The Game-Changer in Flavour and Essence Preservation: Fluid Air's New Approach

Fluid Air is showing Australian businesses the vast benefits of low-temperature spray drying over traditional heat drying, with greatly improved efficiency and longevity.

As a subdivision of Spraying Systems, Fluid Air uses spray drying technology that excels in producing high-quality powder by removing water at low temperatures in a nitrogen-rich environment.

These critical characteristics significantly boost product lifespan when compared to traditional drying techniques in extreme temperatures. This is particularly evident in flavour preservation.

Dr. Bogan Zisu, Fluid Air’s Global Research Head, says, “Our technologies, due to their capacity to operate at reduced temperatures, yield many advantages, especially for heat-sensitive materials.”

“Fluid Air uniquely incorporates an electrostatic charge during drying to effectively encapsulate oils.”

Dr Zisu points out that the nitrogen-filled atmosphere of their drying process is a distinctive feature. Conventional spray drying technologies often rely on extremely high temperatures to optimize productivity, which may risk quality.

Up to 7 x the efficiency when drying flavours

Dr Zisu describes a trial conducted with a company that manufactures lemon-flavoured candies. With traditional high-heat drying techniques used by a flavours manufacturer retained approximately 10% acetaldehyde.

However, using Fluid Air’s electrostatic system, retention of the volatile acetaldehyde increased to 70%. Despite the low cost of candies making this method not cost-effective for this particular example, it effectively demonstrates the efficacy of Fluid Air’s machines, and how it can be applied across a range of industries.

Preserving and Enhancing Flavours in Products

The current technology was initially designed a decade ago to address a specific food production challenge, but its usage quickly expanded.

“To address flavour encapsulation, particularly oil flavour encapsulation, we collaborated with a flavour-focused company to develop this electrostatic spray dryer,” Zisu elucidates.

Typically, flavour preservation or representation employs encapsulation methods to confine the flavour in a gel, liquid, or more commonly, a powdered form.

“The industry leans towards powder due to its compatibility with both water-soluble and lipid-soluble flavours,” notes Dr Zisu. “Removing water results in a stable, easy-to-handle product, cuts down shipping expenses, and introduces many other benefits.”

Applying Lower Temperatures in Spray Drying

Dr Zisu further emphasizes that the powdered form of the product likely presents the most stable state, and decreasing water content bolsters stability while reducing risks.

Temperature and oxygen levels often dictate stability. “We utilize significantly cooler drying temperatures, which flavour the retention of volatile compounds,” declares Zisu.

The nitrogen-based method minimizes oxygen’s role during processing, augmenting product stability and offering broad applications within the food manufacturing industry.

Fluid Air: Transforming the Industry

Recently, a surge in Australian SMEs and start-ups has stimulated industry interest.

“Most inquiries come from smaller start-ups lacking established infrastructure. Hence they are keen on exploring the capabilities of these technologies as they scale,” observes Dr Zisu.

Looking for opportunities for expansion, these budding businesses typically view this technology as a valuable addition to their processes.

The enhanced shelf life Fluid Air can offer benefits product transportation and export by ensuring longevity during transit.

“For instance, the product might be stored on a container ship for a long duration, and temperature variations can accelerate deterioration, impacting the product’s shelf life,” Dr Zisu explains.

Science and Innovation: Driving Superior Outcomes

Nitrogen processing, which produces an oxygen-free environment during drying, is another element boosting product longevity.

“Besides heat conservation from lower temperatures, oxidative breakdown also triggers product loss via oxidation reactions,” explains Dr Zisu.

“Our drying technology functions in a nitrogen environment, where nitrogen displaces oxygen, lessening oxidative breakdown.”

Fluid Air can test your products at our Melbourne Testing Facility

For clients keen on the Polar Dry® technology, Fluid Air and Spraying Systems Australia offer a flexible approach, supported by a research and development facility in Melbourne.

Dr Zisu notes that their testing facility in Melbourne is replete with advanced analytical capabilities, crafted to assist their customers to the fullest. Fluid Air’s testing centre is geared towards flexibility, keenly attuned to the particular requirements of their clients.

Mark Condro, the Fluid Air Business Development Manager, acknowledges the significant capital investment customers need to make in their technology. To assuage any concerns, Fluid Air is pleased to offer certain free testing methods to demonstrate the capabilities of their technology.

According to Condro, “We strive to collaborate with our customers to ensure that their business reaps the benefits, considering the substantial investment these machines represent. We are confident that our technology is the way forward.”

Condro continues, “The efficiency improvements it can offer are substantial, which is why we are willing to devote time to demonstrate our confidence in our product.”

Dr Zisu further explains the benefits of their technology. “There is a decrease in bioactivity when traditional heat spray drying technology is used. On the contrary, our electrostatic spray drying technology results in negligible loss post-drying. Also, our method allows for extended storage periods while still maintaining the bioactivity.”

Dr Zisu also offers reassurance about their readiness to cater to specific testing requirements. “It is all up to the customer. If they need specific testing based on our existing capabilities, we can certainly accommodate that. Our lab is fully equipped. Besides converting liquid feed into powder, we can also analyse the liquid feed before drying and the powder properties after drying.”

“We have virtually all the resources needed for characterizing powder. For instance, we can determine the moisture content, water activity, and glass transition temperature of the powder,” concludes Dr Zisu.

Fluid Air has a wide range of applications and the ability to scale up to any challenge

From high-value dairies to flavouring and essences, Fluid Air delivers big ideas that help you preserve active ingredients, accelerate production, and reduce waste—all with cost efficiency in mind.

Fluid Air has the range to suit the size and needs of your business with machines tailored for R&D, feasibility studies, as well as small, medium, and large-scale commercial manufacturing.

“We have dryers of diverse sizes, ranging from a compact benchtop unit for feasibility testing to our largest commercial dryer capable of industrial scale, we can meet the needs of any business.”

Contact us today: Mark.condro@spray.com.au