a b s t r a c t
The relative extent of crystallization for lactose and sucrose within spray dryers allows the WLF equation to be tested
for this type of in-process crystallization, since this equation suggests that the crystallization rate is related to the
difference between the material temperature and the glass-transition temperature of that particular material. In this
study, the amount of sucrose crystallization during drying was studied using a bench-top spray dryer (Buchi B290)
over a practical range of inlet gas temperatures (95220 C). It has been found that very large changes in the degree of
crystallinity for the nal spray-dried product can be achieved for sucrose by using different inlet gas temperatures,
compared with much smaller changes in the crystallinity of lactose for a similar range of inlet temperatures. This
result supports the suggestion that the crystallization rate is related to the difference between the material temperature and the glass-transition temperature, since sucrose has a much lower glass-transition temperature than
lactose. The results have the potential to be implemented to achieve specied degrees of crystallinity in many powder
materials produced from spray-drying processes.
2008 The Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.
Keywords: Stickiness barrier; Sucrose; Crystallization kinetics; WLF equation; Operating condition(s)
1.
Introduction
Spray drying is a potential process to obtain crystalline powders in a single step, rather than multi-stage conventional
crystallization processes where crystallization is normally followed by a further drying step. Lactose and sucrose have the
same molecular weight, but due to the difference in their
molecular conguration they have different glass-transition
temperatures (Slade and Levine, 1994). Spray drying of sucrose
is known to be difcult because its glass-transition temperature is low (62 C; Roos, 1993), making this material sticky
at low drying temperatures (Bhandari et al., 1997b; Bhandari
and Howes, 1999). However, recent work on combining the
drying and crystallization processes (Chiou et al., 2008a,b) suggests that drying at temperatures above the glass-transition
temperature hastens the subsequent transition from a sticky
amorphous material to a less sticky crystalline one. Hence
continuing the transformation from a sticky amorphous material right through to the less sticky crystalline state by
operating the dryer at a sufciently high temperature may
assist in the spray drying of sucrose by creating more crystalline sucrose at these high temperatures.
The WilliamsLandelFerry equation (Williams et al., 1955)
has been applied to many polymer systems to nd the rate
of crystallization as a function of the material temperature
(T) and the glass-transition temperature (Tg ) at constant temperature and controlled humidity conditions (Bhandari and
Howes, 1999; Roos and Karel, 1992, 1991a,b, 1990; Levine and
Slade, 1986; Soesanto and Williams, 1981). Also, both the
glass-transition temperature (Tg ) and the difference between
material and glass-transition temperatures (T Tg ) have been
used to dene and/or evaluate material properties such as
crystallization (Bhandari and Howes, 1999), caking, lumping
and agglomeration (Bhandari and Howes, 1999; Aguilera et
al., 1995), the effect of storage conditions on retaining specic material properties (Paterson et al., 2005; Bhandari and
Howes, 1999; Senoussi et al., 1995; Schenz, 1995), the effects
of conditions for reactions to take place (Meste et al., 2002;
Buera and Karel, 1993), and to measure the diffusion rate constant during curing (Wise et al., 1997). Again, almost all of
88
2.
2.1.
Materials
2.2.
Sample preparation
2.3.
2.4.
Moisture sorption and moisture content
measurement
Crystallization behaviour was studied according to the
method described in previous work (Imtiaz-Ul-Islam and
Langrish, in press). However, for these set of experiments,
a mass of 0.55 g of the powder product obtained just after
spray drying the sample solution was placed on a Petri dish
as a monolayer (one particle thick), and the mass change as a
function of storage time was recorded (by computer using the
Mettler Toledo Balance Link v3.01 program) once per minute
over a period of 12 days until the mass of the sample and dish
stayed constant for more than 6 h. Afterwards, a moisture content measurement was done by oven drying the samples for
24 3 h at 100 C.
2.5.
Analytical experiments
Both the original (raw) sample, and the product dried at a high
inlet gas temperature (220 C) and the lowest pump rate (3%),
were assessed and compared, in order to investigate possible
thermal degradation of the spray-dried products using the following analytical techniques and procedures. These analytical
89
3.
3.1.
2.5.3.
2.5.4.
2.6.
90
44 (1)
23 8 (4)
3 0.4 (2)
32 (1)
20 5 (2)
<1 0.1 (3)
24 3 (2)
9 4 (3)
<1 0.4 (3)
1 (1)
<1 (2)
<1 0.05 (3)
<1 (1)
<1 (1)
<1 0.2 (3)
<1 (1)
<1 (1)
<1 0.3 (3)
3%
5%
10%
4 (1)
14 1(2)
<1 (2)
3 (1)
4 (1)
8 4 (3)
10 (1)
8 (1)
7 7 (3)
9 9 (3)
120
105
85
65
45
Pump rate
Table 1 Average yields of the spray-dried products at different inlet gas temperatures.
95
160
200
210
220
91
<1 (1)
<1 0.3 (4)
<1 0.1 (2)
<1 (1)
<1 0.2 (2)
9 4 (3)
<1 0.01 (2)
<1 0.3 (3)
11 1 (3)
8 (1)
9 1 (2)
10 2 (3)
20 3 (2)
15 (1)
15 3 (3)
16 (1)
17 (1)
18 9 (3)
9 (1)
13 4 (3)
9 2 (3)
8 (1)
6 2 (3)
10 (1)
4 4 (2)
9 9 (2)
1 (1)
13 (1)
3%
5%
10%
Peak height (mean standard
deviation, number of runs)
200
160
120
105
95
85
65
45
3.2.
Pump rate
Table 2 Average peak heights of the spray-dried products at different inlet gas temperatures. [Change in moisture content, % (100 kg kg1 dry basis).].
210
220
92
Fig. 6 Mass spectra of raw (top) and spray-dried (bottom) sucrose in the positive ion mode.
for lower inlet gas temperatures and lower liquid ow rates.
However, the outlet gas temperature does not collapse the
curves in Figs. 3 and 4 to a noticeable extent, suggesting that
the temperature-time history of the particles throughout the
dryer may be important, as included in the model by Chiou et
al. (2008a).
Nevertheless, Table 2 shows that the sorption peak heights
(a measure of the degree of crystallinity) for sucrose can be
altered from less than 1% to about 20% (based on these sorption test results) depending on the pump (liquid ow) rate,
which is signicant compared with the alteration found for
lactose from around 8 to 9% (Chiou et al., 2008a). As expected,
the change in crystallinity for sucrose is higher than that for
lactose for a similar range of inlet gas temperatures, due to
the lower glass-transition temperature for sucrose that gives
greater scope for changing the difference between the material temperature and the glass-transition temperature in this
spray dryer.
3.3.
Assessment of the degree of thermal degradation
for spray-dried sucrose
Two samples of sucrose (raw sucrose and spray-dried sucrose)
were analyzed for degradation products that could have
resulted from the processing by spray drying. Three analytical
tests (Liquid ChromatographyMS, FTIR, Ion Chromatography)
were performed to assess the product composition and degradation of powders produced at an inlet gas temperature of
220 C and a 3% pump rate. Simple sugars form complex
degradation products upon heating at aerobic and anaerobic conditions, in a process called caramelization (Jiang et al.,
2008). Caramelization is the process of removal of water from
a sugar molecule, followed by isomerization and polymerization steps. The polymerization products are very complex
and poorly dened compounds with high molecular weights
and a system of conjugated double bonds responsible for the
characteristic dark brown color of thermally dehydrated sugar
molecules.
LCMS mass spectra of the two samples were obtained by a
ow injection using a mobile phase of 80% CH3 CN and 20% H2 O
(data not shown). A strong sodiated adduct ion was observed
in the positive mode (Fig. 6) but only a low intensity negative
sucrose ion was detected in the negative mode (Fig. 7). Ammonium acetate (10 mM CH3 COONH4 ) was added to water, and
this signicantly increased sucrose ionization in the negative
mode, where a strong deprotonated peak was observed with
an m/z of 341.2 and a dimmer with m/z of 683.4. No additional
peaks with higher m/z ratios were observed for the spray-dried
sample, indicating the absence of product degradation.
Ion Chromatography (IC) tests were performed for the
spray-dried sucrose samples to assess the purity. According to
the analysis, no detectable presence of degraded sugar units
was found.
Two virtually identical spectra were obtained from the FTIR
analysis of raw and spray-dried sucrose (Fig. 8). This suggests
that no new functional group(s) were formed, and there was
no evidence for any breakage of existing chemical bonds in
the case of spray-dried sucrose.
93
Fig. 7 Mass spectra of raw (top) and spray-dried (bottom) sucrose in negative ion mode.
The MDSC results also suggest that both the raw sucrose
and the dried sucrose at these conditions were very crystalline
in nature, by showing similar melting curves (heat of melting
102.9 J/g and 100.0 J/g for spray-dried and raw sucrose powders, respectively) in the thermographs (Fig. 9). There were
no indications of glass transitions, and crystallization due to
amorphicity of the powders in the thermograph obtained from
the MDSC analysis was absent (Fig. 9). This proves the very
similar nature of the raw and spray-dried sucrose powders in
terms of their crystallinity.
The test results from all these methods are in good agreement and conrm that the sucrose dried at these operating
3.4.
SEM micrographs
The surface morphology in the following micrograph also conrms the crystallinity of the powders produced at an inlet gas
temperature of 220 C and a 3% pump rate (Fig. 10).
94
Fig. 10 Sucrose powders produced at inlet gas temperature of 220 C and a 3% pump rate.
4.
Conclusions
Stickiness of sucrose and sugar-rich materials at higher processing conditions has been an issue not allowing those
products to be spray dried on an industrial scale, because of
low yield. It has been found that very large changes in the
degree of crystallinity for the nal spray-dried product can be
achieved for sucrose by using different inlet gas temperatures,
compared with much smaller changes in the crystallinity of
lactose for a similar range of inlet temperatures. This result
supports the suggestion that the crystallization rate is related
to the difference between the material temperature and the
glass-transition temperature. Therefore, with materials having low glass-transition temperatures, such as sucrose, the
yield from spray drying can be signicantly increased by
processing the materials at sufciently high inlet gas temperatures without necessarily degrading the products signicantly,
through crystallizing the materials within the dryer.
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