Skip to main content
Log in

Spray-freeze-drying as emerging and substantial quality enhancement technique in food industry

  • Review
  • Published:
Food Science and Biotechnology Aims and scope Submit manuscript

Abstract

Spray freeze drying is an emerging technology in the food industry with numerous applications. Its ability to preserve food quality, maintain nutritional value, and reduce bulk make it an attractive option to food manufacturers. Spray freeze drying can be used to reduce the water content of foods while preserving the shelf life and nutritional value. Spray freeze-drying of food products is a process that involves atomizing food into small droplets and then flash-freezing them. The frozen droplets are then placed in a vacuum chamber and heated, causing the liquid to evaporate and the solid particles to become a dry powder. Spray freeze drying has become a valuable tool for the food industry through its ability to process a wide range of food products. This review’s prime focus is understanding spray freeze-dried approaches and emphasizing their applicability in various products.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Fig. 1
Fig. 2
Fig. 3
Fig. 4

(Adapted from Cao et al., 2020)

Fig. 5

Similar content being viewed by others

References

  • Adali MB, Barresi AA, Boccardo, G Pisano R. Spray freeze-drying as a solution to continuous manufacturing of pharmaceutical products in bulk. Processes. 6: 709 (2020).

    Google Scholar 

  • Ali ME, Lamprecht A. Spray freeze drying as an alternative technique for lyophilization of polymeric and lipid-based nanoparticles. International Journal of Pharmaceutics. 516: 170-177 (2017)

    CAS  PubMed  Google Scholar 

  • Baldelli A, Oguzlu H, Liang DY, Subiantoro A Woo, MW Pratap-Singh A. Spray freeze drying of dairy products: Effect of formulation on dispersibility. Journal of Food Engineering. 335: 111191 (2022)

    CAS  Google Scholar 

  • Bhatta S, Stevanovic Janezic T, Ratti C. Freeze-drying of plant-based foods. Foods. 9: 87 (2020)

    CAS  PubMed  PubMed Central  Google Scholar 

  • Buljeta I, Pichler A, Šimunović J, Kopjar M. Polysaccharides as carriers of polyphenols: Comparison of freeze-drying and spray-drying as encapsulation techniques. Molecules. 27: 5069 (2022)

    CAS  PubMed  PubMed Central  Google Scholar 

  • Cao L, Xu Q, Xing Y, Guo X, Li W, Cai Y. Effect of skimmed milk powder concentrations on the biological characteristics of microencapsulated Saccharomyces cerevisiae by vacuum-spray-freeze-drying. Drying Technology. 4: 476-494 (2020)

    Google Scholar 

  • da Fonseca Machado, AP Alves Rezende, C Alexandre Rodrigues, R Fernández Barbero, G de Tarso Vieira e Rosa, P Martínez J. Encapsulation of anthocyanin-rich extract from blackberry residues by spray-drying, freeze-drying and supercritical antisolvent. Powder Technology. 340: 553-562 (2018)

    Google Scholar 

  • De Mohac, LM Raimi-Abraham, B Caruana, R Gaetano, G Licciardi M. Multicomponent solid dispersion a new generation of solid dispersion produced by spray-drying. Journal of Drug Delivery Science and Technology. 57: 101750 (2020)

    Google Scholar 

  • Deotale SM, Dutta S, Moses JA, Anandharamakrishnan C. Stability of instant coffee foam by nanobubbles using spray-freeze drying technique. Food and Bioprocess Technology. 11: 1866-1877 (2020)

    Google Scholar 

  • Di A, Zhang S, Liu X, Tong Z, Sun S, Tang Z, Chen XD, Wu WD. Microfluidic spray dried and spray freeze-dried uniform microparticles potentially for intranasal drug delivery and controlled release. Powder Technology. 379: 144-153 (2021)

    CAS  Google Scholar 

  • Djekic I, Tomic N, Bourdoux S, Spilimbergo S, Smigic N, Udovicki B, Hofland G, Devlieghere F, Rajkovic A. Comparison of three types of drying (supercritical CO2, air and freeze) on the quality of dried apple–quality index approach. LWT. 94: 64-72 (2018)

    CAS  Google Scholar 

  • Elik A, Koçak Yanık DK, Göğüş FA comparative study of encapsulation of carotenoid enriched-flaxseed oil and flaxseed oil by spray freeze-drying and spray drying techniques. LWT. 143: 111153 (2021)

    CAS  Google Scholar 

  • Gonçalves A, Estevinho BN, Rocha F. Microencapsulation of vitamin A: A review. Trends in Food Science and Technology. 51: 76-87 (2016)

    Google Scholar 

  • Haghighi DM, Faghihi H, Darabi M, Mirmoeini MS, Vatanara A. Spray freeze drying to solidify nanosuspension of cefixime into inhalable microparticles. Daru. 1: 17-27 (2022)

    Google Scholar 

  • Herman RA, Ayepa E, Fometu SS, Shittu S, Davids JS, Wang J. Mulberry fruit post-harvest management: Techniques, composition, and influence on quality traits—A review. Food Control. 140: 109126 (2022)

    CAS  Google Scholar 

  • Hou X, Liu W, Zuo W, Zhang R, Zou Q, Zhang S, Zhu Y, Mei Z, Wang N, Wei J, Zhang Z, Chen X. Analysis of enzymes and phenolic metabolites which affecting the anti-browning property of’Shannongsu’pear. LWT. 168: 113919 (2022)

    CAS  Google Scholar 

  • Hundre SY, Karthik P, Anandharamakrishnan C. Effect of whey protein isolate and β-cyclodextrin wall systems on stability of microencapsulated vanillin by spray–freeze drying method. Food Chemistry. 174: 16-24 (2015)

    CAS  PubMed  Google Scholar 

  • Ishwarya SP. Spray-freeze-drying of foods and bioproducts: Theory, applications and perspectives. CRC Press (2022)

    Google Scholar 

  • Ishwarya SP, Anandharamakrishnan C, Stapley AGF. Spray-freeze-drying: A novel process for the drying of foods and bioproducts. Trends in Food Science and Technology. 2: 161-181 (2015)

    Google Scholar 

  • Ishwarya SP, Anandharamakrishnan C, Stapley AGF. Spray-freeze-drying of dairy products. In C. Anandharamakrishnan (Ed.), Handbook of drying for dairy products (pp. 123-148). John Wiley. Sons (2017)

    Google Scholar 

  • ISO/TR. (en)Nanotechnologies—Plain language explanation of selected terms from the ISO/IEC 80004 series (2017)

  • Kaimal AM, Tidke VB, Mujumdar AS, Thorat BN. Food security and sustainability through solar drying technologies: A case study based on solar conduction dryer. Materials Circular Economy. 1: 1-23 (2022)

    Google Scholar 

  • Kandasamy S, Naveen R. A review on the encapsulation of bioactive components using spray‐drying and freeze‐drying techniques. Journal of Food Process Engineering. 8: e14059 (2022)

    Google Scholar 

  • Kanwate BW, Ballari RV, Kudre TG. Influence of spray-drying, freeze-drying and vacuum-drying on physicochemical and functional properties of gelatin from Labeo rohita swim bladder. International Journal of Biological Macromolecules. 121: 135-141 (2019)

    CAS  PubMed  Google Scholar 

  • Lammerskitten A, Wiktor A, Siemer C, Toepfl S, Mykhailyk V, Gondek E, Rybak K, Witrowa-Rajchert, D, Parniakov, O. The effects of pulsed electric fields on the quality parameters of freeze-dried apples. Journal of Food Engineering. 252: 36-43 (2019)

    CAS  Google Scholar 

  • Lavanya MN, Preethi R, Moses JA, Anandharamakrishnan C. Production of bromelain aerosols using spray-freeze-drying technique for pulmonary supplementation. Drying Technology. 3: 358-370 (2021)

    Google Scholar 

  • Liang W, Chan AYL, Chow MYT, Lo FFK, Qiu Y, Kwok PCL, Lam JKW. Spray freeze drying of small nucleic acids as inhaled powder for pulmonary delivery. Asian Journal of Pharmaceutical Sciences. 2: 163-172 (2018)

    Google Scholar 

  • Loewen A, Chan B, Li-Chan ECY. Optimization of vitamins A and D3 loading in reassembled casein micelles and effect of loading on stability of vitamin D3 during storage. Food Chemistry. 240: 472-481 (2018)

    CAS  PubMed  Google Scholar 

  • Lolli A, Maslova V, Bonincontro D, Basile F, Ortelli S, Albonetti S. Selective oxidation of HMF via catalytic and photocatalytic processes using metal-supported catalysts. Molecules. 23(11): 2792 (2018)

    CAS  PubMed  Google Scholar 

  • Luo C, Mi S, Zhou N, Liu Z, Cai L. Modelling the primary drying stage of the spray freeze drying process based on the non-equilibrium formulation. International Journal of Heat and Mass Transfer. 188: 122659 (2022)

    Google Scholar 

  • Ly A. Atmospheric spray freeze-drying on common biologics and excipients as a comparison to lyophilization (2019)

  • Martínez-Navarrete N, Salvador A, Oliva C, Camacho MM. Influence of biopolymers and freeze-drying shelf temperature on the quality of a mandarin snack. LWT. 99: 57-61 (2019).

    Google Scholar 

  • Merivaara A, Zini J, Koivunotko E, Valkonen S, Korhonen O, Fernandes FM, Yliperttula M. Preservation of biomaterials and cells by freeze-drying: Change of paradigm. Journal of Controlled Release. 336: 480-498 (2021)

    CAS  PubMed  Google Scholar 

  • Meryman HT. Sublimation freeze-drying without vacuum. Science. 3376: 628-629 (1959)

    Google Scholar 

  • Moayyedi M, Eskandari MH, Rad AHE, Ziaee E, Khodaparast MHH, Golmakani MT. Effect of drying methods (electrospraying, freeze drying and spray drying) on survival and viability of microencapsulated Lactobacillus rhamnosus ATCC 7469. Journal of Functional Foods. 40: 391-399 (2018)

    CAS  Google Scholar 

  • Moeller H, Martin D, Schrader K, Hoffmann W, Lorenzen PC. Spray- or freeze-drying of casein micelles loaded with vitamin D2: Studies on storage stability and in vitro digestibility. LWT. 97: 87-93 (2018)

    CAS  Google Scholar 

  • Mohammadalinejhad S, Kurek MA. Microencapsulation of anthocyanins—Critical review of techniques and wall materials. Applied Sciences. 9: 3936 (2021)

    Google Scholar 

  • Mozaffar S, Radi M, Amiri S, McClements DJ. A new approach for drying of nanostructured lipid carriers (NLC) by spray-drying and using sodium chloride as the excipient. Journal of Drug Delivery Science and Technology. 61: 102212 (2021)

    CAS  Google Scholar 

  • Mutukuri TT, Darwish A, Strongrich AD, Peroulis D, Alexeenko A, Zhou QT. Radio frequency-assisted ultrasonic spray freeze drying for pharmaceutical protein solids. Journal of Pharmaceutical Sciences. 1: 40-50 (2023)

    Google Scholar 

  • O’Sullivan JJ, Norwood EA, O’Mahony JA, Kelly AL. Atomisation technologies used in spray drying in the dairy industry: A review. Journal of Food Engineering. 243: 57-69 (2019)

    Google Scholar 

  • Pardeshi S, More M, Patil P, Pardeshi C, Deshmukh P, Mujumdar A, Naik J. A meticulous overview on drying-based (spray-, freeze-, and spray-freeze) particle engineering approaches for pharmaceutical technologies. Drying Technology. 11: 1447-1491 (2021)

    Google Scholar 

  • Parthasarathi S, Anandharamakrishnan C. Enhancement of oral bioavailability of vitamin E by spray-freeze drying of whey protein microcapsules. Food and Bioproducts Processing. 100: 469-476 (2016)

    Google Scholar 

  • Pellicer JA, Fortea MI, Trabal J, Rodríguez-López MI, Gabaldón JA, Núñez-Delicado E. Stability of microencapsulated strawberry flavour by spray drying, freeze drying and fluid bed. Powder Technology. 347: 179-185 (2019)

    CAS  Google Scholar 

  • Poursina N, Vatanara A, Rouini MR, Gilani K, Najafabadi AR. The effect of excipients on the stability and aerosol performance of salmon calcitonin dry powder inhalers prepared via spray freeze drying process. Acta Pharmaceutica. 2 :207-218 (2016)

    Google Scholar 

  • Reddy P, Jialal I. Biochemistry, fat soluble vitamins. gov/books/NBK534869/ (2020)

  • Ren J, Liao M, Ma L, Chen F, Liao X, Hu X, Ji J. Effect of spray freeze drying on the structural modification and rehydration characteristics of micellar casein powders. Innovative Food Science & Emerging Technologies. 80: 103093 (2022)

    Google Scholar 

  • Rezvankhah A, Emam-Djomeh Z, Askari G. Encapsulation and delivery of bioactive compounds using spray and freeze-drying techniques: A review. Drying Technology. 38: 235-258 (2020)

    CAS  Google Scholar 

  • Rockinger U, Funk M, Winter G. Current approaches of preservation of cells during (freeze-) drying. Journal of Pharmaceutical Sciences. 8: 2873-2893 (2021)

    Google Scholar 

  • Rostamnezhad M, Jafari H, Moradikhah F, Bahrainian S, Faghihi H, Khalvati R, Bafkary R, Vatanara A. Spray freeze-drying for inhalation application: Process and formulation variables. Pharmaceutical Development and Technology. 3: 251-267 (2022)

    Google Scholar 

  • Saboti D, Maver U, Chan HK, Planinšek O. Novel budesonide particles for dry powder inhalation prepared using a microfluidic reactor coupled with ultrasonic spray freeze drying. Journal of Pharmaceutical Sciences. 7: 1881-1888 (2017)

    Google Scholar 

  • Sadiq U, Gill H, Chandrapala J, Shahid F. Influence of spray drying on encapsulation efficiencies and structure of casein micelles loaded with anthraquinones extracted from Aloe vera plant. Applied Sciences. 1: 110 (2023)

    Google Scholar 

  • Šeregelj V, Ćetković G, Čanadanović-Brunet J, Šaponjac VT, Vulić J, Lević S, Nedović V, Brandolini A, Hidalgo A. Encapsulation of carrot waste extract by freeze and spray drying techniques: An optimization study. LWT. 138: 110696 (2021)

    Google Scholar 

  • Shaik L, Chakraborty S. Effect of pH and total fluence on microbial and enzyme inactivation in sweet lime (Citrus limetta) juice during pulsed light treatment. Journal of Food Processing and Preservation. 8: e16749 (2022)

    Google Scholar 

  • Silva JVC, O’Mahony JA. Flowability and wetting behaviour of milk protein ingredients as influenced by powder composition, particle size and microstructure. International Journal of Dairy Technology. 702: 277-286 (2017)

    Google Scholar 

  • Smaniotto F, Prosapio V, Zafeiri I, Spyropoulos F. Freeze drying and rehydration of alginate fluid gels. Food Hydrocolloids. 99: 105352 (2020)

    CAS  Google Scholar 

  • Surface energy (2021). https://chem.libretexts.org/@go/page/183363. Retrieved September 22, 2022

  • Teixeira CCC, Cabral T PdF, Tacon LA, Villardi IL, Lanchote AD, Freitas LA Pd. Solid state stability of polyphenols from a plant extract after fluid bed atmospheric spray-freeze-drying. Powder Technology. 319: 494-504 (2017)

    CAS  Google Scholar 

  • Tomas M, Jafari S M. Influence of food processing operations on vitamins. Elsevier (2018)

    Google Scholar 

  • Vincenzetti S, Cecchi T, Perinelli DR, Pucciarelli S, Polzonetti V, Bonacucina G, Ariani A, Parrocchia L, Spera DM, Ferretti E, Vallesi P, Polidori P. Effects of freeze-drying and spray-drying on donkey milk volatile compounds and whey proteins stability. LWT. 88: 189-195 (2018)

    CAS  Google Scholar 

  • Vishali DA, Monisha J, Sivakamasundari SK, Moses JA, Anandharamakrishnan C. Spray freeze drying: Emerging applications in drug delivery. Journal of Controlled Release. 300: 93-101 (2019)

    CAS  PubMed  Google Scholar 

  • Xi Q, Miao J, Cao Z, Wang H. Inhalable aerosol microparticles with low carrier dosage and high fine particle fraction prepared by spray-freeze-drying. International Journal of Pharmaceutics: X. 5: 100158 (2023)

    CAS  PubMed  Google Scholar 

  • Yang M, Peng J, Zi Y, Shi C, Kan G, Wang X, Zhong J. Encapsulation of fish oil by complex coacervation and freeze drying with modified starch aid. Food Hydrocolloids. 137: 108371 (2023)

    CAS  Google Scholar 

  • Zhang F, Ma X, Wu X, Xu Q, Tian W, Li Z. Inert particles as process aid in spray-freeze drying. Drying Technology (2019)

    CAS  Google Scholar 

  • Zhang R, Zhou L, Li J, Oliveira H, Yang N, Jin W, Zhu Z, Li S, He J. Microencapsulation of anthocyanins extracted from grape skin by emulsification/internal gelation followed by spray/freeze-drying techniques: Characterization, stability and bioaccessibility. LWT. 123: 109097 (2020)

    CAS  Google Scholar 

  • Zhang S, Yan S, Lu K, Qiu S, Chen X D, Wu W D. Spray freeze dried niclosamide nanocrystals embedded dry powder for high dose pulmonary delivery. Powder Technology. 415: 118168 (2023)

    CAS  PubMed  Google Scholar 

Download references

Acknowledgements

The authors are thankful to the Department of Bioengineering, Integral University, Lucknow, Uttar Pradesh, India, Department of Biotechnology, Axis Institute of Higher Education, Kanpur, Uttar Pradesh, India, Department of Food Technology, Islamic University of Science and Technology Kashmir, India for providing the necessary support during the preparation of this manuscript.

Author information

Authors and Affiliations

Authors

Corresponding authors

Correspondence to Rahul Singh or Aamir Hussain Dar.

Ethics declarations

Conflict of interest

There is no conflict of interest between the authors.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Singh, P., Pandey, V.K., Singh, R. et al. Spray-freeze-drying as emerging and substantial quality enhancement technique in food industry. Food Sci Biotechnol 33, 231–243 (2024). https://doi.org/10.1007/s10068-023-01409-8

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s10068-023-01409-8

Keywords

Navigation