Unlocking the Potential of Spray Drying for Agro-products: Exploring Advanced Techniques, Carrier Agents, Applications, and Limitations

Spray drying, which is a cost-effective dehydration method in the food industry, excels at preserving product integrity. Still, it has problems like losing quality because of heat, not being able to control particle sizes as well as it could, wasting energy, and nozzle blockages that make bioactive compounds like vitamin C, carotenoids, flavanols, and anthocyanins less effective. A new era of spray drying is unfolding, marked by breakthroughs such as ultrasound-assisted, nano, vacuum, dehumidified air, superheated steam, pulse combustion, foam, and flame methods, which promise improved preservation, energy use, and powder consistency. These technologies refine the drying process, shoring up the defense of delicate bioactives, averting nozzle blockages, and honing particle size precision. Additionally, the spray chilling method bolsters the resilience of vulnerable ingredients through processing and storage. The exploration of novel biopolymers as carriers aims to combat public health issues like obesity and cardiovascular disease. This critical review captures the transformative strides made by recent spray drying approaches and encapsulating agents, driving food processing forward towards greater quality, health benefits, and industrial sustainability.

Graphical Abstract