period

Drying Technology r2_0404 Page 68


ZEODRATATION Batch plant

Plant for fruits and spices ( max 120 kg/h water sublimation)

Drying Technology r2_0404 Page 69


ZEODRATATION - Advantages

QUALITY
Product structure retained.
Flavourings and colourings preserved

ECONOMY
Low energy consumption (exothermic reaction).
Low maintenance cost
Easy installation.

ECOLOGY
Only waste product is clean water.
Total absence of chlorinated refrigerants (HCFCs).

Drying Technology r2_0404 Page 70


Extruded products

y Breakfast cereals y Snacks


y Drink powder y pet food
y instant products

Drying Technology r2_0404 Page 71


VBT 190 m2 for malted drink CH

Drying Technology r2_0404 Page 72


VBT 190 m2 for malted drink MY

Drying Technology r2_0404 Page 73


Heating and vacuum skid unit

Drying Technology r2_0404 Page 74


VBT 60 m2 GMP Pharma FR

Drying Technology r2_0404 Page 75


VBT 100 m2 for bakery mix DE

Drying Technology r2_0404 Page 76


VBT 64 m2 for soups DE

Drying Technology r2_0404 Page 77


2 x VBT 30 m2 for malted drink NG

Drying Technology r2_0404 Page 78


VBT 6 m2 for herbal medicine MY

Drying Technology r2_0404 Page 79


Vacuum belt drier

Many thanks for your


Attention !
Drying Technology r2_0404 Page 80

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