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Maker - Product Challenge

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Industrial drying machines are designed to remove moisture from your product. But the drying process must cater to variations in the state of matter and molecular structure of the input material. Industrial dryer technology exploits the modes of heat transfer (convection, conduction, radiation, evaporative cooling) to control the moisture content.

Drying

Food powder is the result of drying and pulverizing food. It has been around since the astronauts when out to space. Fruits have a short shelf life and are difficult to preserve due to their high water content.  Fruit powder processing allows you to keep the nutrients of the fruits for a longer time, even off-season.

Fruit powder

When you need to produce ultra-fine powders, the milling and drying process employed is what ensures the consistency of your product. To process minerals and chemicals, you need a machine which is powerful, flexible, simple to maintain.


<h2>Versatile and highly efficient milling and drying</h2>
Atritor’s cell mill has been constructed to produce ultra-fine powders. It is able to grind, flash dry, classify and surface coat powders at the same time. Its capacity ranges from 50 kilograms per hour to 15 tonnes per hour, with evaporation rates up to 3,000 kilograms per hour.

The feed can be dosed directly into the machine via a screw feeder or via the inlet air duct. It is then ground in a vertically mounted, multi-stage rotating rotor. Each of the rotor sections is constructed with up to 200 quick-change blades. There is also the possibility for a classifier which is mounted at the discharge section to ensure that oversized feed particles are either discarded or recirculated.

The mill acts as an efficient dryer when the process air is heated using a hot air generator or even waste heat from another process. It can reach an inlet temperature of up to 450ºC. Heat energy from the process can be recovered from the heated air stream and utilized to preheat the intake air. After flash drying, the product is kept cool due to evaporative cooling via the constant exposure of new surface areas of the product created during attrition.

In the case of minerals that require surface treatment, the cell mill provides a range of coatings and surface modifiers that can be added on the side of the machine during the milling process. It has a wide range of applications, from minerals like GCC, clay and limestone to chemicals, dyes, pigments and a wide range of food ingredients and by-products.

Milling and drying machine for fine powders

Drying and grinding can be an important feature when trying to process products such as raw and refined minerals, organic and inorganic chemicals, food ingredients and waste streams. It is crucial to maintain particle size and consistent quality of the finished product during such processes. You will need an efficient and abrasion resistant attrition solution to pulverise and dry your product into your required particle size.


<h2>A simplified process while drying and grinding ensuring high product quality</h2>
Atritor’s Dryer-Pulveriser is able to grind and dry the product simultaneously. It is an air-swept mill that uses an air stream to efficiently process the product and controls the final particle size. It is able to process feedstocks of up to 50+mm and production capacities from 100kg/h up to 30t/h with evaporation rates up to 6,000 kilograms per hour.

The mill acts as an efficient dryer when the process air is heated using a hot air generator or waste heat from another process. It can reach an inlet temperature of up to 550ºC. Heat energy from the process can be recovered from the heated air stream. After flash drying, the product is kept cool due to evaporative cooling. The output temperature of the product is maintained accordingly to control the moisture content of the product.

The Flash drying grinder for powders is configured with a combination of variable speed rotor, hammer arrangement and fixed pins. Turbulence inside the grinding area creates attrition to reduce the particle size, which can be controlled for simple deagglomeration of the product. An internal classifier configuration can also be used to further control particle size.

The ‘A’-series is constructed with internals that are resistant to abrasion for applications that can cause high amounts of wearing to the equipment. Where the desired amount of evaporation required far exceeds the grinding duty, the ‘B’-series machine of a lighter weight, fully fabricated configuration permitting higher airflows can be used for non-wearing product or duties, as well as for for applications in which stainless steel contact parts may be necessary.

Flash drying grinder for powders

Extracting the essential acids and compounds from fruits and plants is a complex process. But the drying stage can jeopardize their natural characteristics. The aromas, flavors, and other organoleptic properties of the volatile substances are crucial to producing quality fruit powders and plant extracts.


<h2>Preserve delicate compounds with gentle freeze-drying</h2>
The DryBand system for freeze-drying by Bucher Merk is designed for fragile substances such as fruit powders and plant extracts. The technology treats materials with low-pressure vacuum drying starting from 0.5 mbar, which can go up to  50 mbar.

The belts in the continuous drying system are used in series and products move between the top and bottom for an extended residence time. The freeze-dryer is suitable for lab-scale to large-scale lyophilization with a feeding range of 2 kg/h to 4,000 kg/h n. The system supports automated independent heated zones, and the final section can be adjusted as a cooling zone.

Continuous freeze-dryer for fruit powders and plant extracts

Delicate fruits with high moisture levels, such as berries, risk losing their properties when exposed to drying. Destroying volatile compounds and acids, even under low-impact conditions, leads to a loss of nutrients, flavors, and aromas. Moisture release is critical for extended shelf life, but the technology for making fruit powders must protect the bioactive properties from degrading.


<h2>Maximize retention of volatile molecules in fruit powders and berries</h2>
The Zeodration system by Bucher Merk uses an adsorption method that selectively draws water but retains the natural compounds. The heart of the unit is a reactor made from zeolite, a crystallized clay with a narrow pore diameter. At the same time, this water-trapping material minimizes the release of volatile compounds from fruit and fresh products.

A low-pressure environment of 0.5-30m bar makes the technology suitable for freeze-drying and processing delicate materials like berries, plant extracts, or herbs without compromising their aromas. Meanwhile, the reactor attracts water molecules, reducing residual moisture to 0.5%. Zeodration integrates into vacuum and lyophilization systems and handles batch and belt operations.

Freeze drying system for berries and fruit powders

Organic volatile compounds from fruits, vegetables and herbs are essential to manufacturing flavors, extracts, and pure powders. But elevating temperatures during the evaporation process risks altering their chemical structure and lowering the quality of the final product.


<h2>Gentle freeze-drying for fruit powders, herbal extracts, and flavors</h2>
The DryBand system by Bucher Merk is a dynamic belt dryer designed to dry delicate food ingredients. The material moves through an intermediate vacuum chamber between the top and bottom belt section. The drying unit has a vacuum range of 0.5 to 50 mbar and a feeding rate of up to 4,000 kg/h.

The continuous system can be configured for variable or constant drying with heating plates underneath the belt. A crushing device at the discharge end breaks the dried products into powders after drying. Meanwhile, the vapors are collected in an integrated condenser.

Vacuum belt dryer for fruit, vegetable and herbal extracts

Bucher Merk Process offers vacuum drying, freeze drying and zeodration solutions for the production of valuable concentrates in food, pharmaceutical and chemical industries.


The grown-ups world is divided into two categories: those who read the entire food label by scrutinizing the unpronounceable ingredients one by one and those who do not. With the clean label trend growing, it is safe to say that the former category is wiping out the latter.

We all want more natural, pure products without chemicals, additives, or sugar. Carriers such as maltodextrin, whether one knows what they are or not, are precisely one of the ingredients that people label as "bad."

Manufacturers add carriers as a drying aid when they make fruit or vegetable powder from carrots, beets, or berries, for example. Using maltodextrin in your powder drying process can improve powder stability, reduce powder hygroscopicity, and increase the powder's bulk density due to its stickiness.

Maltodextrin is a multifunctional carrier. It is not only a drying agent but also a filler, a fat replacement, and a thickener. Carriers can contribute to a more efficient and smooth drying process resulting in higher throughput.
<h2>So, if maltodextrin plays a role in the powder drying process, why does it have the whole world against it?</h2>
Because it is nothing else but a complex form of sugar.

Maltodextrin is a polysaccharide, i.e., it is a carbohydrate made out of several sugar molecules bonded together. Although this white powder comes from natural products such as corn, rice, potato starch, tapioca, or wheat, it is highly processed.

In terms of chemistry, starch undergoes hydrolysis, a chemical process where water and acids break down the starch into sugar molecules.

Mystery solved. There's nothing wrong with maltodextrin; it just doesn't fit into today's healthier and purer demand.
<h2>Can we also dry fruit extracts without a carrier for a purer result? Ask the experts!</h2>
This is precisely what we did.

To find an answer, we spoke with Andreas Hauri and Dieter Merk, food-drying experts from <a href="https://www.bucherunipektin.com/" target="_blank" rel="noopener">Bucher Unipektin</a>.

"<em>Let's start by saying that not all products can be dried carrier free. For example, sticky products such as honey require a drying aid anyway.</em>" Dieter explains. "<em>But people are asking for a native product</em>," he continues. "<em>And when they buy, for example, an artichoke extract, they do not want to find any maltodextrin in it.</em> "

Andreas states, "<em>By gently vacuum drying these high-value and delicate extracts at low temperatures, you can obtain a pure fruit or vegetable extract while using minimal or no carriers.</em>" The liquid extract lies on a belt running through a vacuum heating tunnel, where it immediately starts to foam up, forming a crispy product.

"<em>We want to keep the product in this foamy, cake-like structure until the end because, in this form, we don't need to add a carrier</em>," Andreas concludes.

The product must pass from a soft status to a hard one, so it can be milled in powder extract after.

The rising concern about food safety and public demands for transparency put pressure on producers. Lucky for them, this new drying method can help manufacturers deal with product reformulation to produce extracts with higher purity.

Clean up your label, drying fruit extracts without using carriers

Food

Our food chain starts in the soil, growing crops and livestock. But between the fields and the stores, there is a line of industrial food processing equipment. Processes may be as minimalistic as cleaning fruit and as complex as homogenizing milk alternatives made from pressed legumes. In each case, processing technology is an important link in the food production chain.

Fruit pulp is a mass of pressed fresh fruit not meant for immediate consumption. Production of fruit pulp avoids wasting food and preserves the flavors and nutrient value of the fruit product. Processed fruit pulp is an ingredient in beverages, sauces, baby foods, jellies, smoothies, and bakery products.

Tradition and manufacturing procedures dictate the distinction between fruit juice, puree, and pulp. Still, naming and labeling are complex and depend on regulations, type of fruit, texture, consistency, preservation methods, and sugar or solid content (measured in Degrees Brix). Depending on your desired output, there are various fruit pulper machines for different stages of production that make the process quicker and more efficient.

Fruit pulp

The building blocks of matter have driven the imagination of philosophers, scientists, and artists for millennia. But, for manufacturers, these elements have a more concrete existence as powders. Powder processing technology conditions these primary materials to create a vast range of products, from chemicals and foods to pharmaceuticals and ceramics.

Powder

Find production technology for Fruit powder drying, and connect directly with leading machine manufacturers worldwide

Fruit powder drying

Which fruit powder drying equipment do you need?

Milling and drying machine for fine powders

Flash drying grinder for powders

Continuous freeze-dryer for fruit powders and plant extracts

Freeze drying system for berries and fruit powders

Vacuum belt dryer for fruit, vegetable and herbal extracts

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