SBIR-STTR Award

This Small Business Innovation Research (SBIR) Phase I project aims to eliminate the use of heat during the process of spray drying liquid emulsions into powders. Typically, a liquid emulsion consists of a high-value liquid ingredient emulsified with a carrier system that when dried captures the liquid ingredient in a powdered form. Traditional spray drying employs air heated up to 400 degrees Fahrenheit to dry the liquids into powders. However, exposing sensitive, volatile liquid ingredients to high temperatures causes molecular degradation that negatively impacts performance. By eliminating the use of heat, it is expected that the quality, solubility, stability and overall performance of powders will be significantly improved. This project will focus on designing novel drying equipment, formulating emulsions, and reducing moisture content in the finished powders. The broader/commercial impact of this project will be the potential to provide an innovative, commercially viable no-heat spray drying technology with the ability to manufacture significant amounts of powdered products for applications in foods, chemicals, probiotics and pharmaceuticals where the production of a free-flowing powder is required. This no-heat spray drying process is anticipated to improve shelf life, create better solubility, reduce costs and deliver a more efficacious product, enabling liquid quality flavors and ingredients in a powder form.

This Small Business Innovation Research Phase II Project of ?No Heat Spray Drying? fundamentally changes the process of spray drying liquids to powders by eliminating the use of heat. Typically, a liquid emulsion consists of a high value liquid ingredient that is emulsified with a carrier system that when dried captures the liquid ingredient in a powdered form. High temperature spray drying remains the preferred method of drying many thermally sensitive materials such as foods, chemicals, probiotics, pharmaceuticals, and in many other applications where the production of a free-flowing powder is required. The current spray drying process employs air heated up to 400° Fahrenheit to dry the liquid into a powder. Exposing sensitive, volatile liquid ingredients to high temperatures causes molecular degradation that negatively impacts performance. By eliminating the use of heat the end result is a significantly improved powder in terms of product quality, solubility, stability and overall performance. Our research will be focused on improving our proprietary technology through dryer optimization and atomization development. This research should yield an innovative, commercially viable "no heat" spray drying technology with the ability to manufacture significant amounts of powdered products. The broader impact/commercial potential of this project spans markets including food & beverage, chemicals, pharmaceuticals, infant formula, coffee, vitamins and numerous other segments where the production of a free flowing powder ingredient is desired. The challenge: how to eliminate the use of heat in converting liquids to powders. By eliminating the use of heat in the manufacturing process, we create significantly improved powder products. Our process is more economical, delivers products with longer shelf life, better encapsulation and improves solubility. Our technology has several societal benefits including decreasing energy consumption and preventing the evaporation of volatile ingredients into the atmosphere. Our technology may be able impact the bioavailability of drugs, decrease tablet sizes, deliver stable Omega 3 ingredients and improve dried milk powder. We are only beginning to explore the potential applications of our revolutionary process technology