阅读说明：本技术 喷雾干燥的粉末 (Spray-dried powder ) 是由 查尔斯·珀欣·贝茨 丹尼尔·迈克尔·施利普夫 杰森·治辛·李 于 2020-03-25 设计创作，主要内容包括：描述了喷雾干燥的封装调味剂粉末,所述粉末具有大尺寸、高可流动性、完全致密且高度可分散和/或可溶并且具有低表面积与体积比和高堆密度的颗粒。这类调味剂粉末提供了调味组分的高保留,并且通过低温喷雾干燥过程,例如,其中通过本文多样地描述的技术强化干燥的一步过程有利地生产了这类调味剂粉末。(Spray-dried encapsulated flavor powders are described having particles of large size, high flowability, fully dense and highly dispersible and/or soluble and having a low surface area to volume ratio and high bulk density. Such flavor powders provide high retention of flavor components and are advantageously produced by a low temperature spray drying process, e.g., a one-step process in which drying is enhanced by the techniques as variously described herein.)

1. A spray-dried encapsulated flavor powder comprising one or more encapsulated flavor ingredients and characterized by the following features:

(A) a dispersion medium dissolution time of less than 60 seconds;

(B) a dispersion medium dispersion time of less than 15 seconds;

(C) in a particle size distribution, at least 75% of the particles in the powder have a particle size of at least 80 μm;

(D) surface area (μm) of particles of the powder in the range of 0.01 to 0.03²) Volume (μm)³) A ratio;

(E) a particle void volume in particles of the powder of less than 10% of the total particle volume;

(F) at 22 to 40lb/ft³(ii) a bulk density of particles of said powder in the range, and

(G) an angle of repose of the powder of not more than 40,

optionally wherein, when the spray dried powder comprises encapsulated oil, the surface oil percentage is less than 1.5%.

2. The spray-dried encapsulated flavor powder of claim 1, wherein the one or more encapsulated flavor ingredients comprise at least one selected from the group consisting of: almond, orange, lemon, lime, tangerine, apricot kefir, fennel, pineapple, coconut, pecan, apple, banana, strawberry, melon, caramel, cherry, blackberry, raspberry, ginger, boysenberry, blueberry, vanilla, honey, molasses, wintergreen oil, cinnamon, clove, butter, cream, butterscotch, butter, coffee, tea, peanut, cocoa, nutmeg, chocolate, cucumber, mint, toffee, eucalyptus, grape, raisin, mango, peach, melon, kiwi, lavender, licorice, maple, menthol, passion fruit, pomegranate, dragon fruit, pear, walnut, peppermint, pumpkin, Shashi, rum, and spearmint.

3. The spray-dried encapsulated flavor powder of claim 1, wherein the one or more encapsulated flavor ingredients are encapsulated by a carrier material comprising at least one selected from the group consisting of: carbohydrates, proteins, lipids, waxes, cellulosic materials, sugars, starches, natural and synthetic polymeric materials.

4. The spray-dried encapsulated flavor powder of claim 1, wherein the one or more encapsulated flavor ingredients are encapsulated by a carrier material comprising at least one selected from the group consisting of: maltodextrin, corn syrup solids, modified starches, gum arabic, modified celluloses, gelatin, cyclodextrins, lecithin, whey protein, and hydrogenated fats.

5. The spray-dried encapsulated flavor powder of claim 1, wherein the one or more encapsulated flavor ingredients are encapsulated by a carrier material comprising a modified starch.

6. The spray-dried encapsulated flavor powder of claim 1, wherein the one or more encapsulated flavor ingredients comprise at least one flavor oil.

7. The spray-dried encapsulated flavor powder of claim 1, comprising a single-step spray-dried encapsulated flavor powder.

8. The spray-dried encapsulated flavor powder of claim 1, characterized by a dispersion medium dissolution time of less than at least one of 45, 40, 35, 30, 25, 20, 15, 12, 10, 8, 7, 6, and 5 seconds.

9. The spray-dried encapsulated flavor powder of claim 1, characterized by a dispersion medium dispersion time of less than at least one of 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 8, 2, and 1 second.

10. The spray-dried encapsulated flavor powder of claim 1, characterized in that in the particle size distribution, at least one of 80%, 85%, 88%, 90%, 91%, 92%, 93%, 94% and 95% of the particles in the powder have a particle size of at least 80 μm.

11. The spray-dried encapsulated flavor powder according to claim 1, characterized in that in the particle size distribution, at least 80% of the particles in the powder have a particle size of at least 80 μm.

12. The spray-dried encapsulated flavor powder of claim 1, characterized in that in the particle size distribution, at least 85% of the particles in the powder have a particle size of at least 80 μm.

13. The spray-dried encapsulated flavor powder of claim 1, characterized in that in the particle size distribution, at least 90% of the particles in the powder have a particle size of at least 80 μm.

14. The spray-dried encapsulated flavor powder of claim 1, characterized by a particle void volume of less than at least one of 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2.5%, 2%, and 1% of the total particle volume.

15. The spray-dried encapsulated flavor powder of claim 1, characterized by a particle void volume of less than 2.5% of the total particle volume.

16. The spray-dried encapsulated flavor powder of claim 1, characterized by a particle void volume of less than 2% of the total particle volume.

17. The spray-dried encapsulated flavor powder of claim 1, characterized in that it is between 25 and 38lb/ft³(ii) a bulk density of particles of said powder within a range.

18. The single-step spray-dried encapsulated flavor powder of claim 1, characterized by an angle of repose of the powder of no more than 35 °.

19. The spray-dried encapsulated flavor powder of claim 1, characterized by an angle of repose of the powder of no more than 30 °.

20. The spray-dried encapsulated flavor powder of claim 1, wherein the particles in the powder are free of large size voids.

21. The spray-dried encapsulated flavor powder of claim 1, wherein the particles in the powder have a non-spherical form.

22. The spray-dried encapsulated flavor powder of claim 1, wherein the particles in the powder have an elongated form.

23. The spray-dried encapsulated flavor powder of claim 1, wherein the powder has an average eccentricity of at least 0.7.

24. The spray-dried encapsulated flavor powder of claim 1, wherein the powder has an average eccentricity in the range of 0.70 to 0.95.

25. The spray-dried encapsulated flavor powder of claim 1, wherein the powder has an average eccentricity in the range of 0.75 to 0.95.

26. The spray-dried encapsulated flavor powder of claim 1, wherein the powder has an average eccentricity in the range of 0.80 to 0.95.

27. The spray-dried encapsulated flavor powder according to claim 1, characterized in that in the particle size distribution at least 80%, 85%, 88%, 90%, 91%, 92%, 93%, 94% or 95% of the particles in the powder have a particle size of at least 85 μ ι η, 90 μ ι η, 95 μ ι η, 100 μ ι η, 110 μ ι η or 120 μ ι η.

28. A spray-dried encapsulated flavor powder according to claim 1, characterized in that in the particle size distribution, at least 80%, 85%, 88%, 90%, 91%, 92%, 93%, 94% or 95% of the particles in the powder have a particle size within a range having any of the endpoints 80 μ ι η, 85 μ ι η, 90 μ ι η, 95 μ ι η, 100 μ ι η, 110 μ ι η, and 120 μ ι η, with the proviso that the lower endpoint of the range is less than the upper endpoint of the range.

29. The spray-dried encapsulated flavor powder of claim 1, characterized by a median particle size of greater than 100 μ ι η.

30. The spray-dried encapsulated flavor powder of claim 1, characterized by an average particle size of greater than 100 μ ι η.

31. The spray-dried encapsulated flavor powder of claim 1, wherein the one or more encapsulated flavor ingredients comprises a flavor oil.

32. The spray-dried encapsulated flavor powder of any one of claims 1 to 31, characterized in that the spray-dried encapsulated flavor powder is produced from a spray-dryable material having a retention level of at least one of 90%, 91%, 92%, 93%, 94%, 35%, 96%, 97%, 98%, 98.5%, 99%, 99.5% and 99.9% based on the weight of flavor components in the spray-dryable material.

Technical Field

The present disclosure relates generally to spray-dried flavor powders (flavor powders, spice powders), and more particularly to single-step spray-dried/single-atomized encapsulated flavor powders with superior use and performance characteristics.

Background

In the field of spray-dried encapsulated flavor powders for use as additives and ingredients in food and/or beverage products, spray-dried flavor powders having a variety of undesirable characteristics are commercially produced. These include susceptibility of the flavour components to oxidation, decomposition and/or degradation, poor dispersibility and/or solubility of the flavour powder in a liquid medium, small powder particle size, high void volume in the powder particles requiring a correspondingly large amount of powder in use and poor flowability which creates difficulties in the distribution and handling of the flavour powder and poor retention of the active flavour component.

Thus, the art continues to seek improvements in spray dried encapsulated flavor powders.

Disclosure of Invention

The present disclosure relates to spray-dried encapsulated flavor powders having the combined properties of large, highly flowable, fully dense, highly dispersible and/or soluble, and low surface area to volume ratio and high bulk density (bulk density) and retention of highly active flavor components relative to prior art spray-dried encapsulated flavor powders.

In various aspects, the present disclosure relates to a spray-dried encapsulated flavor powder, e.g., a single-step spray-dried encapsulated flavor powder, comprising one or more encapsulated flavor ingredients and characterized by one or more, and preferably all, of the following features:

(A) a dispersion medium dissolution time of less than 60 seconds;

(B) a dispersion medium dispersion time of less than 15 seconds;

(C) wherein at least 75% of the particles in the powder have a particle size distribution with a particle size of at least 80 μm;

(D) surface area (μm) of particles of the powder in the range of 0.01 to 0.03²) Volume (μm)³) A ratio;

(E) a particle void volume in the particles of the powder of less than 10% of the total particle volume;

(F) at 22 to 40lb/ft³A bulk density of particles of the powder in the range of (a), and

(G) an Angle Of Repose (Angle Of Repose ) Of the powder Of not more than 40 DEG,

optionally wherein when the spray-dried powder contains encapsulated Oil, the Surface Oil Percentage is less than 1.5%.

In another aspect, the present disclosure relates to a spray-dried encapsulated flavor powder, e.g., a single-step spray-dried encapsulated flavor powder, having at least 90% flavor component retention, which may also be characterized by any of the above-described features (a) - (G) and/or the surface oil percentages specified above.

Other aspects of the present disclosure relate to these spray-dried encapsulated flavor powders characterized by any two, three, four, five, six, or all seven of the above-described features (a) - (G), optionally wherein when the spray-dried powder contains an encapsulated oil, the ratio of the amount of surface oil per unit in the corresponding amount to the amount of encapsulated oil is less than 1.5%.

In various aspects, the present disclosure relates to a single-step spray-dried encapsulated flavor powder as described above, wherein the one or more encapsulated flavor ingredients are selected from the group consisting of: almond, orange, lemon, lime, tangerine, apricot kefir, fennel, pineapple, coconut, pecan, apple, banana, strawberry, melon, caramel, cherry, blackberry, raspberry, ginger, boysenberry, blueberry, vanilla, honey, molasses, wintergreen oil, cinnamon, clove, butter, cream, butterscotch, butter, coffee, tea, peanut, cocoa, nutmeg, chocolate, cucumber, mint, toffee, eucalyptus, grape, raisin, mango, peach, melon, kiwi, lavender, licorice, maple (maple), menthol, passion fruit, pomegranate, dragon fruit, pear, walnut, peppermint, pumpkin, sand (rober), rum, and spearmint.

In various other aspects, the present disclosure relates to a single-step spray-dried encapsulated flavor powder as described in aspects above, wherein the encapsulated flavor is encapsulated by a carrier material selected from the group consisting of: carbohydrates, proteins, lipids, waxes, cellulosic materials, sugars, starches, natural and synthetic polymeric materials.

Other aspects, features and embodiments of the disclosure will be more fully apparent from the following description and appended claims.

Drawings

This patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the office upon request and payment of the necessary fee.

FIG. 1 is a graphical representation of the temperature of the spray material droplets during the spray drying process to produce spray-dried encapsulated flavor powder particles as a function of the percent solids of the droplets, showing the droplets and production in a conventional high temperature spray drying process ("spray-dried powder")Spray-dried encapsulated flavor powders ('s) of the present disclosure "Powder ") through the development of a drying phase to which the low-temperature spray-dried droplets are subjected.

Fig. 2 is an electron micrograph at 2500X magnification of spray dried encapsulated flavor powder particles produced by conventional high temperature spray drying showing the hollow character (central void) of such particles.

Fig. 3 is an electron micrograph at 1510X magnification of spray dried encapsulated flavor powder particles of the present disclosure showing the dense nature of such particles due to the absence of large-scale voids as shown by the powder particles of fig. 2.

Figure 4 is a graph of the composition percentage of lemon oil showing the flavor components in such flavored oils.

Fig. 5 is a graph of the composition percentages of lemon oil showing flavor components in such flavor oils as originally contained in the lemon oil spray-dried with a carrier (lemon oil) and encapsulated in the spray-dried powder as disclosed herein (lemon DriZoom).

FIG. 6 is a pie chart showing the weight percent of flavor components of the fruit juice wine jet flavoring material.

Fig. 7 is a pie chart showing the weight percent of flavor components of the fruit juice jet wine flavoring material of fig. 6 encapsulated as in the spray dried powder of the present disclosure.

Fig. 8 is a schematic diagram of a spray-drying system that can be used to produce the spray-dried encapsulated flavor powder of the present disclosure.

Fig. 9 is a schematic diagram of a portion of the spray drying process system of fig. 8 in a cross-sectional view (breakthrough view) showing the enhancement of the intensity of the spray drying process by inducing localized turbulence within the interior volume of the spray drying vessel in the system.

Fig. 10 is a schematic view of another spray drying apparatus that may be used to produce the encapsulated flavored spray dried powders of the present disclosure, wherein the apparatus includes a turbulent mixing nozzle array on a wall of the spray drying chamber configured to inject brief, intermittent turbulent air blasts into the primary fluid stream in the spray drying chamber.

Fig. 11 is a schematic view of other spray drying equipment that may be used to produce the encapsulated flavored spray dried powders of the present disclosure.

Detailed Description

The present disclosure relates to spray-dried encapsulated flavor powders, e.g., single-step spray-dried encapsulated flavor powders, having the combined properties of large, highly flowable, fully dense and highly dispersible and/or soluble, and low surface area to volume ratio and high bulk density and high retention of active flavor components relative to prior art spray-dried encapsulated flavor powders.

As used herein, the term "flavoring agent" refers to a substance used to produce a sensation of taste or a combination of taste and flavor. In subsequent use, the flavoring agent may be an additive ingredient used in foods and/or beverages to enhance their quality and appeal.

The term "single-step spray-dried" in connection with the powder of the present disclosure means that the powder is produced only by low-temperature spray-drying (inlet temperature of the drying fluid flowing to the spray-drying vessel <110 ℃) comprising contacting atomized particles of the spray-dryable material produced by a single-source atomizer with a drying fluid to achieve a dryness of the solvent to less than 5 wt% of the solvent from the spray-dryable material (based on the total weight of the spray-dried powder) without any post-spray-drying treatment, such as fluidized bed treatment, coating or chemical reaction. A "single source atomizer" as indicated in this definition refers to a single atomizer receiving one type of spray-dryable material from a respective feed source, i.e. the atomizer does not receive different spray-dryable materials from different feed sources at the same time.

Various measurement/determination techniques suitable for various characteristics of the spray-dried encapsulated flavor powders of the present disclosure are described below.

Dissolution time of dispersion medium

Dispersion medium dissolution time the rate at which the spray-dried powder dissolves in water as the dispersion medium is measured. The procedure for determining the dissolution time of the dispersion medium is as follows:

1) 2 grams of the spray dried powder was poured into 100 grams of water (in a 150mL beaker) while the water was stirred with a mixer at 250RPM at room temperature.

2) Brix measurements (measurement of dissolved solids in aqueous solution, as determined by a Milwaukee Instruments MA871 digital brix refractometer) of the powder and water composition were measured at 15 second intervals after the powder began to dissolve in the water and all measurements were recorded.

3) When the brix value equilibrated and 1 minute did not change, the time value was reported as the dissolution value.

4) The method is characterized in that: at 2 and 4 minutes, the mixing was increased from 250RPM to 500RPM and 1000RPM, respectively, to ensure complete mixing.

Dispersion time of dispersion medium

Dispersion medium dispersion time the amount of time required to disperse the spray-dried powder in water as the dispersion medium was measured. The procedure for determining the dispersion medium dispersion time was as follows:

1) 2 grams of the spray dried powder was poured into 100 grams of water (in a 150mL beaker) while the water was stirred at 250RPM at room temperature.

2) At 2 and 4 minutes, the mixing was increased from 250RPM to 500RPM and 1000RPM, respectively, to ensure complete mixing.

3) The dispersion medium dispersion time was recorded as the time required for all the powder to settle below the water surface in the stirred beaker. Once the powder is in contact with water, time begins.

Particle size distribution

The particle size distribution of the spray-dried powder was measured by a Beckman Coulter LS 13320 particle size analyzer that provided a volume distribution output.

1) About 1 gram of the spray dried powder was loaded into a sampling tube.

2) The Beckman Coulter LS 13320 vacuums the powder into the analysis chamber according to the manufacturer's protocol.

3) The laser diffraction data were interpreted by the Fraunhofer method and reported as volume distribution.

4) The particle size is reported as the median value from the distribution (d 50).

Surface area (. mu.m)²) Volume (μm)³) Ratio of

The surface area to volume ratio describes the volume (in μm) of material relative to the volume (mass) of the particles³In units), the amount of surface area (in μm) to which the particles are exposed²In units). The reduced particle surface area per unit volume reduces the area available for product oxidation. Therefore, in order to reduce the surface area to volume ratio, it is preferable to increase the particle diameter because of the valueAnd (4) in proportion. The surface area to volume ratio is calculated using the particle diameters (particle size values) resulting from the particle size distribution. The median value (d50) was used for surface area/volume calculations, assuming spherical particles.

Void volume of particles

The particle void volume is determined as a calculated percentage of the volume occupied by any air pockets inside the particle. Particle void volume measurements relied on Scanning Electron Microscope (SEM) cross-sectional views to observe the internal cross-section of the particles for measurement. The particle void volume value is reported as a percentage calculated from the volume of the entire particle defined by the void volume/particle outer boundary. The procedure for determining the void volume of the particles was as follows:

1) about 100mg of the powder was mixed well in 5mL of epoxy resin.

2) The resin was cast in a mold (Electron Microscopy Sciences part number 70900) and allowed to cure for 1 day.

3) After curing, the mold is scored and split in half to present a clean surface of cross-sectional particles embedded in the resin.

4) Microscopic imaging analysis was performed at 5KV, between.1 and 1 KX. From the cross-sections, the cross-sectional diameter of the particles and any cross-section of the internal voids were measured using Image analysis software (Image J, National Institute of Health).

5) The void volume is determined by dividing the sum of the void volumes (calculated from V4/3 pi r 3) by the volume of the entire particle and multiplying by 100.

Bulk density

The bulk density of the particles of the powder was measured by ASTM standards. The procedure is as follows:

1) the calibrated Copley BEP 225 mL density cups were peeled off on a balance.

2) The cup was filled until overflowing and the excess was scraped off.

3) The powder + cup was reweighed.

4) The weight in grams is divided by 25mL (volume of cup) and multiplied by 62.428 to convert to pounds/ft ^ 3.

Angle of repose

The angle of repose, also referred to as the flowability index, of the spray-dried powder was determined as follows:

1) the angle of repose of the cone formed by the powder flowing through the funnel onto the catch plate (catch plate) was measured using a Copley BEP2 flow meter.

2) The funnel was secured 75mm above the collection tray using a messenger tool with the adjustment gate (shutter) closed.

3) About 30g of powder was weighed out and placed in a funnel for analysis.

4) The powder was discharged quickly, allowing all of the powder to pour out.

5) For products with poor flowability, a stirring connection with a slow, smooth stirring movement is used.

6) The height (h) and diameter (d) of the cone produced on the collection tray were measured. Then, the angle of repose was calculated using the following formula:

or

Table 1 below relates the summarized flow properties to specific angle of repose values.

TABLE 1

Percent surface oil

Surface oil percentage, surface oil/total powder weight ratio is a measure of the surface oil in which the powder was washed from by hexane washing and oil content was quantified by gas chromatography-mass spectrometry (GC-MS). The concentration of the washed oil in hexane was multiplied by the weight of hexane used, divided by the weight of the washed powder and multiplied by 100 to obtain the surface oil percentage. The procedure is as follows:

1) 35g of the spray-dried powder were placed in a cellulose filter paper cartridge (Whatman grade 603, 33 mm. times.100 mm)

2) The filter paper cartridge was then placed in a soxhlet extractor.

3) 100g of hexane was weighed and placed in a 250mL flat bottom flask and connected to a Soxhlet extraction apparatus.

4) The flask was heated to boiling on a hot plate while stirring with a magnetic stir bar. The hexane was refluxed for 4 hours.

5) After 4 hours of reflux operation, the flask was allowed to cool. Once cooled, hexane aliquots were recovered for GC-MS analysis.

The quantitative method comprises the following steps:

1) a 5-point calibration curve was generated using the flavor group being analyzed to determine a linear correlation between the detector response value and the surface oil cleaning solution concentration.

2) The surface oil percentage was determined according to the following formula:

the dryness of the single pass spray dried encapsulated flavor powder of the present disclosure was measured to exclude any flavor oils present in the spray dried powder, which identifies the extent to which the product powder is free of water and other volatile solvent media. Preferably, the dryness of the single pass spray dried encapsulated flavor powder is characterized by no more than 5% by weight water and/or other volatile solvent medium in the powder, more preferably no more than 2% by weight, more preferably no more than 1% by weight and most preferably less than 0.75% by weight, based on the total weight of the powder.

In various embodiments, the weight of water and/or other volatile solvent medium in the spray-dried powder can be less than 5%, 4.8%, 4.6%, 4.5%, 4.4%, 4.2%, 4%, 3.8%, 3.6%, 3.5%, 3.4%, 3.2%, 3%, 2.8%, 2.6%, 2.5%, 2.4%, 2.2%, 2%, 1.8%, 1.6%, 1.5%, 1.4%, 1.3%, 1.2%, 1.1%, 1%, 0.9%, 0.8%, 0.7%, 0.6%, 0.5%, 0.4%, 0.3%, 0.2%, 0.1%, or 0.05% based on the total weight of the powder, depending on the handling of the spray-dried powder and the requirements for subsequent use of the powder.

The present disclosure provides spray-dried encapsulated flavor powders having superior use and performance characteristics in various aspects, as is apparent from the various features described herein.

The spray-dried encapsulated flavor powder of the present disclosure provides a high level of retention of the original flavor component in the powder, which in various embodiments can be at least 90%, 91%, 92%, 93%, 94%, 35%, 96%, 97%, 98%, 98.5%, 99%, 99.5%, or 99.9% based on the weight of the flavor component in the spray-dryable material from which the spray-dried encapsulated flavor powder is produced. The flavor component may include a single or multiple flavor compounds and ingredients. In this regard, the spray-dried encapsulated flavor powder of the present disclosure is characterized by a "fingerprint" of the flavor component that is highly identical to the flavor component compounds and ingredients in the starting material from which the powder is formed.

In one aspect, the present disclosure relates to a spray-dried encapsulated flavor powder, e.g., a single-step spray-dried encapsulated flavor powder, comprising one or more encapsulated flavor ingredients and characterized by one or more, and preferably all, of the following features:

(A) a dispersion medium dissolution time of less than 60 seconds;

(B) a dispersion medium dispersion time of less than 15 seconds;

(C) wherein at least 75% of the particles in the powder have a particle size distribution with a particle size of at least 80 μm;

(D) surface area (μm) of particles of the powder in the range of 0.01 to 0.03²) Volume (μm)³) A ratio;

(E) a particle void volume in the particles of the powder of less than 10% of the total particle volume;

(F) at 22 to 40lb/ft³A bulk density of particles of the powder in the range of (a), and

(G) an angle of repose of the powder of not more than 40,

optionally wherein when the spray dried powder contains encapsulated oil, the surface oil percentage is less than 1.5%.

Thus, the spray-dried encapsulated flavor powder of the present disclosure may be characterized by any one of characteristics (a) - (G) and/or a surface oil percentage of less than 1.5%.

The spray-dried encapsulated flavor powder of the present disclosure is most preferably characterized by all of the above features (a) - (G) and other features where the surface oil percentage is less than 1.5% when the spray-dried powder contains encapsulated oil.

In the spray-dried encapsulated flavor powder of the present disclosure, for example, in a single-step spray-dried encapsulated flavor powder, the one or more encapsulated flavor ingredients may be of any suitable type and may, for example, comprise at least one selected from the group consisting of: almond, orange, lemon, lime, tangerine, apricot kefir, fennel, pineapple, coconut, pecan, apple, banana, strawberry, melon, caramel, cherry, blackberry, raspberry, ginger, boysenberry, blueberry, vanilla, honey, molasses, wintergreen, cinnamon, clove, butter, cream, butterscotch, butter, coffee, tea, peanut, cocoa, nutmeg, chocolate, cucumber, mint, toffee, eucalyptus, grape, raisin, mango, peach, melon, kiwi, lavender, licorice, maple, menthol, passionflower fruit, pomegranate, dragon fruit, pear, walnut, peppermint, pumpkin, sand, rum, and spearmint.

In various embodiments, the one or more encapsulated flavor ingredients comprise at least one flavor oil.

The spray-dried encapsulated flavor powders of the present disclosure may include any suitable carrier material as an encapsulant for the respective flavor ingredients of the powder. Illustrative examples of carrier materials include, without limitation, at least one selected from the group consisting of carbohydrates, proteins, lipids, waxes, cellulosic materials, sugars, starches, natural and synthetic polymeric materials. Specific materials that may be advantageously used include maltodextrin, corn syrup solids (corn syrup dry powder), modified starches, gum arabic, modified celluloses, gelatin, cyclodextrins, lecithin, whey protein, and hydrogenated fats (hydrogenated fat). Preferably, the carrier material is a modified starch material. A variety of spray dried carriers are identified in table 2 below.

TABLE 2

In various embodiments, the spray-dried encapsulated flavor powder of the present disclosure can be characterized by a dispersion medium dissolution time of less than 45, 40, 35, 30, 25, 20, 15, 12, 10, 8, 7, 6, or 5 seconds.

In various embodiments, the spray-dried encapsulated flavor powder of the present disclosure can be characterized by a dispersion medium dispersion time of less than 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 8, 2, or 1 seconds.

In particular embodiments, the spray-dried encapsulated flavor powder of the present disclosure may have a particle size distribution in which at least 80%, 85%, 88%, 90%, 91%, 92%, 93%, 94%, or 95% of the particles in the powder have a particle size of at least 80 μm. In other embodiments, the spray-dried encapsulated flavor powder of the present disclosure may have a particle size distribution in which at least 80%, 85%, 88%, 90%, 91%, 92%, 93%, 94%, or 95% of the particles in the powder have a particle size of at least 85 μ ι η, 90 μ ι η, 95 μ ι η, 100 μ ι η, 110 μ ι η, or 120 μ ι η, or within a range having any of the endpoints 80 μ ι η, 85 μ ι η, 90 μ ι η, 95 μ ι η, 100 μ ι η, 110 μ ι η, and 120 μ ι η, provided the lower endpoint of the range is less than the upper endpoint of the range. In other embodiments, the spray-dried encapsulated flavor powder of the present disclosure can have a median particle size of greater than 100 μm, or alternatively, an average particle size.

In various embodiments, the spray-dried encapsulated flavor powder of the present disclosure can have a particle void volume of less than 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2.5%, 2%, or 1% of the total particle volume.

In various embodiments, the bulk density of the particles of the spray-dried encapsulated flavor powder of the present disclosure may be from 22 to 40lb/ft³Or more preferably in the range of 25 to 38lb/ft³Within the range of (1).

In various embodiments, the spray-dried encapsulated flavor powder of the present disclosure may have an angle of repose of no more than 40 °, more preferably no more than 35 °, and most preferably no more than 30 °.

The spray-dried encapsulated flavor powder of the present disclosure is formed by low temperature spray drying (<110 ℃ inlet temperature of the spray drying vessel), wherein the drying operation is carried out to obtain a powder characterized by the various features described herein.

Preferably, the spray-drying operation is carried out as a single-step spray-drying operation to form a corresponding single-step spray-dried encapsulated flavor powder.

Spray drying operations may advantageously be carried out under drying intensive conditions in which localized turbulence is created in the drying fluid in the spray drying vessel to enhance mass transfer of water and other volatile solvent species from the wet atomized droplets in the spray drying vessel into the drying fluid and produce a powder having the performance characteristics described herein.

Illustrative operating conditions useful in the production of these powders are described more fully below with reference to illustrative spray-drying systems that can be used for this purpose.

Referring now to the drawings, FIG. 1 is a graphical representation of the temperature of the spray material droplets during the spray drying process to produce spray-dried encapsulated flavor powder particles as a function of the percent solids of the droplets, showing the droplets in a conventional high temperature spray drying process ("spray-dried powder") and producing the spray-dried encapsulated flavor powders (') "Powder ") through the development of a drying phase to which the low-temperature spray-dried droplets are subjected.

As shown in fig. 1, conventional high temperature spray-dried powders that can be produced by spray-drying with an inlet temperature in a spray-dryer of 380-400 ° F undergo a solvent evaporation stage, a diffusion stage, and a heating stage in which the droplets of the feedstock material undergo high temperatures that produce smaller particles, hollow spheres, and, when the encapsulated flavor comprises a flavor oil, high surface oil formation.

In contrast, spray-dried encapsulated flavor powders of the present disclosure that are spray-dried by spray-drying with an inlet temperature in the spray-dryer below 110 ℃ produce fully dense, larger particles and have low surface oil content due to low temperature processing in the diffusion stage.

Figure 2 is an electron micrograph at 2500X magnification of spray dried encapsulated flavor powder particles produced by conventional high temperature spray drying showing the hollow nature (central void) of such particles. The encapsulated flavor was Valencia oil and the spray-dried powder particles were produced by spray-drying at an inlet temperature in a spray-dryer of 380-. As shown in the micrograph, the powder particles have a hollow character, which means that a large part of the overall particle volume is made up of void volume.

Fig. 3 is an electron micrograph at 1510X magnification of spray dried encapsulated flavor powder particles of the present disclosure showing the dense nature of such particles due to the absence of large size voids as shown by the powder particles of fig. 2. According to the present disclosure, the encapsulated flavor is Valencia oil, and the spray-dried powder particles are produced by spray-drying at an inlet temperature in a spray dryer of 190-.

Thus, as is apparent from a comparison of fig. 2 and 3, while the spray-dried encapsulated flavor powder particles produced by conventional high temperature spray drying (fig. 2) are generally spherical in form with substantially hollow characteristics, the spray-dried encapsulated flavor powder particles of the present disclosure have fully dense characteristics, are free of large-sized voids and are in non-spherical form, having elongated characteristics.

Thus, the spray-dried encapsulated flavor powder of the present disclosure may also differ in shape eccentricity from spray-dried encapsulated flavor powder particles produced by conventional high temperature spray drying, wherein the powder produced by conventional high temperature spray drying has an eccentricity value that may be about 0 to 0.55 when the powder particles are characterized by automated image processing and analysis techniques, and wherein the powder of the present disclosure has an average eccentricity value that may be at least 0.70, and may be, for example, in the range of 0.70 to 0.95, 0.75 to 0.95, 0.80 to 0.95, or in other suitable eccentricity values.

As used in this context, the eccentricity value of a spray-dried particle may be determined as the eccentricityWhere a is the length of the longer half axis of the particle when viewed in two-dimensional view, and b is the shorter half axis of the particle when viewed in two-dimensional view. By sprayingAnalysis of a representative sample of the mist dried powder, the average eccentricity E of the powder can be determined as a characteristic thereof.

FIG. 4 is a graph of the composition percentages of lemon oil showing the flavor components in such flavor oils, including, for example, a-pinene, b-pinene, sabinene, myrcene, limonene, g-terpinolene, a-bergamotene, geraniol, and nerol.

Fig. 5 is a graph of the composition percentages of lemon oil showing the flavor components of such flavored oils also shown in the graph shown in fig. 4. Fig. 5 shows various flavor components as originally contained in lemon oil spray dried with a carrier (lemon oil) and encapsulated in spray dried powder as disclosed herein (lemon DriZoom). As shown by the pair of bars where the flavor ingredients (raw base oil and spray-dried encapsulated flavor powder) are identical, the spray-dried powders of the present disclosure achieve high retention levels of each of the ingredients of the initial flavor oil, i.e., a-pinene, b-pinene, sabinene, myrcene, limonene, g-terpinolene, a-bergamotene, geraniol, and nerol.

FIG. 6 is a pie chart showing the weight percent of flavor components of the fruit juice wine jet flavoring material. The flavoring material for fruit juice wine contains 28% limonene, 66.2% benzaldehyde, 4.6% isoamyl acetate, 0.7% ethyl hexanoate and 0.5% ethyl butyrate. The fruit juice wine-jet flavoring material was spray dried at an inlet temperature in a spray dryer at a temperature below 110 ℃ to produce the packaged flavor powder of the present disclosure having a composition as shown in fig. 7 containing 25.3% limonene, 68.6% benzaldehyde, 4.8% isoamyl acetate, 0.8% ethyl hexanoate, and 0.5% ethyl butyrate. Thus, the encapsulated flavor powder encapsulating the fruit juice wine jet flavor material achieved a retention level of 97% of the original blend components spray dried to produce the powder.

Fig. 8 is a schematic view of an illustrative spray-drying system that can be used to produce the spray-dried encapsulated flavor powder of the present disclosure.

As shown, the spray drying process system 10 includes a spray dryer 12, the spray dryer 12 including a spray drying vessel 14 having an upper cylindrical portion 18 and a downwardly converging conical lower portion 16. In this embodiment, the spray dryer vessel 14 is provided with an array of spray bars (puffer jet)20 mounted in two circumferentially extending, longitudinally spaced rows, wherein each spray bar is circumferentially spaced from an adjacent spray bar in the row. Each lance in each row is arranged to be supplied with secondary drying fluid via a secondary fluid feed line 24 connected to the source structure 22, which lances may extend circumferentially around the spray dryer vessel 14 such that each lance is connected to a second fluid feed line 24 in the same manner as the lances shown on the opposite side of the spray dryer vessel 14 in the system shown in figure 1. The use of a nozzle induces local turbulence in the drying fluid in the inner volume of the spray drying vessel.

Spray-dried encapsulated flavor powders of the present disclosure can be produced using spray-drying containers that do not use such nozzles or other devices to induce localized turbulence in the drying fluid, but such devices can provide enhanced drying of the droplets of spray-dryable material introduced into the interior volume of the container, which can be highly advantageous in the production of spray-dried encapsulated flavor powders characterized by the various features described herein (features (a) - (G) above, as well as the surface oil percentage features discussed above as applicable when the spray-dried powder contains encapsulated flavor oil in the flavor component).

In the system of fig. 8, the secondary fluid source structure 22 is shown schematically, but in practice it may be comprised of suitable piping, valves and manifolds connected to the secondary fluid supply tank and to a pump, compressor or other motive fluid driver which produces a pressurized secondary drying fluid stream directed into the lance 20 in the secondary fluid feed line 24.

At the upper end of the spray drying vessel 14, an inlet 26 is provided through which the spray-dried, spray-dryable, liquid flavouring composition in the spray drying vessel 14 is flowed into a liquid composition feed line 40 by a liquid flavouring composition pump 38 which receives the liquid flavouring composition in a liquid flavouring composition feed line 36 from the liquid composition feed vessel 28. The liquid flavouring composition to be spray dried may be dispensed in the liquid flavouring composition supply container 28, for example, liquid flavouring composition ingredients may be supplied to the supply container for mixing therein under the influence of a mixer device (not shown in fig. 1) internally disposed in the liquid composition supply container 28. Such a mixer device may be or include a mechanical mixer, a static mixer, an ultrasonic mixer or other device that effects the blending and homogenization of the liquid flavoring composition that is subsequently spray-dried.

For example, as shown, when the liquid composition to be spray dried is a slurry or emulsion of solvent, carrier and product flavoring material, the solvent may be supplied from the solvent supply container 30 to the liquid flavoring composition supply container 28, the carrier material may be supplied from the carrier material supply container 32 to the liquid composition supply container 28, and the product flavoring material may be supplied from the product flavoring material supply container 34 to the liquid flavoring composition supply container 28.

Thus, the liquid flavouring composition to be spray-dried flows from the liquid composition supply container 28 through the liquid flavouring composition supply line 36 to the pump 38 and then under the action of the pump flows in the liquid flavouring composition feed line 40 to the inlet 26 of the spray-drying container 14 to a spraying device, such as an atomiser or nozzle, arranged in the inlet region of the internal volume of the spray-drying container. At the same time, the primary drying fluid flows in a primary drying fluid feed line 70 to the inlet 26 of the spray drying vessel 14, at the lower end of which the dry powder product and the drying effluent fluid flow to the effluent line 42 for flow through the interior volume of the spray drying vessel from its upper cylindrical portion 18 to its lower conical portion 16. During the flow of the primary drying fluid through the interior volume of the spray drying vessel 14, the nozzles 20 are selectively activated to introduce the secondary drying fluid at a suitable pressure and flow rate to induce localized turbulence in the drying fluid flow stream throughout the interior volume for enhancing the mass transfer and drying efficiency of the spray drying vessel.

The dried encapsulated flavor powder product flowing in effluent line 42 and the effluent drying fluid are delivered to cyclone 44 where the dried encapsulated flavor powder solids are separated from the effluent drying fluid, wherein the separated encapsulated flavor powder solids are delivered in product feed line 46 to dried encapsulated flavor powder product collection container 48. The dried, encapsulated powdered flavor product in collection container 48 can be packaged in such a container or the product can be transported to a packaging facility (not shown in fig. 8) where the collected dried, encapsulated powdered flavor product is packaged in bags, bins, or other containers for shipping and end use.

The effluent drying fluid separated from the dried encapsulated flavor powder product in cyclone 44 flows in an effluent fluid feed line 52 to a baghouse 52 where any residual entrained powder in the effluent fluid is removed to produce a powder-removed effluent fluid which then flows in an effluent fluid transfer line 54 to a blower 56 from which it flows in a blower discharge line 58 to a condenser 60 where the effluent fluid is thermally conditioned as desired, wherein the thermally conditioned effluent fluid flows in a recycle line 62 to a blower 64 from which the recycled effluent fluid flows in a pump discharge line 66 to a dehumidifier 68 where residual solvent vapor is removed to adjust the relative humidity and dew point characteristics of the drying fluid to a level suitable for spray drying operations, wherein the dehydrated drying fluid then flows in a primary drying fluid feed line 70 to the spray drying vessel 14 Inlet 26, as previously described.

In various embodiments, the dehumidifier may be constructed and arranged to provide the primary and secondary drying fluids to the spray drying container 14 at predetermined relative humidity and dew point characteristics, or a plurality of dehumidifiers may be provided in the spray drying system for such purposes.

Fig. 9 is a schematic diagram of a portion of the spray drying process system shown in fig. 8 in a cross-sectional view, illustrating the effect of the induction of local turbulence in the interior volume of the spray drying vessel in the spray drying system.

As shown, the inlet 26 of the spray dryer 14 includes an upper wall 80 on which the inlet 26 is disposed that receives the primary drying fluid in the primary drying fluid feed line 70 and the spray-dryable liquid flavoring composition in the liquid flavoring composition feed line 40. In the inlet, the introduced spray-dryable liquid flavor composition flows into atomizer nozzle 88 extending through upper wall 80 and is discharged at its open lower end as atomized spray 76 of droplets 84 falling through the interior volume of spray drying vessel 14 in the direction indicated by arrow a while contacting the primary drying fluid introduced into inlet 26 from primary drying fluid feed line 70, which then flows downwardly as indicated by arrow 78 for fluid passing through opening 82 in upper wall 80 so that the simultaneously introduced primary drying fluid and atomized liquid flavor composition droplets 84 contact each other.

The drying fluid introduced into the interior volume of the spray drying vessel 14 may be introduced in such a way as to induce significant turbulence in the inlet region of the spray drying vessel, amplified by the injection of the secondary drying fluid to induce localized turbulence throughout the interior volume of the spray drying vessel during contact of the drying fluid with the atomized liquid flavor composition droplets.

Thus, during such contacting of the primary drying fluid and the atomized droplets of the spray-dryable liquid flavoring composition, the nozzle 20 may be actuated by an actuation signal transmitted in the signal transmission line 202 from the CPU 200 to initiate injection of the secondary drying fluid fed in the secondary fluid feed line 24 from the nozzle 72 distal of the nozzle to introduce a turbulent injection stream 74 of the secondary drying fluid that, upon interaction with the primary drying fluid flow stream, creates a localized turbulent zone 86 in the interior volume of the spray drying vessel 14 to enhance mass transfer and drying efficiency.

Accordingly, the CPU 200 may be programmably arranged and configured to intermittently, cyclically and repeatedly actuate the spray bars 20 to provide a series of impacts (bursts) of the turbulent secondary drying fluid into the primary drying fluid flow stream that disrupts and vigorously mixes the drying fluid with the atomized liquid flavor composition droplets, and wherein other spray bars of the plurality of spray bars associated with the spray dryer container 14 may be actuated simultaneously or non-simultaneously relative to the spray bars 20, in any suitable pattern and schedule of "firings" of the respective spray bars throughout the system.

The induction of local turbulence in the internal volume of the spray drying container enables a very high level of mass transfer of solvent from the spray-dried flavor composition droplets to the drying fluid during the spray drying operation, thereby enabling spray-dried encapsulated flavor powder products to be achieved using a minimum spray drying container volume, thereby achieving reductions in capital equipment, energy and operating costs. This advantage is particularly significant in low temperature spray drying operations and enables the effective use of significantly smaller and more efficient spray drying process systems in high speed spray drying operations used to produce the spray dried encapsulated flavor powders of the present disclosure.

In carrying out the spray-drying operation to produce the spray-dried encapsulated flavor powder, any suitable drying fluid that produces a spray-dried encapsulated flavor powder product that meets the characteristics of the powder product described herein can be used. While in various embodiments air is preferred for the production of spray-dried encapsulated flavor powders, in other embodiments the drying fluid may comprise oxygen, oxygen-enriched air, nitrogen, helium, argon, neon, carbon dioxide, carbon monoxide, or other fluid substances, including single component fluids and fluid mixtures. In various embodiments, the drying fluid may be present in the form of a gas or vapor and should be configured and caused to flow through the spray drying vessel under process conditions that provide a suitable mass transfer driving force for the transfer of solvent or other desired volatizable material from the spray of spray-dried flavor composition material to the drying fluid.

The solvent used in the spray-dryable liquid flavouring composition may be of any suitable type and may for example comprise water, inorganic solvents, organic solvents and mixtures, blends, emulsions, suspensions and solutions thereof. In various embodiments, organic solvents may be used, such as, for example, acetone, chloroform, methanol, dichloromethane, ethanol, Dimethylformamide (DMF), dimethyl sulfoxide (DMS), glycerol, ethyl acetate, n-butyl acetate, and mixtures of water and one or more of the foregoing. In particular embodiments, a solvent selected from the group consisting of water, alcohol, and hydro-alcoholic solutions may be advantageously used.

The carrier material used to encapsulate the flavouring component in the spray-dryable liquid flavouring composition may be of any suitable type and may for example be selected from carbohydrates, proteins, lipids, waxes, cellulosic materials, sugars, starches, natural and synthetic polymeric materials and mixtures of two or more of the foregoing. Preferred carriers include starch carriers, sugar carriers, and cellulose carriers.

When the spray-dryable liquid flavouring composition comprises a slurry or emulsion of the carrier, flavouring component and solvent, the viscosity of the slurry material may be controlled by appropriate formulation such that upon spray-drying of the liquid flavouring composition, the viscosity is advantageously in the range of from 300mPa-s (1mPa-s ═ 1 centipoise) to 28,000mPa-s or greater. In various other applications, the viscosity may be in a range where the lower limit of the range is any of 325, 340, 350, 375, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950 and 1000mPa-s, and where the upper limit of the range is greater than the lower limit and is within the range of any of 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, 1000, 2000, 3000, 4000, 5000, 6000, 7000, 8000, 9000, 10,000, 11,000, 12,000, 13,000, 14,000, 15,000, 16,000, 17,000, 18,000, 19,000 and 20,000, where any viscosity range includes any of these lower limits and any of these upper limits used in various specific applications. In some applications, a preferred viscosity is from 500 to 16,000mPa-s, and in other applications, a preferred viscosity is from 1000 to 4000 mPa-s.

In various embodiments, it is desirable to control the solvent ratio within the spray-dryable slurry or emulsion so that the solvent ratio within the slurry does not exceed 50% by weight based on the total weight of the slurry (emulsion) at the time of the spray-drying operation. For example, in various applications, the solvent ratio in the slurry may be 20 to 50 weight percent, or 20 to 45 weight percent, or 20 to 40 weight percent or 25 to 35 weight percent based on the same total weight at the spray drying step, depending on the particular spray drying operation and the particular flavor components and other materials involved.

The temperature of the drying fluid introduced into the spray drying vessel is below 110 ℃ as measured at the inlet of the spray drying vessel (inlet temperature of the drying fluid flowing to the spray drying vessel). In various applications, the inlet temperature of the drying fluid may be controlled to be less than 100 ℃, 95 ℃, 90 ℃, 85 ℃, 80 ℃, 75 ℃, 70 ℃, 65 ℃, 60 ℃, 55 ℃, 50 ℃, 45 ℃, 40 ℃, 35 ℃, 30 ℃, 25 ℃ or 20 ℃ depending on the specifics of the particular spray drying operation involved. As shown by a graphical comparison of fig. 1, the "constant" rate period in low temperature spray drying is very short or nonexistent due to the initial low solvent concentration of the slurry or emulsion, thereby controlling drying almost from the beginning by diffusion from the inner particle core through the porous drying layer to produce a fully dense dry powder product free of hollow regions or shell structures. When using local turbulence induction in this low temperature process, a high concentration gradient is achieved between the surface of the spray particles (droplets) and the surrounding drying fluid.

In a spray-drying operation, the relative humidity of the drying fluid must be properly controlled to carry out the spray-drying process in order to obtain a spray-dried encapsulated flavor powder having the desired characteristics. In various embodiments, the drying fluid flowing into the spray drying chamber may have a relative humidity of no more than: 35%, 30%, 25%, 20%, 15%, 12%, 10%, 8%, 6%, 5%, 4%, 3%, 2.5%, 2%, 1.8%, 1.6%, 1.5%, 1.4%, 1.3%, 1.2%, 1.1%, 1.0%, 0.9%, 0.8%, 0.7%, 0.6%, 0.5%, 0.4%, 0.3%, 0.2%, 0.1%, 0.05%, 0.02%, or 0.01%.

In various embodiments, the relative humidity of the stream of drying fluid flowing into the spray drying chamber may be within a range, wherein the lower endpoint of the range is any of: 10^-4％、10^-3％、10^-2％、10^-1%, 1%, 1.5% or 2%, and whereinThe upper end point of the range is greater than the lower end point of the range and is any one of: 35%, 30%, 20%, 15%, 12%, 10%, 8%, 6%, 5%, 4%, 3%, 2.5%, 2%, 1.8%, 1.6%, 1.5%, 1.4%, 1.3%, 1.2%, 1.1%, 1.0%, 0.9%, 0.8%, 0.7%, 0.6%, 0.5%, 0.4%, 0.3%, 0.2%, 0.1%, 0.05%, 0.02%, 0.01%, or 0.05%. For example, the stream of drying fluid flowing into the spray drying chamber may have a relative humidity within the following range: 10^-4% to 35%, 10^-3% to 18%, 0.005 to 17%, 0.01 to 15%, 0.01 to 5%, 0.1 to 5% or 0.001 to 2%.

As another option that may be useful for enhancing the spray drying operation for producing the spray-dried encapsulated flavor powder, the spray drying process may further comprise applying an electrohydrodynamic charge (often mistakenly called electrostatic charge) to at least one of the spray-dryable liquid flavor composition and the atomized spray of liquid flavor composition particles for electrohydrodynamic spray drying of the spray-dryable liquid flavor composition. Such electrohydrodynamic spraying operations may be carried out under any suitable voltage conditions suitable for the particular application for which the electrohydrodynamic spraying is employed. In various embodiments, the electrohydrodynamic charge may be in the range of 0.25 to 80kV, but it is understood that in a particular application a higher or lower electrohydrodynamic charge may be imparted to the flavoring composition material to be spray dried. In various embodiments, the electrohydrodynamic charge imparted to the particles to be spray dried may be in the range of 0.5 to 75kV, or 5 to 60kV, or 10 to 50kV or at other suitable ranges or other specific values.

In other embodiments of electrohydrodynamic spray drying, the raw liquid flavor composition can be sprayed through an electrohydrodynamic nozzle operatively coupled to a voltage source arranged to apply a cyclic switching voltage to the nozzle, e.g., between a high voltage and a low voltage or other voltage range within any of the voltages discussed above.

Post-atomization charging (post-atomization charging) of spray-dryable flavour composition droplets may be carried out using a corona discharge type atomizer using an external electrode with a grounded nozzle, or if the spray-dryable flavour composition droplets have good electrical conductivity properties, such post-atomization charging may be carried out by electron beam irradiation of the atomized droplets.

Thus, the electrohydrodynamic charging of the spray-dryable liquid flavouring composition may be carried out before, during or after the atomization of such flavouring composition. A variety of different types of electrohydrodynamic spraying devices can be used in electrohydrodynamic spraying systems and operations, for example, an electrohydrodynamic spraying device positioned to introduce an electrohydrodynamically charged spray of a spray-dryable liquid flavor composition into the interior volume of a spray-drying vessel for contact with a drying fluid therein.

The generation of a spray of the spray-dryable liquid flavouring composition for contact with the drying fluid may be effected using any suitable apparatus, including an atomiser, a nebuliser (nebulizer), an ultrasonic disperser, a centrifugal device, a nozzle or other suitable device. The liquid flavouring composition may be introduced into the internal volume of the spray drying vessel in the form of a liquid film or filament (filament) which breaks up to form droplets. A variety of equipment and techniques can be used to form a spray of the liquid composition in the form of droplets or finely divided liquid particles. For example, the droplet size and distribution may be fairly constant in a given spray-drying system, and the droplets may be in the range of 10-300 μm or in other suitable ranges.

Fig. 10 is a schematic view of another spray drying apparatus that may be used to produce the encapsulated flavored spray dried powders of the present disclosure, wherein the apparatus includes a turbulent mixing nozzle array on a wall of the spray drying chamber configured to inject brief, intermittent turbulent air blasts (air bursts) into the primary fluid stream in the spray drying chamber.

As shown, the spray drying system 500 includes a raw material precursor flavor composition source 502 from which a raw material precursor flavor composition flows in a feed line 504 to a raw material composition treatment unit 506 where the precursor flavor composition is processed or treated to produce a spray-dryable liquid flavor composition. Such upstream processing units may be of any suitable type and may, for example, comprise a concentration unit wherein the product material to be spray dried is concentrated in line 508 from a feedstock precursor flavor composition concentration to a higher concentration in the spray-dryable liquid flavor composition discharged from the concentration unit.

The spray-dryable liquid flavoring composition flows from the raw flavoring composition processing unit 506 in the liquid flavoring composition feed line 508 through the pump 510 to the raw material feed line 512, from where it flows into the spray dryer inlet 516 of the spray dryer container 518, and is then atomized by the atomizer 514 to produce an atomized spray 520 of the spray-dryable liquid flavoring composition. At the same time, the conditioned drying fluid flows in a conditioned drying fluid feed line 570 to the inlet 516 of the spray dryer vessel 518, thereby causing the introduced conditioned drying fluid to flow through the interior volume 522 of the spray dryer vessel 518 to contact the atomized spray of the spray-dryable liquid flavor composition.

In so-called two-fluid atomization, the conditioned drying fluid, or any portion thereof, may flow through the atomizer 514, or the conditioned drying fluid may flow as a separate stream into the interior volume 522 of the spray drying container 518, relative to the introduction of the spray-dryable liquid composition and its passage through the atomizer 514.

The atomizer 514 may be of any suitable type, and may, for example, comprise any of a rotary atomizer, a centrifugal atomizer, a nozzle atomizer, a nebulizer, an ultrasonic atomizer, and the like, as well as combinations of two or more of the foregoing. The atomizer may be electrohydrodynamic to effect electrohydrodynamic spray drying of the concentrated feedstock composition as previously described, or the atomizer may be characterized as non-electrohydrodynamic.

Regardless of the particular atomizer type and atomization mode used, an atomized spray 520 of the base composition is introduced into the interior volume 522 of the spray drying container 518, and atomized droplets of the spray-dryable liquid composition are contacted with the conditioned drying fluid during passage through the interior volume to the spray dryer outlet 524 to dry the atomized droplets and produce a spray-dried encapsulated flavor powder product.

The spray drying vessel 518 may optionally be equipped with a secondary drying fluid peripheral feed line 526, wherein the arrows of each schematic feed line 526 represent injector jets arranged to introduce a secondary drying fluid into the interior volume 522 of the spray drying vessel 518. Thus, the feed line 526 and its injector jets may pass through corresponding wall openings in the spray drying container 518 such that the injector jets are aligned internally, or the injector jets may be arranged such that they communicate with the wall openings in the spray drying container such that the secondary drying fluid is injected into the interior volume 522 therethrough. The secondary drying fluid may be introduced into the interior volume of the spray drying vessel at a pressure and flow rate sufficient to create a localized turbulence 530 at or near the point of introduction into the interior volume of the spray drying vessel.

The secondary drying fluid peripheral feed lines 526 are shown coupled to a secondary drying fluid manifold 528 through which secondary drying fluid flows to the respective feed lines 526. The secondary drying fluid may be introduced into the interior volume of the spray drying vessel in a continuous manner or in a batch manner. The secondary drying fluid may be introduced in an impingement form (e.g., in a time-sequential manner), and the injector jets may be programmably arranged under the monitoring and control of a central processor unit, such as CPU 590 shown in fig. 10.

This local induction of turbulence enhances the diffusivity and mass transfer of the liquid solvent from the atomized droplets of concentrated base flavoring composition to the drying fluid present in the spray drying vessel.

The spray drying container 518, as a further enhancement to the drying of the atomized droplets of concentrated base flavoring composition in the interior volume of the container, may be equipped with a secondary drying fluid center feed line 532 as shown. The secondary drying fluid central feed line 532 is provided with a series of longitudinally spaced secondary drying fluid central feed line injector jets 534, wherein the secondary drying fluid can be injected at sufficient pressure and flow rate conditions to create a turbulent zone 536 where the secondary drying fluid is injected.

The secondary drying fluid introduced into the interior volume of the spray drying vessel by feed line 526 and associated injector jets can be introduced into the interior volume of the spray drying vessel from injector jets 534 in a continuous manner or in a batch manner to provide a zone of turbulence 536 in which the secondary drying fluid is injected at a central portion of the interior volume 522 in the spray drying vessel. The secondary drying fluid may be introduced in an impingement fashion (e.g., in a time-sequential manner) through the central feed line injector jet 534, and the injector jet may be programmably arranged under the monitoring and control of a central processor unit, such as CPU 590 shown in fig. 10.

As shown in fig. 10, a combination of peripheral jets and central jets may be used to provide local turbulence throughout the interior volume of the spray dryer vessel, in the central region as well as in the outer wall regions of the interior volume to carry out the spray drying process, wherein abnormal flow behavior, such as dead or stagnant zones, in the interior volume is minimized. Accordingly, a very advantageous hydrodynamic mass transfer environment is provided to produce spray-dried encapsulated flavor powders having the features variously described herein.

Spray dried encapsulated flavor powder produced by contacting atomized droplets of concentrated base flavor composition with the drying fluid in the spray dryer vessel interior volume and effluent drying gas are discharged from the spray dryer vessel in spray dryer outlet 524 and flow in spray dryer effluent line 538 to cyclone 540. Instead of a cyclone separator device, any other suitable solid/gas separation unit with suitable characteristics may be employed. The cyclone 540 separates the dried encapsulated flavor solids from the drying fluid, wherein the dried encapsulated flavor solids flow in a dried solids discharge line 542 to a dried solids collection vessel 544. The dry fluid with the eliminated solids content flows from the cyclone in dry fluid discharge line 546, flowing through fine filter 548 to reach condenser 550. In the condenser 550, the drying fluid is cooled, causing condensation of condensable gases therein, with the condensate being discharged from the condenser in a condensate discharge line 552.

The resulting condensate stripped drying fluid then flows in a drying fluid recycle line 554 having a pump 556 therein to a drying fluid conditioning assembly 568 along with any required make-up drying fluid introduced into the drying fluid make-up feed line 610. The drying fluid conditioning assembly conditions the recirculating drying fluid and any added supplemental drying fluid to flow in a conditioned drying fluid feed line 570 to the spray dryer vessel 518. The drying fluid conditioning assembly may include a dehumidifier and/or a heat exchange (heater/cooler) apparatus to provide drying fluid for recirculation under appropriate desired temperature and relative humidity conditions.

Thus, the drying fluid (including any necessary supplemental drying fluid) may be provided to the drying fluid conditioning assembly 568 from a suitable source, or to the spray drying system at other suitable locations in the system, and wherein any suitable preconditioning operation is performed by associated equipment or devices, as desired at the desired temperature, pressure, flow rate, composition, and relative humidity. Thus, for example, supplemental dry fluid may be provided to the conditioning assembly 568 from a tank, storage container, or other source (e.g., ambient atmosphere, with air as such dry fluid).

As a source of secondary drying fluid in the system, a portion of the recycled drying fluid from the drying fluid recycle line 554 may be diverted in a secondary drying fluid feed line 572 containing a flow control valve 574 to the secondary drying fluid conditioning assembly 576. The secondary dry fluid conditioning assembly 576 may be constructed and arranged in any suitable manner and may have the same or similar features as the construction and arrangement of the dry fluid conditioning assembly 568. Accordingly, the secondary drying fluid conditioning assembly 576 conditions the secondary drying fluid such that it is in a condition suitable for use of the secondary drying fluid in the system.

The conditioned secondary drying fluid flows from the secondary drying fluid conditioning assembly 576 through a secondary drying fluid feed line 578, which thereby flows in a secondary drying fluid feed line 580 including a pump 582 to the manifold 528, while the remainder of the conditioned secondary drying fluid flows in the secondary drying fluid feed line 578 to a pump 584, which flows in a secondary drying fluid feed line 586 from the secondary drying fluid feed line to the secondary drying fluid center feed line 532 for introduction in a central region of the interior volume of the spray dryer vessel, as previously described.

It will be appreciated that the system illustrated in fig. 10 may alternatively be constructed and arranged wherein the drying fluid conditioning assembly 568 processes both the primary and secondary drying fluids of the drying fluid, while not providing a separate secondary drying fluid conditioning assembly 576, for example, when the primary and secondary drying fluids have substantially the same characteristics with respect to their associated fluid characteristics. It will also be appreciated that when the primary and secondary drying fluids are or include different gases or are otherwise different in their associated fluid characteristics, separate flow circulation loops may be provided for each of the primary and secondary drying fluids.

The fig. 10 system is shown as including a Central Processor Unit (CPU)590 that is arranged to monitor and/or control operations in the system, and when used in control, may be used to generate control signals for plant and/or fluid condition regulation to maintain operation at a set point or otherwise desired operating condition. As mentioned, the CPU may be operably connected to the conditioning assemblies 568 and 576 to control components thereof, such as dehumidifiers, thermal controllers, heat exchange devices, and the like.

CPU 590 is illustratively shown in fig. 10 as being operatively coupled to pump 510, drying fluid conditioning assembly 568, auxiliary drying fluid conditioning assembly 576, flow control valve 574, pump 582, pump 556 and pump 584, respectively, via monitoring and/or control signal transmission lines 592,594, 596, 598, 600, 602 and 604.

It will be appreciated that the particular arrangement of CPUs shown in fig. 10 has illustrative features and that the CPUs may be additionally arranged with respect to any component, element, feature and unit of the overall system including the concentration unit 506 to monitor and/or control any suitable operating component, element, feature, unit, condition and parameter. For this purpose, the system may comprise suitable sensors, detectors, components, elements, features and units with respect to monitoring capabilities. The signal transmission line may be a bidirectional signal transmission line, or may constitute a wiring including a monitoring signal transmission line and a separate control signal transmission line.

It will be appreciated that the spray drying system may be embodied in an arrangement in which the contact gas, the auxiliary contact gas, the drying fluid and the auxiliary drying fluid, or any two or more thereof, may have substantially the same composition, temperature and/or relative humidity, thereby achieving capital equipment and operating cost efficiencies and corresponding system requirement simplification. Thus, for example, all of the contact gas, auxiliary contact gas, drying fluid and auxiliary drying fluid may be air, nitrogen, argon or other gas from a common gas source, and such common gas may be provided at substantially the same temperature and relative humidity, thereby enabling the use of common thermal conditioning and dehumidification equipment.

Thus, the fig. 10 system provides a spray drying system with high efficiency in which localized turbulence induction can be used throughout the interior volume of the spray drying vessel to produce the disclosed high performance spray dried encapsulated flavor powder with specific powder characteristics that can be achieved by corresponding selection of process operating conditions.

Fig. 11 is a schematic view of other spray drying equipment that may be used to produce the encapsulated flavored spray dried powders of the present disclosure.

The spray drying system 700 shown in fig. 11 includes a spray drying vessel 702 having an internal volume 704. Disposed within the interior volume is an atomizer 706 depending downwardly (dependent) from an inlet feed assembly 708. Inlet feed assembly 708 includes a spray-dryable flavor composition feed line 710 and a drying fluid feed line 712 arranged such that spray-dryable flavor composition flows from a suitable source (not shown in fig. 11) through feed line 710 to atomizer 706. The atomizer operates to produce an atomized spray-dryable composition that is discharged into the interior volume 704 of the spray dryer vessel 702. A drying fluid feed line 712 flows a drying fluid from a source (not shown) through the inlet feed assembly 708 to the interior volume 704 of the spray dryer vessel 702.

The spray dryer vessel 702 is provided with a plurality of nozzle injectors 714, 716, 718, 720, 722, and 724, each having a feed line connected to a secondary source of drying fluid. The nozzle injector injects the secondary drying fluid at flow rate and pressure conditions suitable for inducing turbulence in the primary drying fluid in the interior volume 704.

In addition to the nozzle injectors, the spray dryer vessel 702 also includes a series of wall-mounted turbulators 728, 730, 732, and 734 sized and shaped to induce turbulence in the drying fluid contacting them during flow of the drying fluid through the interior volume of the vessel. An effluent discharge line 726 is at the lower end of the conical lower portion of the container through which the spray-dried encapsulated flavor powder and effluent drying fluid are discharged from the container.

The turbulators shown in fig. 11 are devices configured to induce turbulence in the drying fluid in contact with the atomized sprayable drying material. The apparatus may be of any suitable type and may include any one or more jets, nozzles, injectors, or the like for injecting a secondary drying fluid into a mass of primary drying fluid to induce turbulence in the drying fluid to enhance the spray-drying operation. Alternatively, the device may be of the type that induces turbulence in the drying fluid upon interaction with the drying fluid, for example, helical twisted belts, static mixer devices, airfoils, Brock turbulators, wire turbulators, coil turbulators, and wall-protruding turbulators. In various embodiments, various types of such devices may be combined with one another, as may be desirable to achieve suitable turbulence intensity for enhancing the drying rate and/or extent of the atomized, spray-dryable flavoring composition.

The spray-dried material and effluent drying fluid may be delivered to a cyclone where the spray-dried encapsulated flavor powder is recovered from the effluent drying fluid, which is then, if desired, treated for complete or partial recycle in the system, or alternatively, drained from the system and introduced with fresh drying fluid as described above.

The spray drying system shown in fig. 11 further comprises a process control unit 736 which is schematically shown having process control signal transmission lines 738 and 740, whereby it is schematically shown that said process control unit is operatively connected to the transfer line for adjusting the flow rate of the drying fluid entering said inner volume and the flow rate of the spray-dryable flavouring material entering said atomizer such that the interaction of the drying fluid with the at least one turbulator generates a turbulence in said drying fluid, e.g. a turbulence in which the length of the kolmogorov is smaller than the average particle size of the spray-dryable material droplets in the atomized spray-dryable material in the inner volume of said container. Accordingly, for this purpose, such an arrangement may include respective flow control valves in spray-dryable flavoring composition feed line 710 and drying fluid feed line 712.

By equationThe above-mentioned kolmogorov length η is defined, where v is the kinematic viscosity of the drying fluid and epsilon is the kinetic energy dissipation rate of the induced turbulence in the drying fluid.

The cole mogorov length can be used to characterize the turbulence induced by the jets or other turbulator assemblies associated with the spray drying vessel during a spray drying operation. The cole mogrol length characterizes the energy dissipating vortices in the turbulence induced in the fluid flow in the interior volume of the spray drying vessel. Can be in a spray drying container just after turbulence is inducedDescribes turbulent kinetic energy in such a flow by a cascade of kinetic energies occurring in space-time in the fluid in the internal volume. The energy introduced into the fluid in the spray drying vessel generates large-scale (typically, it appears as hydrodynamic instabilities on a whole scale) by fluid injection or by flow disruption. The energy is then transferred to progressively smaller scales on an overall scale, initially by a non-viscous mechanism, such as vortex drawing, and subsequently by viscous dissipation to heat. When graphically displayed on a log plot of energy as a function of wavenumber, the discrete manner (discrete region) of the range containing the initial energy, followed by the inertial range and followed by the final dissipation range, reflecting the induced turbulence, is readily viewed as displaying an energy cascade in which large vortices in the low wavenumber region are converted into smaller and smaller vortices and eventually dissipate into heat. The scale at which the dissipative attenuation starts is the Col-mogrol scaleWhere ε is the turbulence dissipation ratio shown in the logarithmic graph, and ν is the kinematic viscosity of the drying fluid.

The turbulence dissipation ratio and the Col Mogolov length are readily determined using standard hot wire anemometry or laser Doppler anemometry techniques. For example, a hot-wire anemometer may be used to generate a turbulent power density value over a range of frequencies by a log-log plot of the turbulent power density as a function of frequency (in hertz), which log-log plot shows the induced turbulence, the inertia range and the dissipation range of the cascade, and by the dissipation range values enables determination of the turbulent dissipation ratio from which the cole-mogrol length can be calculated by the above-described cole-mogrol conversion formula.

Advantageously, for the production of spray-dried encapsulated flavor powders having the features variously discussed herein, turbulence may be induced in at least 5% by volume of the drying fluid volume in the interior volume of the container to provide significant enhancement of the spray-drying operation. More generally, turbulence may be induced in at least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 or more volume percent of the dry fluid volume in the interior volume of the container. Thus, it is advantageous to maximize the amount of drying fluid in which turbulence is induced and the volumetric portion of the drying fluid in the interior volume of the container in which turbulence is induced may advantageously comprise the drying fluid in contact with the atomizer, thereby enabling turbulence to be induced as quickly as possible when introducing the drying fluid and contacting the atomized spray-dryable flavouring composition.

In the fig. 11 apparatus, the process control unit 736 may be adapted to adjust the flow rate of the drying fluid entering the inner volume and the flow rate of the spray-dryable flavouring material entering the atomizer such that the average particle size of the spray-dryable flavouring material droplets in the atomized spray-dryable flavouring material in the inner volume of the container is in the range of 50 to 300 μm, or in other droplet size ranges.

Additionally or alternatively, the process control unit may be adapted to regulate the flow rate of the drying fluid entering the interior volume and the flow rate of the spray-dryable flavouring composition material entering the atomizer such that the turbulence dissipation ratio of the turbulence induced in the interior volume of the spray-drying container is greater than 25m²/s³. For this purpose, the process control unit may include a microprocessor, microcontroller, general or special purpose programmable computer, programmable logic controller, or the like, programmably arranged for implementing the spray drying process operations by suitable hardware, software, or firmware in the process control unit. The process control unit may include a memory having random access, read-only, flash or other features, and may include a database of operating procedures or other information indicative of the operating performance of the system.

Thus, there are a variety of spray-drying systems and apparatuses, and a corresponding variety of processing methods and techniques, that can be variously used to produce the spray-dried encapsulated flavor powders of the present disclosure having the attributes and features described herein.

To this end, the spray-drying operation may be carried out within the various operating conditions and parameters described herein, while selectively varying the same depending on the specific structure and configuration of the spray-drying system and apparatus used, to empirically determine suitable operating condition process packs (process envelopes) for producing the spray-dried encapsulated flavor powders of the present disclosure containing one or more encapsulated flavor ingredients and characterized by one or more, and preferably all, of the following characteristics, e.g., a single-step spray-dried encapsulated flavor powder:

(A) a dispersion medium dissolution time of less than 60 seconds;

(B) a dispersion medium dispersion time of less than 15 seconds;

(C) wherein at least 75% of the particles in the powder have a particle size distribution with a particle size of at least 80 μm;

(D) surface area (μm) of particles of the powder in the range of 0.01 to 0.03²) Volume (μm)³) A ratio;

(E) a particle void volume in the particles of the powder of less than 10% of the total particle volume;

(F) at 22 to 40lb/ft³The bulk density of the particles of the powder in the range, and

(G) an angle of repose of the powder of not more than 40,

optionally wherein when the spray dried powder contains encapsulated oil, the surface oil percentage is less than 1.5%.

Furthermore, although illustrative flavor materials have been identified as such in the previous disclosure: almond, orange, lemon, lime, tangerine, apricot kefir, fennel, pineapple, coconut, pecan, apple, banana, strawberry, melon, caramel, cherry, blackberry, raspberry, ginger, boysenberry, blueberry, vanilla, honey, molasses, wintergreen oil, cinnamon, clove, butter, cream, butterscotch, butterscoffy, coffee, tea, peanut, cocoa, nutmeg, chocolate, cucumber, mint, toffee, eucalyptus, grape, raisin, mango, peach, melon, kiwi, lavender, licorice, maple, menthol, passionflower fruit, pomegranate, dragon fruit, pear, walnut, peppermint, pumpkin, Shashi, rum and spearmint, it will be recognized that a variety of other flavors and flavor blends are suitable for the spray-dried encapsulated flavor powders of the present disclosure to provide the excellent retention levels and other high performance characteristics variously described herein.

Thus, in various embodiments, a spray-dried encapsulated flavor powder of the present disclosure comprising one or more encapsulated flavor ingredients may be characterized by the following features:

(A) a dispersion medium dissolution time of less than 60 seconds;

(B) a dispersion medium dispersion time of less than 15 seconds;

(C) wherein at least 75% of the particles in the powder have a particle size distribution with a particle size of at least 80 μm;

(D) surface area (μm) of particles of the powder in the range of 0.01 to 0.03²) Volume (μm)³) A ratio;

(E) a particle void volume in the particles of the powder of less than 10% of the total particle volume;

(F) at 22 to 40lb/ft³The bulk density of the particles of the powder in the range, and

(G) an angle of repose of the powder of not more than 40,

optionally wherein when the spray dried powder contains encapsulated oil, the surface oil percentage is less than 1.5%,

and such spray-dried encapsulated flavor powder can also be characterized by any one or more of the following characteristics (1) - (31):

(1) the one or more encapsulated flavouring ingredients comprise at least one selected from the group consisting of: almond, orange, lemon, lime, tangerine, apricot kefir, fennel, pineapple, coconut, pecan, apple, banana, strawberry, melon, caramel, cherry, blackberry, raspberry, ginger, boysenberry, blueberry, vanilla, honey, molasses, wintergreen oil, cinnamon, clove, butter, cream, butterscotch, butter, coffee, tea, peanut, cocoa, nutmeg, chocolate, cucumber, mint, toffee, eucalyptus, grape, raisin, mango, peach, melon, kiwi, lavender, licorice, maple, menthol, passionflower fruit, pomegranate, dragon fruit, pear, walnut, peppermint, pumpkin, salad, rum, and spearmint;

(2) the one or more encapsulated flavouring ingredients are encapsulated by a carrier material comprising at least one selected from the group consisting of: carbohydrates, proteins, lipids, waxes, cellulosic materials, sugars, starches, natural and synthetic polymeric materials;

(3) the one or more encapsulated flavouring ingredients are encapsulated by a carrier material comprising at least one selected from the group consisting of: maltodextrin, corn syrup solids, modified starches, gum arabic, modified celluloses, gelatin, cyclodextrins, lecithin, whey protein, and hydrogenated fats;

(4) one or more encapsulated flavouring ingredients are encapsulated by a carrier material, the carrier material comprising a modified starch;

(5) the one or more encapsulated flavor ingredients comprise at least one flavor oil;

(6) the spray-dried encapsulated flavor powder of claim 1 comprising a single-step spray-dried encapsulated flavor powder;

(7) the spray-dried encapsulated flavor powder is characterized by a dispersion medium dissolution time of less than at least one of 45, 40, 35, 30, 25, 20, 15, 12, 10, 8, 7, 6, and 5 seconds;

(8) the spray-dried encapsulated flavor powder is characterized by a dispersion medium dispersion time of less than at least one of 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 8, 2, and 1 seconds;

(9) the spray-dried encapsulated flavor powder is characterized by a particle size distribution in which at least one of 80%, 85%, 88%, 90%, 91%, 92%, 93%, 94%, and 95% of the particles in the powder have a particle size of at least 80 μm;

(10) the spray-dried encapsulated flavour powder is characterised by a particle size distribution wherein at least 80% of the particles in the powder have a particle size of at least 80 μm;

(11) the spray-dried encapsulated flavour powder is characterised by a particle size distribution wherein at least 85% of the particles in the powder have a particle size of at least 80 μm;

(12) the spray-dried encapsulated flavour powder is characterised by a particle size distribution wherein at least 90% of the particles in the powder have a particle size of at least 80 μm;

(13) the spray-dried encapsulated flavor powder is characterized by a particle void volume of less than at least one of 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2.5%, 2%, and 1% of the total particle volume;

(14) the spray-dried encapsulated flavor powder is characterized by a particle void volume of less than 2.5% of the total particle volume;

(15) the spray-dried encapsulated flavor powder is characterized by a particle void volume of less than 2% of the total particle volume;

(16) the spray-dried encapsulated flavor powder is characterized by being in the range of 25 to 38lb/ft³(ii) a bulk density of particles of the powder within the range;

(17) the spray-dried encapsulated flavor powder is characterized by an angle of repose of the powder of no more than 35 °;

(18) the spray-dried encapsulated flavor powder is characterized by an angle of repose of the powder of no more than 30 °;

(19) the particles in the powder do not contain large-size gaps;

(20) the particles in the powder have a non-spherical form;

(21) the particles in the powder have an elongated form;

(22) the powder has an average eccentricity of at least 0.7;

(23) the powder has an average eccentricity in the range of 0.70 to 0.95;

(24) the powder has an average eccentricity in the range of 0.75 to 0.95;

(25) the powder has an average eccentricity in the range of 0.80 to 0.95;

(26) the spray-dried encapsulated flavor powder is characterized by a particle size distribution in which at least 80%, 85%, 88%, 90%, 91%, 92%, 93%, 94% or 95% of the particles in the powder have a particle size of at least 85 μ ι η, 90 μ ι η, 95 μ ι η, 100 μ ι η, 110 μ ι η or 120 μ ι η;

(27) the spray-dried encapsulated flavor powder is characterized by a particle size distribution in which at least 80%, 85%, 88%, 90%, 91%, 92%, 93%, 94%, or 95% of the particles in the powder have a particle size within a range having any of the endpoints 80 μm, 85 μm, 90 μm, 95 μm, 100 μm, 110 μm, and 120 μm, with the proviso that the lower endpoint of the range is less than the upper endpoint of the range;

(28) the spray-dried encapsulated flavor powder is characterized by a median particle size of greater than 100 μm;

(29) the spray-dried encapsulated flavor powder is characterized by an average particle size of greater than 100 μm;

(30) the one or more encapsulated flavor ingredients comprise flavor oils; and

(31) the spray-dried encapsulated flavor powder is characterized by a flavor component retention level of at least one of 90%, 91%, 92%, 93%, 94%, 35%, 96%, 97%, 98%, 98.5%, 99%, 99.5%, or 99.9% based on the weight of the flavor component in the spray-dryable material from which the spray-dried encapsulated flavor powder is produced,

particularly preferred embodiments thereof include feature (31) and any one or more of features (1) to (30).

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Thus, although the present disclosure has been described herein with reference to particular aspects, features and illustrative embodiments, it will be understood that the application of the present disclosure is not limited thereto but extends to and encompasses numerous other variations, modifications and alternative embodiments, as will suggest themselves to those of skill in the art based on the description herein. Accordingly, the invention as hereinafter claimed is intended to be broadly construed and interpreted, as including all such variations, modifications and alternative embodiments, within its spirit and scope.