Use a spray dryer to quickly dry the material. Spray dryers are very efficient; in one step they can turn a solution into a dry powder. Dry powders are usually easier to handle in production. This also allows ingredients that would otherwise be liquid to be incorporated into dry powder mixes such as premixes. The resulting powder formed by the spray drying process is free flowing and easy to handle and foul.
Spray dryers work by separating solids from liquids by evaporation. To do this, the liquid is sprayed through nozzles into the stream of hot steam. Solids form from liquids when water leaves the droplets. Solids were collected through the outlet. Spray drying microcapsules is a very different fluid bed process. In spray drying encapsulation we go from liquid to powder. The process starts with an emulsion or dispersion.
Unlike the fluidized bed method, spray drying does not produce intact microcapsules; we do not build a shell or matrix on the outside of the particles. Instead, in the spray drying process, we take another ingredient in and then dry this emulsion to quickly create a dispersion or emulsion of the ingredient.
To the outer edges of the resulting dry granules there will always be some active ingredient or active ingredients. The inner core is more protection. Examples of applications in spray drying include fat-soluble vitamins such as vitamin A, vitamin D, and vitamin E. When spray drying these vitamins are more stable in shelf life, but there will always be a certain amount of surface oil.
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