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1. (WO2019028446) ULTRAHIGH EFFICIENCY SPRAY DRYING APPARATUS AND PROCESS
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THE CLAIMS

What is claimed is:

1. A method of processing a spray dryable liquid composition to form a spray dried product, said method comprising:

generating a spray of the spray dryable liquid composition;

contacting the spray of spray dryable liquid composition in a spray drying contact zone with a stream of primary drying fluid;

injecting pressurized secondary drying fluid into the stream of primary drying fluid in the spray drying contact zone at multiple loci thereof to provide localized turbulence at said multiple loci; and

recovering the spray dried product from the spray drying contact zone.

2. The method of claim 1, wherein the primary drying fluid and secondary drying fluid are introduced to the spray drying contact zone at temperature below 100°C and above freezing temperature of solvent in the spray dryable liquid composition.

3. The method of claim 1, wherein said injecting is continuously or intermittently conducted during said contacting.

4. The method of claim 1, wherein the primary drying fluid and secondary drying fluid are each independently selected from the group consisting of air, oxygen, oxygen-enriched air, nitrogen, helium, argon, neon, carbon dioxide, carbon monoxide, and combinations of two or more of the foregoing.

5. The method of claim 1, wherein the spray dryable liquid composition comprises at least one product material selected from the group consisting of food materials, beverage materials, fragrance materials, pigment materials, flavor materials, pharmaceutical materials, therapeutic materials, medication materials, homeopathic materials, biological materials, probiotic materials, construction materials, formulating materials, and mixtures, blends, composites, and combinations of two or more different materials of the foregoing.

6. The method of claim 1, wherein the spray dryable liquid composition comprises solvent selected from the group consisting of water, alcohol, and aqueous alcohol solution.

7. The method of claim 1, wherein the spray dryable liquid composition comprises at least one carrier selected from the group consisting of carbohydrates, proteins, lipids, waxes, cellulosic materials, sugars, starches, and natural and synthetic polymeric materials.

8. The method of claim 1, wherein the spray dryable liquid composition has a viscosity in a range of from 300 mPa-s to 28,000 mPa-s, and comprises from 20 to 50% by weight of solvent, based on total weight of the spray dryable liquid composition.

9. The method of claim 1, wherein the primary drying fluid and secondary drying fluid are introduced to the spray drying contact zone at temperature below at least one of 95°C, 90°C, 85°C, 80°C, 75°C, 70°C, 65°C, 60°C, 55°C, 50°C, 45°C, 40°C, 35°C, 30°C, 25°C, and 20°C, and wherein said temperature is above freezing temperature of solvent in the spray dryable liquid composition.

10. The method of claim 1, wherein the primary drying fluid and secondary drying fluid are introduced to the spray drying contact zone at below 20% relative humidity.

11. The method of claim 1, comprising controlling said injecting with a control system executing a predetermined cycle timer program.

12. A spray drying system, comprising:

a spray drying vessel including an interior volume for contacting of introduced spray dryable liquid composition and a stream of primary drying fluid, said vessel including a spraying device positioned to introduce a spray of the spray dryable liquid composition into the interior volume for said contacting, an inlet for introduction of the primary drying fluid to the interior volume, and an outlet for discharging spray dried product and effluent drying fluid from the interior volume; and

a multiplicity of secondary fluid injectors constructed and arranged to introduce pressurized secondary drying fluid into the interior volume at flow conditions providing localized turbulence in the stream of primary drying fluid in the interior volume at multiple loci in the stream of primary drying fluid.

13. The spray drying system of claim 12, wherein said multiplicity of secondary fluid injectors are mounted on the spray drying vessel in an array.

14. The spray drying system of claim 13, wherein the array of secondary fluid injectors comprises at least one circumferentially extending row of secondary fluid injectors, each secondary fluid injectors in each said row being circumferentially spaced apart from adjacent secondary fluid injectors in said row, and wherein multiple rows when present are axially spaced apart with respect to a central axis of the spray drying vessel.

15. The spray drying system of claim 12, wherein each of the multiplicity of secondary fluid injectors is actuatable for secondary fluid injection by a control system to supply a transient burst of secondary fluid to the interior volume of the spray drying vessel.

16. The spray drying system of claim 12, wherein a selected one or ones of said multiplicity of secondary fluid inj ectors is actuatable by the control system to supply a transient burst of secondary fluid to the interior volume of the spray drying vessel, while selected others of said multiplicity of secondary fluid injectors are deactuated, in a predetermined sequence in which each of the multiplicity of secondary fluid injectors is intermittently actuated in the predetermined sequence.

17. The spray drying system of claim 12, wherein each of the multiplicity of secondary fluid injectors is actuatable to continuously supply secondary fluid to the interior volume of the spray drying vessel during spray drying operation therein.

18. The spray drying system of claim 12, comprising flow circuitry receiving spray dried product and effluent drying fluid from the outlet of the spray drying vessel, said flow circuitry containing a fluid/solids separator constructed and arranged to separate spray dried product from the effluent drying fluid, and a dehumidifier configured to dry the effluent drying fluid, from which spray dried product has been separated, to a predetermined extent, said flow circuitry being constructed and arranged to recycle the drying fluid, subsequent to its being dried by the dehumidifier, to the inlet of the spray drying vessel, as at least part of the primary drying fluid introduced to the interior volume of the spray drying vessel.

19. The spray drying system of claim 12, comprising a primary drying fluid source constructed and arranged to provide primary drying fluid to the spray drying vessel at temperature below 100°C and above freezing temperature of solvent in the spray dryable liquid composition.

20. The spray drying system of claim 12, further comprising:

(a) a source of primary drying fluid and a source of secondary drying fluid, wherein each of the respective sources of primary drying fluid and secondary drying fluid independently contains a fluid selected from the group consisting of air, oxygen, oxygen-enriched air, nitrogen, helium, argon, neon, carbon dioxide, carbon monoxide, and combinations of two or more of the foregoing;

(b) a source of the spray dryable liquid composition, wherein the source of the spray dryable liquid composition contains spray dryable liquid composition comprising (i) at least one product material selected from the group consisting of food materials, beverage materials, fragrance materials, pigment materials, flavor materials, pharmaceutical materials, therapeutic materials, medication materials, homeopathic materials, biological materials, probiotic materials, construction materials, formulating materials, and mixtures, blends, composites, and combinations of two or more different materials of the foregoing, (ii) at least one carrier selected from the group consisting of carbohydrates, proteins, lipids, waxes, cellulosic materials, sugars, starches, and natural and synthetic polymeric materials, and (iii) solvent, wherein the spray dryable liquid composition has a viscosity in a range of from 300 mPa-s to 28,000 mPa-s, and comprises from 20 to 50% by weight of solvent, based on total weight of the spray dryable liquid composition.

21. The spray drying system of claim 12, comprising a primary drying fluid source constructed and arranged to provide primary drying fluid to the spray drying vessel at temperature below at least one of 95 °C, 90°C, 85°C, 80°C, 75°C, 70°C, 65°C, 60°C, 55°C, 50°C, 45°C, 40°C, 35°C, 30°C, 25°C, and 20°C, and wherein said primary drying fluid temperature is above freezing temperature of solvent in the spray dryable liquid composition, and comprising a secondary drying fluid source constructed and arranged to provide secondary drying fluid to the spray drying vessel at temperature below at least one of 95°C, 90°C, 85°C, 80°C, 75°C, 70°C, 65°C, 60°C, 55°C, 50°C, 45°C, 40°C, 35°C, 30°C, 25°C, and 20°C, and wherein said secondary drying fluid temperature is above freezing temperature of solvent in the spray dryable liquid composition.

22. The spray drying system of claim 12, comprising a dehumidifier constructed and arranged to provide the primary drying fluid and secondary drying fluid to the interior volume of the spray drying vessel at below 20% relative humidity.

23. A method of spray drying of a spray dryable material in a primary drying fluid flow stream, comprising intermittently, transiently, and cyclically injecting secondary drying fluid into the primary drying fluid flow stream at multiple loci in the primary drying fluid flow stream, so as to create transient localized turbulence at such loci that enhances drying of the spray dryable material, or alternatively, continuously injecting secondary drying fluid into the primary drying fluid flow stream at multiple loci in the primary drying fluid flow stream, so as to create localized turbulence at such loci that enhances drying of the spray dryable material.

24. The method of claim 23, wherein the primary drying fluid flow stream and secondary drying fluid are each provided to the spray drying at temperature below 100°C and above freezing temperature of any solvent in the spray dryable liquid material.

25. The method of claim 24, wherein the spray dryable material is provided to the spray drying at a viscosity in a range of from 300 mPa-s to 28,000 mPa-s, and comprising from 20 to 50% by weight of solvent, based on total weight of the provided spray dryable material.

26. The method of claim 23, wherein the primary drying fluid flow stream and secondary drying fluid are each provided to the spray drying at below 20% relative humidity.

27. The method of claim 23, wherein the primary drying fluid flow stream and secondary drying fluid are each independently selected from the group consisting of air, oxygen, oxygen-enriched air, nitrogen, helium, argon, neon, carbon dioxide, carbon monoxide, and combinations of two or more of the foregoing.

28. The method of claim 23, wherein the spray dryable material comprises at least one material selected from the group consisting of food materials, beverage materials, fragrance materials, pigment materials, flavor materials, pharmaceutical materials, therapeutic materials, medication materials, homeopathic materials, biological materials, probiotic materials, construction materials, formulating materials, and mixtures, blends, composites, and combinations of two or more different materials of the foregoing.

29. The method of claim 23, wherein the spray dryable material as provided to the spray drying comprises at least one carrier selected from the group consisting of carbohydrates, proteins, lipids, waxes, cellulosic materials, sugars, starches, and natural and synthetic polymeric materials.

30. The method of claim 23, comprising intermittently, transiently, and cyclically injecting secondary drying fluid into the primary drying fluid flow stream at multiple loci in the primary drying fluid flow stream, so as to create transient localized turbulence at such loci that enhances drying of the spray dryable material.

31. A method of processing a spray dryable liquid composition to form a spray dried product, said method comprising:

generating an electrostatically charged spray of the spray dryable liquid composition;

contacting the electrostatically charged spray of spray dryable liquid composition in a spray drying contact zone with a stream of primary drying fluid;

injecting transient bursts of pressurized secondary drying fluid into the stream of primary drying fluid in the spray drying contact zone at multiple loci thereof to provide localized turbulence at said multiple loci; and

recovering the spray dried product from the spray drying contact zone.

32. The method of claim 31, wherein the primary drying fluid and secondary drying fluid are introduced to the spray drying contact zone at temperature below 100°C and above freezing temperature of solvent in the spray dryable liquid composition.

33. The method of claim 31, wherein said injecting of transient bursts is continuously or intermittently conducted during said contacting.

34. The method of claim 31, wherein the primary drying fluid and secondary drying fluid are each independently selected from the group consisting of air, oxygen, oxygen-enriched air, nitrogen, helium, argon, neon, carbon dioxide, carbon monoxide, and combinations of two or more of the foregoing.

35. The method of claim 31, wherein the spray dryable liquid composition comprises at least one product material selected from the group consisting of food materials, beverage materials, fragrance materials, pigment materials, flavor materials, pharmaceutical materials, therapeutic materials, medication materials, homeopathic materials, biological materials, probiotic materials, construction materials, formulating materials, and mixtures, blends, composites, and combinations of two or more different materials of the foregoing.

36. The method of claim 31, wherein the spray dryable liquid composition comprises solvent selected from the group consisting of water, alcohol, and aqueous alcohol solution.

37. The method of claim 31, wherein the spray dryable liquid composition comprises at least one carrier selected from the group consisting of carbohydrates, proteins, lipids, waxes, cellulosic materials, sugars, starches, and natural and synthetic polymeric materials.

38. The method of claim 31, wherein the spray dryable liquid composition has a viscosity in a range of from 300 mPa-s to 28,000 mPa-s, and comprises from 20 to 50% by weight of solvent, based on total weight of the spray dryable liquid composition.

39. The method of claim 31, wherein the primary drying fluid and secondary drying fluid are introduced to the spray drying contact zone at temperature below at least one of 95°C, 90°C, 85°C, 80°C, 75°C, 70°C, 65°C, 60°C, 55°C, 50°C, 45°C, 40°C, 35°C, 30°C, 25°C, and 20°C, and wherein said temperature is above freezing temperature of solvent in the spray dryable liquid composition.

40. The method of claim 31, wherein the primary drying fluid and secondary drying fluid are introduced to the spray drying contact zone at relative humidity below at least one of 20%, 18%, 15%, 12%, 10%, 8%, 5%, 2.5%, 2%, 1.5%, 1% and 0.5% relative humidity.

41. The method of claim 31, comprising controlling said injecting with a control system executing a predetermined cycle timer program.

42. A spray drying system, comprising:

a spray drying vessel including an interior volume for contacting of introduced spray dryable liquid composition and a stream of primary drying fluid, said vessel including an electrostatic spraying device positioned to introduce an electrostatically charged spray of the spray dryable liquid composition into the interior volume for said contacting, an inlet for introduction of the primary drying fluid to the interior volume, and an outlet for discharging spray dried product and effluent drying fluid from the interior volume; and

a multiplicity of secondary fluid injectors constructed and arranged to introduce transient bursts of pressurized secondary drying fluid into the interior volume at flow conditions providing localized turbulence in the stream of primary drying fluid in the interior volume at multiple loci in the stream of primary drying fluid.

43. The spray drying system of claim 42, wherein said multiplicity of secondary fluid injectors are mounted on the spray drying vessel in an array.

44. The spray drying system of claim 43, wherein the array of secondary fluid injectors comprises at least one circumferentially extending row of secondary fluid injectors, each secondary fluid injector in each said row being circumferentially spaced apart from adjacent secondary fluid injectors in said row, and wherein multiple rows when present are axially spaced apart with respect to a central axis of the spray drying vessel.

45. The spray drying system of claim 42, wherein each of the multiplicity of secondary fluid injectors is actuatable for secondary fluid injection by a control system to supply the transient bursts of secondary fluid to the interior volume of the spray drying vessel.

46. The spray drying system of claim 42, wherein a selected one or ones of said multiplicity of secondary fluid injectors is actuatable by the control system to supply the transient bursts of secondary fluid to the interior volume of the spray drying vessel, while selected others of said multiplicity of secondary fluid injectors are deactuated, in a predetermined sequence in which each of the multiplicity of secondary fluid injectors is intermittently actuated in the predetermined sequence.

47. The spray drying system of claim 42, wherein each of the multiplicity of secondary fluid injectors is actuatable to continuously supply the transient bursts of secondary fluid to the interior volume of the spray drying vessel during spray drying operation therein.

48. The spray drying system of claim 42, comprising flow circuitry receiving spray dried product and effluent drying fluid from the outlet of the spray drying vessel, said flow circuitry containing a fluid/solids separator constructed and arranged to separate spray dried product from the effluent drying fluid, and a dehumidifier configured to dry the effluent drying fluid, from which spray dried product has been separated, to a predetermined extent, said flow circuitry being constructed and arranged to recycle the drying fluid, subsequent to its being dried by the dehumidifier, to the inlet of the spray drying vessel, as at least part of the primary drying fluid introduced to the interior volume of the spray drying vessel.

49. The spray drying system of claim 42, comprising a primary drying fluid source constructed and arranged to provide primary drying fluid to the spray drying vessel at temperature below 100°C and above freezing temperature of solvent in the spray dryable liquid composition.

50. The spray drying system of claim 42, further comprising:

(a) a source of primary drying fluid and a source of secondary drying fluid, wherein each of the respective sources of primary drying fluid and secondary drying fluid independently contains a fluid selected from the group consisting of air, oxygen, oxygen-enriched air, nitrogen, helium, argon, neon, carbon dioxide, carbon monoxide, and combinations of two or more of the foregoing;

(b) a source of the spray dryable liquid composition, wherein the source of the spray dryable liquid composition contains spray dryable liquid composition comprising (i) at least one product material selected from the group consisting of food materials, beverage materials, fragrance materials, pigment materials, flavor materials, pharmaceutical materials, therapeutic materials, medication materials, homeopathic materials, biological materials, probiotic materials, construction materials, formulating materials, and mixtures, blends, composites, and combinations of two or more different materials of the foregoing, (ii) at least one carrier selected from the group consisting of carbohydrates, proteins, lipids, waxes, cellulosic materials, sugars, starches, and natural and synthetic polymeric materials, and (iii) solvent, wherein the spray dryable liquid composition has a viscosity in a range of from 300 mPa-s to 28,000 mPa-s, and comprises from 20 to 50% by weight of solvent, based on total weight of the spray dryable liquid composition.

51. The spray drying system of claim 42, comprising a primary drying fluid source constructed and arranged to provide primary drying fluid to the spray drying vessel at temperature below at least one of 95 °C, 90°C, 85°C, 80°C, 75°C, 70°C, 65°C, 60°C, 55°C, 50°C, 45°C, 40°C, 35°C, 30°C, 25°C, and 20°C, and wherein said primary drying fluid temperature is above freezing temperature of solvent in the spray dryable liquid composition, and comprising a secondary drying fluid source constructed and arranged to provide secondary drying fluid to the spray drying vessel at temperature below at least one of 95°C, 90°C, 85°C, 80°C, 75°C, 70°C, 65°C, 60°C, 55°C, 50°C, 45°C, 40°C, 35°C, 30°C, 25°C, and 20°C, and wherein said secondary drying fluid temperature is above freezing temperature of solvent in the spray dryable liquid composition.

52. The spray drying system of claim 42, comprising a dehumidifier constructed and arranged to provide the primary drying fluid and secondary drying fluid to the interior volume of the spray drying vessel at below 20% relative humidity.

53. A method of electrostatic spray drying of an electrostatically charged spray dryable material in a primary drying fluid flow stream, comprising intermittently, transiently, and cyclically injecting secondary drying fluid into the primary drying fluid flow stream at multiple loci in the primary drying fluid flow stream, so as to create transient localized turbulence at such loci that enhances drying of the electrostatically charged spray dryable material, or alternatively, continuously injecting secondary drying fluid into the primary drying fluid flow stream at multiple loci in the primary drying fluid flow stream, so as to create localized turbulence at such loci that enhances drying of the electrostatically charged spray dryable material.

54. The method of claim 53, wherein the primary drying fluid flow stream and secondary drying fluid are each provided to the electrostatic spray drying at temperature below 100°C and above freezing temperature of any solvent in the electrostatically charged spray dryable material.

55. The method of claim 54, wherein the spray dryable material is provided to the electrostatic spray drying at a viscosity in a range of from 300 mPa-s to 28,000 mPa-s, and comprising from 20 to 50% by weight of solvent, based on total weight of the provided spray dryable material.

56. The method of claim 53, wherein the primary drying fluid flow stream and secondary drying fluid are each provided to the electrostatic spray drying at relative humidity below at least one of 20%, 18%, 15%, 12%, 10%, 8%, 5%, 2.5%, 2%, 1.5%, 1% and 0.5% relative humidity.

57. The method of claim 53, wherein the primary drying fluid flow stream and secondary drying fluid are each independently selected from the group consisting of air, oxygen, oxygen-enriched air, nitrogen, helium, argon, neon, carbon dioxide, carbon monoxide, and combinations of two or more of the foregoing.

58. The method of claim 53, wherein the spray dryable material comprises at least one material selected from the group consisting of food materials, beverage materials, fragrance materials, pigment materials, flavor materials, pharmaceutical materials, therapeutic materials, medication materials, homeopathic materials, biological materials, probiotic materials, construction materials, formulating materials, and mixtures, blends, composites, and combinations of two or more different materials of the foregoing.

59. The method of claim 53, wherein the spray dryable material as provided to the electrostatic spray drying comprises at least one carrier selected from the group consisting of carbohydrates, proteins, lipids, waxes, cellulosic materials, sugars, starches, and natural and synthetic polymeric materials.

60. The method of claim 53, comprising intermittently, transiently, and cyclically injecting secondary drying fluid into the primary drying fluid flow stream at multiple loci in the primary drying fluid flow stream, so as to create transient localized turbulence at such loci that enhances drying of the electrostatically charged spray dryable material.

61. A spray drying process for drying a spray dryable liquid composition to a dried powder product, comprising:

atomizing the spray dryable liquid composition to generate an atomized spray of liquid particles of the spray dryable liquid composition into a spray drying chamber;

flowing a stream of primary drying fluid into the spray drying chamber for flow through the spray drying chamber, to contact the spray of liquid particles therein for drying of the liquid particles to form the dried powder product;

injecting bursts of pressurized secondary drying fluid into the stream of primary drying fluid spray drying chamber at multiple loci thereof under conditions providing localized turbulence at said multiple loci; and

discharging from the spray drying chamber effluent drying fluid and the dried powder product dried by contact with the drying fluid in the spray drying chamber.

62. The spray drying process of claim 61, wherein each of the primary drying fluid and secondary drying fluid is independently selected from the group consisting of air, oxygen, oxygen-enriched air, nitrogen, helium, argon, neon, carbon dioxide, carbon monoxide, and mixtures of two or more of the foregoing.

63. The spray drying process of claim 61, wherein the primary drying fluid is the same as the secondary drying fluid.

64. The spray drying process of claim 61, wherein the primary drying fluid is different from the secondary drying fluid.

65. The spray drying process of claim 61 , wherein the spray dryable liquid composition comprises a carrier.

66. The spray drying process of claim 65, wherein the carrier comprises a material selected from the group consisting of carbohydrates, proteins, lipids, waxes, cellulosic materials, sugars, starches, and natural and synthetic polymeric materials.

67. The spray drying process of claim 61, wherein the carrier comprises a material selected from the group consisting of starch carriers, sugar carriers, and cellulosic carriers.

68. The spray drying process of claim 61, wherein the spray dryable composition does not comprise a carrier.

69. The spray drying process of claim 61, wherein the primary drying fluid and secondary drying fluid are introduced into the spray drying chamber at temperature in a range of 180°C-200°C.

70. The spray drying process of claim 61, wherein the primary drying fluid and secondary drying fluid are introduced into the spray drying chamber at temperature below 100°C.

71. The spray drying process of claim 61, wherein the primary drying fluid and secondary drying fluid are introduced into the spray drying chamber at temperature below at least one of 95°C, 90°C, 85°C, 80°C, 75°C, 70°C, 65°C, 60°C, 55°C, 50°C, 45°C, 40°C, 35°C, 30°C, 25°C, or 20°C.

72. The spray drying process of claim 61, wherein the spray dryable liquid composition comprises at least one product material selected from the group consisting of food materials, beverage materials, fragrance materials, pigment materials, flavor materials, pharmaceutical materials, therapeutic materials, medication materials, homeopathic materials, biological materials, probiotic materials, construction materials, formulating materials, and mixtures, blends, composites, and combinations of two or more different materials of the foregoing.

73. The spray drying process of claim 61, wherein the spray dryable liquid composition comprises at least one product material selected from the group consisting of flavors, fragrances, foods, and beverages.

74. The spray drying process of claim 61, wherein the spray dryable composition comprises at least one product material, and at least one additional ingredient selected from the group consisting of solvents, carriers, adjuvants, excipients, surfactants, anti-agglomerants, anti-caking agents, co-active ingredients, wetting agents, dispersants, emulsifiers, stabilizers, antioxidants, preservatives, encapsulants, pore-forming agents, hardeners, and mixtures, blends, composites, and combinations of two or more of the foregoing additional ingredients.

75. The spray drying process of claim 61, wherein the spray dryable composition has a viscosity in a range of from 300 mPa-s to 28,000 mPa-s.

76. The spray drying process of claim 61, having a viscosity in a range in which a lower limit of the range is any one of 325, 340, 350, 375, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, and 1000 mPa-s, and in which an upper limit of the range is greater than the lower limit and is any one of 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, 1000, 2000, 3000, 4000, 5000, 6000, 7000, 8000, 9000, 10,000, 11,000, 12,000, 13,000, 14,000, 15,000, 16,000, 17,000, 18,000, 19,000, and 20,000.

77. The spray drying process of claim 61, wherein the spray dryable composition has a viscosity in a range of from 500 mPa-s to 16,000 mPa-s.

78. The spray drying process of claim 61, wherein the spray dryable composition has a viscosity in a range of from 1000 mPa-s to 4000 mPa-s.

79. The spray drying process of claim 61, wherein the spray dryable composition has a viscosity in a range of from 10 mPa-s to 200 mPa-s.

80. The spray drying process of claim 61, wherein the spray dryable composition comprises a carrier, product material, and solvent, wherein the solvent in the composition does not exceed 50% by weight, based on total weight of the composition.

81. The spray drying process of claim 80, wherein the solvent in the composition comprises from 20 to 50% by weight, based on total weight of the composition.

82. The spray drying process of claim 80, wherein the solvent in the composition comprises from 20 to 40% by weight, based on total weight of the composition.

83. The spray drying process of claim 80, wherein the solvent in the composition comprises from 25 to 35% by weight, based on total weight of the composition.

84. The spray drying process of claim 80, wherein the spray dryable composition has a viscosity of from 10 to 200 mPa-s, wherein the solvent in the composition comprises from 50 to 70 % by weight, based on total weight of the composition, and wherein the primary drying fluid and secondary drying fluid are introduced into the spray drying chamber at temperature in a range of 180°C-200°C.

85. The spray drying process of claim 61 , wherein the drying fluid introduced into the spray drying chamber has a relative humidity below 20% relative humidity.

86. The spray drying process of claim 61, wherein the drying fluid introduced into the spray drying chamber has a relative humidity below at least one of 18%, 15%, 12%, 10%, 8%, 5%, 2.5%, 2%, 1.5%, 1% and 0.5% relative humidity.

87. The spray drying process of claim 61, comprising electrostatic charging of the spray dryable liquid composition and/or the atomized spray of liquid particles.

88. The spray drying process of claim 87, wherein said electrostatic charging applies an electrostatic charge to the atomized spray of liquid particles that is in a range of from 0.25 kV to 80 kV.

89. The spray drying process of claim 61, wherein the spray dryable liquid composition comprises a beverage product material, and the spray dryable liquid composition does not comprise a carrier.

90. The spray drying process of claim 61, wherein the spray dryable liquid composition comprises solvent selected from the group consisting of water, inorganic solvents, organic solvents, and mixtures, blends, emulsions, suspensions, and solutions thereof.

91. A spray drying system, comprising:

(a) a spray drying vessel comprising:

(i) an interior volume arranged to receive an atomized spray-dryable material and drying fluid for contacting of the atomized spray-dryable material with the drying fluid in the interior volume;

(ii) at least one drying fluid inlet by which the drying fluid is introduced into the interior volume for said contacting; and

(iii) a spray-dried material outlet communicating with the interior volume, arranged to discharge spray-dried material and effluent drying fluid from the vessel;

(b) an atomizer adapted to receive a spray-dryable material and discharge the atomized spray-dryable material into the interior volume of the vessel for said contacting;

(c) at least one turbulator adapted to generate turbulence in the drying fluid in the interior volume of the vessel;

(d) a process control unit adapted to regulate flow rate of drying fluid into the interior volume and flow rate of the spray-dryable material to the atomizer so that interaction of the drying fluid with the at least one turbulator produces turbulence in the drying fluid having a Kolmogorov length less than average particle size of spray-dryable material droplets in the atomized spray-dryable material in the interior volume of the vessel.

92. The spray drying system of claim 91, wherein said turbulence is induced in at least 5 volume % of the volume of drying fluid in the interior volume of the vessel.

93. The spray drying system of claim 91, wherein said turbulence is induced in at least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 volume % of the volume of drying fluid in the interior volume of the vessel.

94. The spray drying system of claim 93, wherein said volume % of the volume of drying fluid in the interior volume of the vessel in which said turbulence is induced includes drying fluid in contact with the atomizer.

95. The spray drying system of claim 91, wherein the at least one turbulator includes one or more nozzles configured to inject pressurized secondary drying fluid into the interior volume of the vessel.

96. The spray drying system of claim 95, wherein the at least one turbulator includes an array of nozzles configured to inject pressurized secondary drying fluid into the interior volume of the vessel.

97. The spray drying system of claim 91, wherein the at least one turbulator comprises at least one selected from among twisted tapes, static mixer devices, airfoils, Brock turbulators, wire turbulators, coil turbulators, and wall protrusion turbulators.

98. The spray drying system of claim 91, wherein the atomizer comprises at least one selected from among nozzle atomizers, applied charge atomizers, nebulizers, rotary atomizers, and ultrasonic atomizers.

99. The spray drying system of claim 91, comprising a drying fluid source coupled to the at least one drying fluid inlet in drying fluid supply relationship with the spray drying vessel.

100. The spray drying system of claim 99, wherein the drying fluid source is constituted to supply the drying fluid to the at least one drying fluid inlet of the spray drying vessel, the drying fluid comprising air, oxygen-enriched air, oxygen, nitrogen, argon, krypton, neon, helium, or a gas mixture comprising two or more of the foregoing drying fluid species.

101. The spray drying system of claim 99, wherein the drying fluid source is constituted to supply the drying fluid to the at least one drying fluid inlet of the spray drying vessel at temperature below at least one of 120°C, 115°C, 110°C, 100°C, 95°C, 90°C, 85°C, 80°C, 75°C, 70°C, 65°C, 60°C, 55°C, 50°C, 45°C, 40°C, 35°C, 30°C, 25 °C, and 20°C, and above freezing temperature of liquid to be volatilized for spray drying of the spray-dryable material.

102. The spray drying system of claim 99, wherein the drying fluid source is constituted to supply the drying fluid to the at least one drying fluid inlet of the spray drying vessel at temperature below 100°C, and above freezing temperature of liquid to be volatilized for spray drying of the spray-dryable material.

103. The spray drying system of claim 91, comprising a spray-dryable material source arranged in spray-dryable material supply relationship to the atomizer.

104. The spray drying system of claim 103, wherein the spray-dryable material source comprises the spray-dryable material in a carrier-free composition.

105. The spray drying system of claim 103, wherein the spray-dryable material source comprises the spray-dryable material in a carrier-comprising composition.

106. The spray drying system of claim 91, wherein the process control unit is adapted to regulate flow rate of drying fluid into the interior volume and flow rate of the spray-dryable material to the atomizer so that the average particle size of the spray-dryable material droplets in the atomized spray-dryable material in the interior volume of the vessel is in a range of from 50 to 300 μιη.

107. The spray drying system of claim 91, wherein the process control unit is adapted to regulate flow rate of drying fluid into the interior volume and flow rate of the spray-dryable material to the atomizer so that turbulence dissipation rate of said turbulence exceeds 25 m2/sec3.

108. The spray drying system of claim 91, wherein the process control unit is adapted to produce intermittent turbulence in the drying fluid.

109. The spray drying system of claim 91 , wherein the process control unit is adapted to produce continuous turbulence in the drying fluid.

110. The spray drying system of claim 91, as configured for electrostatic spray-drying.

111. A process for producing a spray-dried material, comprising:

generating an atomized spray-dryable material;

contacting the atomized spray-dryable material with drying fluid to form spray-dried material;

recovering the spray-dried material from the drying fluid; and

during said contacting, inducing turbulence in the drying fluid having a Kolmogorov length less than average particle size of spray-dryable material droplets in the atomized spray-dryable material.

1 12. The process of claim 1 1 1, wherein said turbulence is induced in at least 5 volume % of the volume of drying fluid engaged in the contacting.

1 13. The process of claim 1 1 1, wherein said turbulence is induced in at least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 volume % of the volume of drying fluid engaged in the contacting.

1 14. The process of claim 1 1 1, wherein the turbulence is induced by injection of pressurized secondary drying fluid.

1 15. The process of claim 1 1 1, wherein the turbulence is induced by interaction of the drying fluid with a turbulator comprising at least one selected from among twisted tapes, static mixer devices, airfoils, Brock turbulators, wire turbulators, coil turbulators, and wall protrusion turbulators.

1 16. The process of claim 1 1 1, wherein the atomized spray-dryable material is generated by an atomizer comprising at least one selected from among nozzle atomizers, applied charge atomizers, nebulizers, rotary atomizers, and ultrasonic atomizers.

1 17. The process of claim 1 1 1, wherein the drying fluid comprises air, oxygen-enriched air, oxygen, nitrogen, argon, krypton, neon, helium, or a gas mixture comprising two or more of the foregoing drying fluid species.

118. The process of claim 111, wherein the drying fluid is introduced to the contacting at temperature below at least one of 120°C, 115°C, 110°C, 100°C, 95°C, 90°C, 85°C, 80°C, 75°C, 70°C, 65°C, 60°C, 55°C, 50°C, 45°C, 40°C, 35°C, 30°C, 25°C, and 20°C, and above freezing temperature of liquid to be volatilized to form the spray-dryable material.

119. The process of claim 111, wherein the average particle size of the spray-dryable material droplets in the atomized spray-dryable material in the contacting is in a range of from 50 to 300 μιη.

120. The process of claim 111, wherein turbulence dissipation rate of the turbulence induced during said contacting exceeds 25 m2/sec3.