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Can sugar mills use spray drying to make products?

Sugar factories have long relied on crystallization to produce their final products. However, after multiple stages of boiling, not all the sucrose can be fully recovered from the raw material. In contrast, many other food industries use techniques like spray-drying or fluidized-bed drying, which allow them to convert liquid materials into solid products in a single step. Could the sugar industry adopt such methods? This idea has been explored for decades, especially abroad. In the 1950s, 1960s, and 1970s, Guangdong conducted large-scale tests in three sugar mills using different spray-drying technologies—high-pressure spray, air spray, and high-speed centrifugal spray. The drying chambers had volumes of several cubic meters, and the feedstock used was sugarcane syrup. Despite these efforts, the results were not successful. The main challenges included: 1. **High moisture absorption**: The dried product tended to absorb moisture easily because cane juice contains a lot of high-molecular organic compounds, which have strong hygroscopic properties. This caused the product to turn into a sticky paste, making storage and handling extremely difficult. 2. **Low thermal efficiency**: The amount of heat required to evaporate moisture was several times higher than that used in traditional crystallization methods, making it energy-intensive and costly. 3. **Limited production capacity**: The equipment had low evaporation rates, meaning even large dryers could only produce small quantities of product. The first issue—moisture absorption—was the most critical. To address this, the raw materials needed to be purified. For example, using white sugar or treating raw sugar solution with clarification and ion exchange resins could reduce the presence of hygroscopic substances. Today, Japan uses a similar spray-drying process to produce a small quantity of instant sugar, known as Q-sugar. Other countries also apply similar methods to create specialty products like T-sugar, agglomerated sugar, and amorphous sugar, typically using refined sugar solutions. While spray-drying shows promise, its application in the sugar industry remains limited due to the challenges outlined. However, with ongoing advancements in purification and drying technologies, there may still be potential for future development.

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