Optimize food drying processes

DRYING TECHNOLOGIES
CONTENTS
INTRODUCTION TO THE TECHNOLOGY OF DRYERS
BELT ROTARY “JET ZONE”
2
All rights reserved – Part or full reproduction is forbidden.
FUNCTIONALITIES AND OBJECTIVES OF
THE FOOD DRYING PROCESS
FOOD preservation / stabilisation unit operation

= decrease in product moisture
 FOOD SAFETY
Decrease in product moisture

= ENERGY INPUT  water evaporation
Reach the product's QUALITY OBJECTIVES

▪ Control and compliance with the H20 objective
▪ Organoleptic quality (formulation, texturization)
▪ Absence of enzymatic and non-enzymatic reactions, and of

the development of microorganisms
3
QUALITY CRITERIA
PRODUCT MOISTURE
▪ Formula: H2O = 100*(water mass / wet product mass)
▪ RAPID measurement method:
• NIR = spectrophotometer close to infrared
• Scales to measure moisture= Method utilised at the research centre (during tests)
▪ STANDARD measurement method = DRY MATTER ANALYSIS
WATER ACTIVITY (aw) = availability of water in the analysed food

▪ Measurement range between 0 and 1
▪ Widely studied parameters in the food industry, for example: pet food, co-
extrusion, fruit cake, etc.
▪ Measurement with “aw meter - Water Activity Meter”
4
Extruded Products Drying Theory
AIR NOTION
Initial (Ta) = DRY AIR TEMPERATURE Subsequent (Th) =MOIST AIR TEMPERATURE
(In this case gaz type = Air) => Temperature given by a probe wrapped inside
a wet wick:
=> (Th) always < (Ta)
Wet wick
DRY AIR MOIST AIR

FLOW FLOW
RELATIVE HUMIDITY (RH): ABSOLUTE HUMIDITY (AH)
RH (%)= Actual Vapor Density / Saturated Vapor Density x 100% = mass of water / mass of dry air
Also known as the hygrometric degree

At saturation: RH = 100% (Dew Point)
5
EXTRUDED PRODUCTS DRYING THEORY
PRINCIPLE OF CONVECTION DRYING
Energy transmission = CONVECTION
Drying mode = DRIVEN
• MOIST AIR FLOW
• COOLER
HOT AND DRY AIR FLOW
WATER VAPOR
ENERGY EVAPORATION OF THE

SIMULTANEOUS
PRODUCT’S WATER
TRANSMISSION
INCREASED PRODUCT TEMPERATURE:
HEAT / MATTER
• T product surface < :
• T hot air
• T boiling of water in the product
WET PRODUCT
6
Oxygen
EXTRUDED PRODUCTS DRYING THEORY atom

(O)
EVAPORATION NOTION (FREE & BOUNDED)

Free water evaporation Bound water evaporation Water (H2O)
▪ Superficial water ▪ Water absorbed in the walls of structures

Hydrogen atom
(H)
Hydrogen atom
(H)
▪ Lightly bound to the product ▪ Water more difficult to extract
T max = 65°C at t = 15 min
T0 = 29°C
The availability of water depends on the product and has

different functions.
7
TYPICAL CURVE OF CONVECTION DRYING
Product MOISTURE
Product Temperature
Constant
rise
30 -15%
Initial
sudden drop
10 – 2 % Slow rise
Retention time
8
EXTRUDED PRODUCTS DRYING PHASE 1 – ADJUSTING TEMPERATURE
• Tp :  product introduced cold or hot
DRYING KINETICS • High Thermal Energy & Fast Drying speed
↗
• Evaporation at the product’s surface
1
PHASE 2 – CONSTANT DRYING SPEED
• Tp = Th = constant if constant air
2 conditions stable
• Driven Drying:
o High Air Temperature
o High air speed
o Dryer air
3 PHASE 3 – DRYING DECREASE

• Drying speed ↘
• Contributed energy:
 less water for evaporation
 less drying energy required
 Tp ↗ and Air Temperature ↗ and
 drying ↘
9
EXTRUDED PRODUCTS DRYING
BASIC FACTORES TO CONTROL DRYING
• TEMPERATURE
• AIR FLOW (VOLUME & SPEED)
• RELATIVE AIR MOISTURE
• RESIDENCE TIME
• PRODUCT VOLUME
• PRODUCT CHARARCTERISTICS

TEMPERATURE EFFECT
WATER HOLDING CAPACITY BY THE AIR
➢ Heated air at 90°C has 100X of water holding capacity than air at 20 °C
➢ With higher temperature the air can hold more water

TEMPERATURE EFFECT
TEMPERATURE EFFECT IN THE RESIDENCE TIME FOR POROUS PRODUCTS
Drying Time
(min) 25
15
100 120 140 160 180 Drying Temperature°C
➢ Heated air at 90°C has 100X of water holding capacity than air at 20 °C
➢ With higher temperature the air can hold more water

AIR FLOW EFFECT
AIR FLOW EFFECT TO THE PRODUCT DRYING TIME
Drying Time (min)
Air Flow Speed (m/s)
The higher the air velocity the higher the heat transfert and drying speed

PRODUCT LAYER EFFECT
DISTRIBUTION OF HOT AIR
INTO THE PRODUCT’S LAYERS
70 °C
80 °C
100 °C
120 °C
140 °C
150 °C
IDEAL
14
DRYING TECHNOLOGY
Clextral EVOLUM belt dryer
SNACK line example
15
CLEXTRAL EVOLUM DRYER
Models: 600
-EV300
-EV600
1200
-EV1200 300
EV 300 EV 600 EV 1200

Products (kg/h at Dryer Outlet) (kg/h at Dryer Outlet) (kg/h at Dryer Outlet)
SNACKS 250 / 300 500 / 600 1000 / 1200
16
Air heated with gas burner or electric resistance
AIR CONDITIONS:
-Recirculation fan
AIR EXTRACTOR -Air flow measurement in the
dryer
-Recirculation of part of the air
-Controlled T
Receiving hopper -Uncontrolled RH
Product
input
Product
Plenum
Spreader
height
Conveyor belt
Zone 1
Zone 2
Product output
Air transmission
limitation Under the plenum
17
DRYING TECHNOLOGY
ROTANTE Rotary dryer for small Ingredients
Example: Couscous line
18
ROTANTE ROTARY DRYER
Short Pasta Line Couscous Line Ingredients Line

1800 kg/h 1200 kg/h 200 – 300 kg/h
3000 kg/h 1800 kg/h 350 – 600 kg/h
3600 kg/h 700 – 1000 kg/h
19
ROTANTE ROTARY DRYER
INFERIOR BUILD SUPERIOR BUILD

- Centrifugal fans
- Batteries (Exchangers)
- Air extraction fan
20
ROTANTE Rotary dryer - INFERIOR BUILD
Discharging
Outlet
Rolling drum cage Feeding inlet

✓ Rolling drum cage
 Product moves very slowly through the dryer
✓ Linear ascent on the Archimedes screws
2 Archimedes screws to ✓ Rolling drum cage with Archimedes screws covered with steel
recover fine particles sheeting
21
ROTANTE Rotary dryer
COMPLEMENTARY FEATURES OF THE ROTARY DRYER
▪ ABSENCE OF DEAD ZONES:

• Homogeneous drying
• No contamination among different products
HYGIENE
▪ LINEAR PRODUCT FLOW:
• Drying control
• Possibility of defining 2 independent zones
 FLEXIBILITY , CONSTANT PRODUCT QUALITY - RELIABILITY
Total
Pertes thermal totales
thermiques losses par
Total
Pertesthermal losses
thermiques through
totales par les extractions
les parois du sécheur through extractions
11%
11%
the walls of1%the dryer 1 %
Energy efficiency Energie sensible cédée au

Sensible energy
support
90% transferred
0% to the
support 0%
Total
Energie energy
totale
transferred
cédée au produit to the
88%
product 88%
22
“JET ZONE” TYPE DRYER/TOASTER
Example: Extruded Flakes Line
23
Two zones,
gas-activated direct air intrusion
toaster-dryer
24
Two zones, gas-activated direct air
intrusion toaster-dryer
CRUNCHY
TOASTED FLAKES
HOT AIR
Chewy
flakes
215- 225°C 185-195°C
INTRUSION TOASTER
(FLUIDISED BED)
25
Drying Technology - Importance of the cooler
▪ Necessary operation for the preservation of food products

= FOOD SAFETY
▪ Prevents condensation of the evaporating water during cooling after leaving

the dryer
26
Thank you for your attention
www.clextral.com
Tous droits réservés – Reproduction intégrale ou partielle interdite.


Optimize food drying processes

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Optimize food drying processes

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DRYING TECHNOLOGIES

BELT ROTARY “JET ZONE”

FOOD preservation / stabilisation unit operation

Decrease in product moisture

Reach the product's QUALITY OBJECTIVES

▪ Organoleptic quality (formulation, texturization)

▪ Absence of enzymatic and non-enzymatic reactions, and of

WATER ACTIVITY (aw) = availability of water in the analysed food

=> (Th) always < (Ta)

DRY AIR MOIST AIR

RELATIVE HUMIDITY (RH): ABSOLUTE HUMIDITY (AH)

Also known as the hygrometric degree

ENERGY EVAPORATION OF THE

EXTRUDED PRODUCTS DRYING THEORY atom

EVAPORATION NOTION (FREE & BOUNDED)

▪ Superficial water ▪ Water absorbed in the walls of structures

T max = 65°C at t = 15 min

The availability of water depends on the product and has

3 PHASE 3 – DRYING DECREASE

• AIR FLOW (VOLUME & SPEED)

• RELATIVE AIR MOISTURE

All rights reserved – Part or full reproduction is forbidden.

WATER HOLDING CAPACITY BY THE AIR

All rights reserved – Part or full reproduction is forbidden.

TEMPERATURE EFFECT IN THE RESIDENCE TIME FOR POROUS PRODUCTS

100 120 140 160 180 Drying Temperature°C

All rights reserved – Part or full reproduction is forbidden.

AIR FLOW EFFECT TO THE PRODUCT DRYING TIME

Drying Time (min)

Air Flow Speed (m/s)

All rights reserved – Part or full reproduction is forbidden.

SNACK line example

EV 300 EV 600 EV 1200

SNACKS 250 / 300 500 / 600 1000 / 1200

Example: Couscous line

Short Pasta Line Couscous Line Ingredients Line

3000 kg/h 1800 kg/h 350 – 600 kg/h

3600 kg/h 700 – 1000 kg/h

INFERIOR BUILD SUPERIOR BUILD

Rolling drum cage Feeding inlet

▪ ABSENCE OF DEAD ZONES:

Energy efficiency Energie sensible cédée au

Example: Extruded Flakes Line

215- 225°C 185-195°C

▪ Necessary operation for the preservation of food products

▪ Prevents condensation of the evaporating water during cooling after leaving

Tous droits réservés – Reproduction intégrale ou partielle interdite.

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