Drying in Bio-Processes

Group Members:
Sakshi Kumari- 21BCM0134
Aayan Das- 21BCM0149
Nandhana Pillai RS- 21BCM0151
Akash Ghosh - 21BCM0160
Pratyay Chaturvedi – 21BCM0164
 Introduction
Drying means removal of water or other liquid content from solid material to reduce the
content of liquid. It is the usually done by heat. Known to be the last stage in a
manufacture process.

Purposes of drying :
•The water activity, which is a measure of the moisture content, when reduced below
certain levels, will make the biological materials free from the survival and growth of
organisms.
•Drying will reduce both the weight and the volume of the product, which will facilitate
easy packaging and transportation.
•The shelf- life of dry products will increase considerably.
 Classification of Dryers

Direct Heat Dryer Indirect Heat Dryer

Batch Continuous Batch Continuous

Tray Dryer Belt Dryer Freeze Dryer Screw Conveyor Dryer

Steam-tube Rotary
Truck Dryer Rotary Dryer Jacketed Shelf
Dryer

Circulation Dyer Flash Dryer Vacuum Tray Dyer Drum Dryer

Fluidized Bed Dryer Tunnel Dryer Agitated Dryer Trough Dryer

 Direct Heat Dryers
Materials are directly heated using heat from a combustion process; the fuel used is typically gas
although pulverized coal, light fuel oil or waste process gasses could also be used.
Batch Dryer
Batch drying is a system at which a certain volume of grain is being dried at a time. The volume is
fixed by the holding capacity of a dryer, and dried to required moisture. After unloading the dried
grain from the dryer, then drying for the next batch of grain can be performed. Batch drying,
therefore, requires loading and unloading time for each batch of grain needed to be dried.

Continuous Dryer
Continuous drying is where grain is continuously flowing though a dryer without stopping. The
continuous drying system offers the lowest operating costs as compared to batch drying systems.
Furthermore, a uniform grain moisture content after drying is obtained, and the drying capacity of the
continuous flow dryer is higher than that of the batch dyer.
 Tray Dryer
Principle: The basic working principle of this incredible machine is the continuous circulation
of hot air.

Working:
• In tray dryer hot air is continuously circulated. Forced convection
heating takes place to remove moisture from the solids placed in trays.
• Simultaneously the moist air is removed partially.
• Wet solid is loaded in to the trays. Trays are placed in the chamber.
• Fresh air is introduced through inlet, which passes through the heaters
and gets heated up.
• The hot air is circulated by means of fans at 2 to 5 m/s.
• The water is picked up by the air. As the water evaporates from the
surface, the water diffuses from the interior of the solids by the
capillary action.
• These events occur in a single pass of air. The time of contact is short
and amount of water picked up in a single pass is small.
• Therefore, the discharged air to the tune of 80 to 90 % is circulated back through the fans. Only 10 to
20% of fresh air is introduced.
• Moist air is discharged through outlet. Thus, constant temperature and uniform air flow over the
materials can be maintained for achieving uniform drying.
• In case of the wet granules as in tablets and capsules drying is continued until the desired moisture
content is obtained.
Advantages:
• Each batch is handled as a separate entity.
• It is more efficient in fuel consumption.
• It is simple to use.
• It provides tendency to over-dry the lower trays.
• It requires little labor costs – merely load and then unload.

Disadvantages:
• The process is time-consuming.
• It requires extra cost.
• Not suitable for oxidizable and thermolabile substances.
Application in Bio-Process Industry:
Pharmaceuticals Industry:
• Preparation of bulk drug: Drying is the final stage of processing. Ex: Dried Aluminum
Hydroxide, spray dried lactose and powdered extracts.
• Preservation of drug products: Drying is necessary in order to avoid deterioration. Ex: Protection
of blood products, skin, tissues and crude drug from microbial growth.
• Tray dryer is used in the drying of the sticky materials.
• Plastic substances can be dried by the tray dryers.
• Wet mass preparations and pastes can be dried in a tray dryer.
Case Study: Tray dryer design under feed uncertainty:
A case study on a nutraceutical beverage
The feed stream includes a mixture of Ilex guayusa (stream
1), Cocoa Husk (stream 2), and Vernonanthura patens
(stream 3). 60 kg of a mixture of these plants are fed into
dryer at ambient temperature. The goal of it is to remove
moisture from the plants to facilitate the decomposition of
the cellular walls.
 FLUIDIZED BED DRYER
Principle: It works on the principle of fluidization, where solid
particles are suspended in a stream of air or gas, creating a fluid-
like state.

Working:
• Wet material is placed in the drying chamber on a perforated
plate or membrane bed.
• An external heater warms the incoming air or gas to the
desired temperature.
• Hot air is introduced through the base, below the particle bed,
via an air distributor for uniform airflow.
• Airflow velocity increases, suspending the particles and
creating a fluid-like state.
• The suspended particles contact the hot air, rapidly absorbing
heat, which evaporates moisture.
• The vaporized moisture is carried away by the air stream, reducing the material's moisture content.
• Moist air exits the dryer through an exhaust system, where filters trap any fine particles.
• Once the desired moisture level is reached, the dry product is collected from the dryer.
• In some systems, a portion of the exhaust air is recirculated to improve energy efficiency.

Advantages
• Fluidization increases surface contact with air, leading to rapid drying.
• Particles are uniformly suspended, promoting even moisture removal.
• Provides stable and controlled drying temperatures.
• Suitable for a variety of particle sizes and shapes.
• High heat and mass transfer rates result in lower energy consumption.

Disadvantages
• High turbulence can cause particle breakage, leading to fines and dust.
• High airflow requirements increase energy costs.
• Materials with high moisture or sticky properties may form clumps.
• Large systems require significant space and initial investment
Application in Bio-process industries:

• Pharmaceuticals: Drying of heat-sensitive materials such as granules and tablets.

• Food and Nutraceuticals: Drying of food particles, powders, and herbs, retaining nutrient and colour
quality.
• Fermentation products: Drying of microbial biomass and enzyme powders.
• Biomass drying: Preparation of biomass for biofuel production.
• Biofertilizers and biopesticides: Drying microbial products and organic fertilizers.

Case Study: Investigating the Trade-Off between Design and Operational Flexibility in Continuous
Manufacturing of Pharmaceutical Tablets
Market globalization, shortened patent lifetimes and the ongoing shift towards personalized medicines
exert unprecedented pressure on the pharmaceutical industry. In the push for continuous pharmaceutical
manufacturing, processes need to be shown to be agile and robust enough to handle variations with
respect to product demands and operating conditions. In this paper we examine the use of operational
envelopes to study the trade-off between the design and operational flexibility of the fluid bed dryer at
the heart of a tablet manufacturing process.
 BELT DRYER
Principle: It works on the principle of using hot air to dry
materials as they move on a conveyor belt.

WORKING:
• The wet product is pumped onto the conveyor belt using a
feeding pump, which controls the flow of the product into
the dryer.
• The swivel arm helps in evenly spreading the wet product
onto the conveyor belt for efficient drying.
• The conveyor belt moves the product through the dryer,
transporting it from the wet product section to the dry
product section.
• As the conveyor belt moves, it passes over multiple heating
plates, which gradually heat the product to evaporate
moisture.
• The heating plates are arranged in sequence to allow for
controlled drying, where moisture is removed gradually
without overheating.
• After the heating plates, the product reaches a cooling plate to stabilize and lower its
temperature.
• Product is fully dried as it leaves the conveyor.
• At the end of the conveyor, a breaker is positioned to break down larger pieces of the dried
product for uniformity.
• Grinds the product into finer particles.
• The dried and crushed product exits the system, ready for packaging or further processing.
Advantages
• Efficient for large-scale, non-stop drying.
• Ensures even moisture removal.
• Recirculates hot air, reducing energy use.
• Suitable for various production volumes.
• Requires minimal manual intervention.
Disadvantages
• Expensive to purchase and install.
• Takes up significant space.
• Regular upkeep needed for optimal performance.
• Not ideal for irregular or sticky materials and ttake longer time for high moisture particles.
Application in Bio-process industries:

• Pharmaceuticals: Drying of herbal extracts, powders, and other active ingredients used in drug
production.
• Waste Treatment (Sludge Drying): Drying of wastewater sludge or organic waste.
• Bioplastics and Biocomposites: Drying of plant fibers, biopolymers, or other bio-based materials
used in bioplastics.
• Food :Drying fruits, vegetables, herbs, and plant-based ingredients.

CASE STUDY: Drying Herbal Extracts Using a Belt Dryer

A pharmaceutical company used a belt dryer to improve the drying process of herbal extracts. The
feed material was semi-liquid herbal extracts with 50-60% moisture content, derived from plants like
ginseng and echinacea. The drying parameters included three temperature zones: 70°C for initial
drying, 50°C for preserving active ingredients, and 40°C for final moisture removal. Airflow was
optimized at 1.5 m/s, and belt speed was set at 0.5 meters per minute. The result was a consistent
final moisture content of 5-7%, 20% energy savings, reduced drying time by 50%, and a 30%
reduction in labor costs.
 Rotary Dryer
Principle: The rotary dryer operates based on the principle of direct or indirect heat
transfer through a rotating drum.
Working:
• Wet material is fed into the high end of a rotating
drum, which is slightly inclined.
• The material tumbles and cascades through the hot air
stream, which flows through the drum. This action
ensures thorough mixing and exposes the material to
the heat for efficient drying.
• Heated air is introduced into the drum either in the
same direction (co-current flow) or opposite direction
(counter-current flow) as the material.
• Material tumbles through the hot air, moisture
evaporates. The rotation of the drum and its slope help
carry the dried material toward the discharge end.
• Exhaust: The evaporated moisture exits the drum along with the exhaust air, while the dried
material exits separately at the lower end of the drum.
• Control Mechanisms: Rotary dryers are equipped with temperature and airflow controls to
adjust drying parameters according to the specific material requirements.

Advantages
• Can handle large volumes of material, making them suitable for high-capacity operations.
• Suitable for a wide range of materials, including granular, powder, or lumpy substances, and can
dry materials with varying moisture contents.
• Its motion maximizes contact between the hot air and material, leading to efficient drying.
• Built to withstand heavy-duty industrial use and harsh environments, making them long-lasting
and robust.
• Rotary dryers operate continuously, allowing for an ongoing drying process and minimizing
downtime.
Disadvantages
• Require significant energy for heating the air, making them costly to operate, especially for
high-temperature drying.
• The movement of materials can create dust, and the exhaust air may require treatment to
control emissions.
• These dryers are often large and need ample space for installation, which may be a constraint
in small facilities.
• Regular maintenance is required to keep the drum and other parts functioning efficiently and
to avoid operational issues over time.

Application in Bio-process industries:

• Pharmaceuticals: Drying of Active Pharmaceutical Ingredients (APIs), Herbal Extracts and

Biomaterials
• Food and Agriculture : Drying of Food Ingredients, Animal Feed Production, Biomass
Drying
• Fermentation Processes: Drying Fermentation Products, Waste Recovery
• Bioplastics and Bio-based Polymers : Polymer Drying, Pellet Production
• Waste Treatment and Environmental Applications : Sludge Drying, Composting and Soil
Amendment Products
Case Study: Rotary dryer in a study based on participatory principles for smallholder scale
drying
Small farmers who mostly live in rural areas need a cheap and easy technique for the post-harvest
production process, especially drying. The participation of farmers is very much needed so that the
design of work tools according to their needs and their use can be sustainable. So far, sun drying is
very dependent on the weather and causes fatigue to farmers due to sun exposure. To overcome
this, a dryer was designed with the application of participatory principles which is part of the
ergonomics application. With the participatory principle, a rotary type dryer was developed for
grain drying. Energy sources use rice husks, which are widely available so that they are easy to
obtain and inexpensive. The rotary type dryer design utilizes this biomass by energy conversion
using a heat exchanger. It is hoped that this type of tool is cheap and easy to operate so that it can
be accepted by small farmers. In addition, small farmers do not experience additional workloads
due to sun exposure which has an impact on the risk of fatigue, increasing productivity.
 Flash Dryer
Principle: In order to quickly evaporate surface moisture, a
flash drier exposes wet material to a hot air stream moving at a
fast speed. A dust collector filters the exhaust after the dry
particles are separated from the air in a cyclone. This
configuration enables effective, ongoing drying.
Working:
• Wet material is introduced into a high-velocity, hot air
stream, initiating rapid drying.
• Intense heat causes surface moisture to evaporate quickly,
achieving efficient drying.
• Material remains suspended in the air stream, ensuring
maximum hot air contact for thorough drying.
• Air and dried particles move into a cyclone separator, where
solid particles are collected.
• Exhaust air passes through a dust collector to remove fine
particles before release.
• High-velocity air stream ensures a short drying time, minimizing thermal degradation of heat-sensitive
materials.
• The drying process is continuous, allowing for consistent material throughput..
• Flash dryers are energy-efficient due to direct heat transfer and minimal retention time for the material.
• The system design can handle a range of materials, from powders to granules, accommodating diverse
drying needs.
Advantages
• Rapid Drying: Flash dryers provide quick drying, making them ideal for materials that require fast moisture
removal.
• Energy Efficiency: Direct contact with the hot air stream ensures efficient heat transfer, reducing energy
consumption.
• Minimized Thermal Degradation: The short drying time helps protect heat-sensitive materials from degradation.

Disadvantages
• High Airflow Requirement: Flash dryers require a high airflow rate, which can increase operational costs.

• Dust Generation: The drying process may generate fine dust, requiring effective dust collection systems to
control emissions.
• Product Losses: Fine particles may be lost in the exhaust air, leading to product loss and the need for recovery
systems.
Application in Bio-process industries:

• Drying of Fermentation Biomass : Flash dryers are used to quickly dry biomass from fermentation processes,
such as yeast or bacterial cells, while preserving cell structure for further processing.

• Enzyme and Protein Drying They facilitate rapid drying of enzymes and proteins, minimizing thermal damage
and retaining bioactivity, which is essential for pharmaceuticals and food industries.

• Waste Treatment in Biorefineries : Flash dryers help process organic waste and sludge from bio-waste
treatment facilities, reducing moisture content and volume, which aids in efficient waste disposal or biofuel
production.

• Drying of Probiotic Cultures : In the production of probiotics, flash dryers are used to maintain the viability of
microorganisms by quickly reducing moisture content, allowing for longer shelf life in finished products.
Case Study: Optimization of Flash Dryer Performance for Biopharmaceutical Drying Applications
• The biopharmaceutical industry is under increasing pressure to improve production efficiency while maintaining
high product quality, particularly in the drying of sensitive biological materials like proteins and enzymes. Flash
dryers, due to their rapid drying capabilities, are becoming a preferred choice for drying these materials,
especially for applications that demand a fine balance between speed and minimal thermal damage. This paper
investigates the performance optimization of flash dryers in the biopharmaceutical sector, focusing on how
variations in operating parameters, such as airflow rate, inlet temperature, and particle size distribution, influence
drying efficiency and product quality. Using computational fluid dynamics (CFD) simulations and experimental
data, the study identifies optimal operating conditions and design configurations that maximize drying
performance while ensuring the preservation of bioactivity in dried products. The findings highlight the trade-
offs between drying time, energy consumption, and product stability, providing valuable insights into the design
and operation of flash dryers for biopharmaceutical applications.
References

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Manzano, Patricia., Salas, Santiago. D., Gonzalez, Yris., Review on Tray dryer design under feed
uncertainty: A case study on a nutraceutical beverage. Food Engineering, Ecuador.
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• Alit, Ida. Bagus., Susana, I Gede. Bawa., Review on Rotary dryer in a study based on participatory
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• Smith, John. R., Williams, Emily. T., Martin, Michael. J., Turner, Sarah. L., Review on
Optimization of Flash Dryer Performance for Biopharmaceutical Drying Applications.
Thank you