Research Work - Group N°04
Research Work - Group N°04
RESEARCH WORK
Docente:
2024-II
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INDEX:
ABSTRACT............................................................................................................................. 3
1. INTRODUCTION..................................................................................................................4
2. OBJECTIVES...................................................................................................................... 5
3. BODY................................................................................................................................... 5
4. CONCLUSIONS.................................................................................................................15
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ABSTRACT
The objective was to describe the conditions required to apply freeze-drying to obtain natural
colorants in Lima, Peru. The freeze-drying process, also known as lyophilization, removes
water from a frozen product through sublimation, a direct phase change from solid to gas.
This method preserves the physical, chemical, and organoleptic properties of the products,
making it ideal for food, pharmaceuticals, and natural colorants. In the food industry, for
example, it is used to preserve dairy products, coffee, and heat-sensitive foods, maintaining
their nutrients and flavors. It is also crucial in obtaining natural colorants from plants, such as
anthocyanins, which are used in food and cosmetics due to their health benefits.
In Lima, Peru, areas with drier climates, such as Chosica, Chaclacayo, and Cieneguilla,
would be most suitable for establishing a freeze-drying plant, as their lower relative humidity
facilitates the process. However, the high investment and operational costs remain a barrier to
widespread implementation, despite its effectiveness in preserving sensitive products. In
conclusion, freeze-drying is a viable technology primarily for specialized sectors, such as the
pharmaceutical industry and certain premium food segments, where the benefits justify the
costs. However, for most companies, financial and market barriers make it difficult to adopt
this technology, limiting its use to situations where its added value is essential.
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1. INTRODUCTION
For a long time, artificial dyes have been the main option in the food industry to provide
different colors and flavors. However, they can cause various problems due to their artificial
composition, like allergies, a decrease in intestinal microbiota and some toxicity risks. These
are just some of the consequences of frequently consuming foods with artificial coloring.
(Centro Universitario del Sur, 2023).
Although each food has regulations on how much dyes are allowed to be used, if several
foods that contain these dyes are consumed, a greater problem is generated. In contrast,
natural dyes, obtained from sources such as fruits, vegetables, flowers and spices, are safer to
consume and generally do not posses the same risks.
In addition, natural dyes are usually more environmentally friendly, since their production
involves fewer synthetic chemicals and is less harmful to ecosystems. In turn, encouraging
the use of natural dyes also promotes sustainable agricultural practices and reduces
dependence on petrochemical products.
Natural dyes, being beneficial to health, would help mitigate a growing threat in Peru,
malnutrition. During the period 2009 to 2022 Chronic malnutrition in children under five
years of age had a reduction of 10.1%, with the proportion of chronic malnutrition for in 2022
of 15.3%. In 2023, chronic malnutrition reached 15.9% and for the first half of 2024 it is
16.2%.(Centro Nacional de Alimentación y Nutrición, 2024), this indicates that since the
beginning of 2023, chronic malnutrition has been increasing.
For this year, chronic malnutrition would have affected 12.2% of children under five years of
age in the first quarter of 2024. This result would represent an increase of 0.7 percentage
points compared to the previous year (Comex, 2024). The use of natural coloring plays a
positive role in malnutrition as nutritional strengthening, allows the access to micronutrients
and greater diversification of diets, with more access to foods of plant origin
On the other hand, obtaining these natural dyes have some difficulties despite its benefits in
terms of health and sustainability. The cost difference is the biggest obstacle currently,
processes to extract natural dyes are more expensive compared to artificial ones, also natural
dyes are less stable than artificial dyes due to being more susceptible to oxidation,
degradation by light and temperature variation, which implies a variation in color.
Some natural dyes come from specific sources that are not always available in all regions or
may be seasonal. This can lead to supply difficulties and increase dependence on certain
crops or geographic regions. Because synthetic dyes are much cheaper and easier to mass
produce, industries often prefer to continue using these products.
First, highlight the growing demand for natural colorants as consumers increasingly prioritize
health benefits and eco-friendly products. The demand for natural colorants has risen as
consumers seek health benefits and eco-friendly options. Natural pigments like anthocyanins,
carotenoids, and betalains provide vibrant color and antioxidant properties, unlike synthetic
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dyes, which can be harmful despite their stability and lower cost. However, these natural
pigments are often unstable, sensitive to light, oxygen, and temperature, which can cause
color fading and reduce their beneficial properties during extraction and storage (Lauria &
Silva, 2024; Toneva et al., 2024).
Sustainable pigment extraction is challenging due to the high energy and solvent use in
traditional methods. Green extraction techniques, such as using supercritical fluids or water,
offer more eco-friendly alternatives, while lyophilization helps preserve pigment quality
through freeze-drying. However, precise control is needed to prevent degradation during
these processes (Baggi et al., 2024; Toneva & Grozeva, 2024).
The extraction of natural colorants, especially using eco-friendly methods like green solvents,
faces several challenges. Green solvents such as supercritical CO₂ (scCO₂) and subcritical
water are favored for their low toxicity and renewable sources. However, maintaining
consistent extract quality is difficult since natural pigments like chlorophyll and carotenoids
are sensitive to heat and oxidation, leading to instability during extraction and storage
(Ngamwonglumlert et al., 2018; Otles & Cagindi, 2008).
Despite the difficulties, the growing demand for healthier and more sustainable products is
driving research and development of more efficient and accessible natural alternatives.
However, challenges in terms of cost, stability and availability remain important barriers to
overcome to make natural dyes more competitive against synthetic ones.
2. OBJECTIVES
2.1. General objective:
● Analyze freeze drying in the industrial field and which industries use this
method.
located.
3. BODY
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Freeze- dry process
The freeze dry process involves the removal of water or other solvents from a frozen product
by a process called sublimation (LABCONCO Corporation, n.d). Sublimation consists in
changing the state of aggregation of some component directly from solid into steam.
This process is widely used because drying at ambient temperatures can change some
properties of some products or even the nature of it, decomposing it in chemical levels. Using
freeze drying, these inconveniences are avoided and a more stable product is obtained. This
also helps with the appearance of the final product; one of the main interests in obtaining
colorants.
It requires a change not only in temperature but also in pressure of the system. This has a lot
to do with phase diagrams of the compounds that are part of the product. Changes in
aggregation state can happen depending on the pressure and temperature. In freeze-dry the
most important change involves a descent on normal pressure going below the triple point of
a substance. In this region, the only change that exists is sublimation.
As we can see in the figure 1, sublimation goes from the region where the substance is in
solid state (point S) and goes directly to gas (point G) without touching the region of liquid
and it is also below the triple point.
In order to achieve this change, three stages are required in freeze-dry: Prefreezing, primary
drying and secondary drying.
Prefreezing
How a material is freezed depends on its composition. The most common case is a material
that contains a solvent like water with dissolved substances. When the aqueous suspension is
cooled, solutes concentration changes in the areas that are not yet freezed; lowering its fusion
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point. Only when all the solute in the suspension is frozen, the product is frozen; and this
happens when the eutectic point is reached.
The rate of cooling also influences the success of freeze-dry, because rapid cooling forms
smaller ice crystals while slower cooling leads to larger crystals which have more alternatives
for easier water vapor escape during drying.
Primary Drying
This stage involves the sublimation of ice to create a structurally stable result. A vacuum
pump lowers environmental pressure around the sample and a cold trap collects water vapor
from the product by condensing it.
Secondary Drying.
The moisture that is left from primary drying is removed by raising the temperature of the
sample in a range that is compatible with the sensitivity of the product. This happens while
the pressure and the cold trap temperature remain stable.
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Freeze drying in other industries
The freeze-drying process preserves the properties of many products and stabilizes them in
the long term, making it especially useful in several industries:
Freeze-dried dairy products are more nutritious than the ones obtained with other dehydration
methods. Especially suitable for the production of baby milk powder. Freeze-dried dairy
products are light, easy to transport and have no critical requirements for the storage
environment. Examples: milk, yogurt, ice cream, cake and other dairy products.
The most important industry where freeze-dry is applied is the coffee industry. Freeze dried
process allows the preservation of the flavors and aromas of the coffee without them being
lost during processing, as is largely the case with spray-dried coffee or regular instant coffee.
In general, it is a better quality product and also more durable than regular instant coffee, as it
can be stored for longer periods without losing its properties.
Dairy industry
Natural dyes are gaining popularity in the food industry and are in demand by consumers,
since it is well known that if administered properly these natural dyes can promote good
health (Murcia, 2015).
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Dairy foods are the food segment with the greatest number of innovations in products and
processes which focus mainly on sensory aspects and in recent years on developing
functional foods. For this reason, yogurt is an attractive food for both consumers and the
industry to innovate in their formulations for natural products (Baqueiro y Guerero, 2017;
Pavón et al., 2011).
For this reason, the use of the plant called “Justicia spicigera” has been proposed as a natural
colorant, in this case for the production of yogurt. Through studies and experiments, a purple
yogurt was obtained, with a predominant herbal smell and flavor thanks to the extract, in
addition, it managed to preserve the active components and nutrients (Chan et al., 2014).
Natural dyes
Natural colorants consist of pigments extracted from a natural source such as vegetables,
fruits, minerals and plants, among others. When added to a food or drink they give it a natural
color. In nature there are hundreds of resources that allow us to obtain natural dyes, while
providing functional health benefits (The Food Tech, 2021). Among the most famous are:
● Spirulina: A blue-green algae, also rich in proteins, widely used in the sports drink
segment.
● Turmeric: It is a great ally for yellow tones, it is famous for its anti-inflammatory
properties.
● Paprika: Not only does it provide its red color, but also antioxidants.
Another known natural dye is the carotenoids, they are found in a wide variety of fruits,
vegetables and plants. They are responsible for the yellow, orange and red tones we see in
many foods and other natural products. In addition to being colorants, carotenoids have
antioxidant properties and health benefits, making them even more valuable in the food and
cosmetics industry.
Anthocyanins belong to the class of natural pigments responsible for the red, purple and blue
colors in many fruits, vegetables and flowers. They are one of the most important groups of
natural dyes and are commonly found in foods such as grapes, blueberries, strawberries,
cherries, blackberries, eggplants, red cabbage, and many flowers. Carotenoids and
anthocyanins are important in the obtention of natural dyes.
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2. Nestlé: Global Reformulation and Sustainability
Nestlé has been another company that has adopted a comprehensive strategy to eliminate
artificial colors and other questioned additives in food. For several years now, Nestlé has
been committed to reducing the use of artificial colors and flavors in its products, as part of
its strategy to improve health and sustainability.
"Our goal is to make our products not only healthier for consumers, but also more sustainable
for the planet. The use of natural ingredients such as natural colorants is a key part of our
strategy." (Nestlé, 2020).
Although some dyes may lose intensity during the process, freeze-drying is the most effective
method for obtaining natural dyes, with a yield of 84.67%. Moreover, the samples obtained
preserve organoleptic, bromatological and nutritional properties of the plant used (Alarcón &
Quinzo, 2018).
The yield of natural dyes in freeze-drying depends largely on the type of pigment and process
factors like:
With proper control of process conditions and the use of protective technologies, such as
encapsulation and antioxidants, it is possible to maximize the yield of natural dyes and
maintain their quality in the long term.
To successfully freeze-dry a sample, your equipment will need to meet certain requirements.
First, the collector of your freeze dryer will need to be 15 to 20 degrees colder than the
freezing point of your sample to trap the water vapor that is being released. You will also
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need a vacuum pump that can reach a minimum of 0.020 mBar. This deep vacuum establishes
a negative pressure, forcing free-flowing water molecules that have left the sample through
sublimation to evacuate the environment around the sample and travel to the collection coil.
You will also need to have a drying accessory, such as: a collector, chamber or tray dryer, and
glassware or trays to hold your sample. Although not required, an endpoint detection system
makes the freeze-drying method (which sometimes takes several days) easier to manage by
keeping you informed of when the sample has finished drying.
Freeze drying machines
1. Freezing machine: Freezes below its melting point
2. Freeze drying chamber: It is responsible for removing the solvent from the product
through a sublimation process.
3. Vacuum system: Evacuates the molecules that are released during sublimation
4. Heating system to the product: Releases the molecules that were not sublimated.
The main equipment in a freeze-drying process is the industrial freeze-dryer. This equipment
is composed of a vacuum chamber, heating shelves, an ice condenser, and a control system,
allowing the sublimation of water in the product at low temperatures and vacuum conditions.
Freeze dryer capacity varies depending on production requirements, with models ranging
from 50 kg to over 500 kg per cycle. The cost of this equipment ranges between $100,000
and $1,000,000 USD, depending on its size and technology.
In addition to the freeze dryer, a vacuum generator and pumping system are needed to
maintain the necessary vacuum during the process. For these functions, high-performance
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pumps are used, designed for industrial vacuum conditions, such as rotary, piston, or dry
positive displacement pumps. The cost of this equipment is approximately $20,000 to
$50,000 USD.
Another critical component is the refrigeration and condensation system, which allows the
temperature of the freeze dryer chamber to be lowered and the extracted water vapor to be
condensed. These systems typically employ refrigerant gasses such as ammonia and require
capacities of several hundred kW for industrial applications. Its cost can vary between
$30,000 and $150,000 USD.
The operation and monitoring of the freeze-drying process are carried out through controllers
and monitoring systems that allow vacuum, temperature, and sublimation to be managed in
real time. These systems also offer remote monitoring and data collection options, often
through the manufacturer's own software. The estimated cost of these systems is $10,000 to
$30,000 USD.
For material handling and internal transportation, a system is required that facilitates the
loading and unloading of the product in the freeze dryer. This system can include loading
carts, mobile shelves, and forklifts, costing approximately $5,000 to $20,000 USD.
The installation and maintenance of this equipment represent significant additional costs. The
initial installation and calibration of the equipment range between $10,000 and $50,000 USD,
while the annual maintenance required to ensure its operability and efficiency is estimated to
be between $5,000 and $15,000 USD.
The budget for industrial freeze-drying equipment varies depending on the scale of
production and the technical specifications required. For a small-scale plant, with a capacity
of 50 to 100 kg per cycle, the estimated cost is $200,000 to $400,000 USD. For a
medium-scale plant, with a capacity of 100 to 300 kg per cycle, the budget can range between
$400,000 and $700,000 USD. Finally, for a large-scale plant, with a capacity greater than 300
kg per cycle, the estimated cost is between $700,000 and $1,200,000 USD or more. These
values are approximate and may vary depending on the manufacturer, market conditions, and
specific process requirements, so it is recommended to obtain detailed quotes from several
suppliers .
The lack of private industry investment in industrial freeze-drying systems can be attributed
to a number of economic, technical and market barriers that affect the attractiveness of this
technology. First of all, one of the most significant factors is the high initial investment cost.
Freeze drying on an industrial scale involves considerable investment in specialized
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equipment, such as industrial freeze dryers, vacuum, refrigeration and control systems. This
equipment can cost up to $1,200,000 USD or more for large-scale plants, which represents a
significant barrier to entry for many companies (Fischer Scientific, 2022). This high initial
cost especially discourages small and medium-sized businesses, which are looking for more
affordable alternatives for dehydrating or preserving products.
In addition to the initial investment, the operating costs of freeze drying are also high. The
process requires a large amount of energy to maintain very low temperatures and vacuum
conditions, resulting in considerable energy consumption. This consumption translates into
high recurring costs, affecting the profitability of the process. In an environment where
energy costs are constantly rising, private companies may be hesitant to commit to
technologies that significantly increase their operating expenses.
The market for freeze-dried products also remains relatively limited. Although freeze-drying
is highly valued for sensitive products, such as gourmet foods, pharmaceuticals and
biological materials, many food or consumer products do not require this level of
preservation. This means that demand is restricted and, in many cases, does not guarantee a
sufficient return on investment. Thus, private companies may view freeze drying as a risky
investment due to dependence on a restricted and highly specialized market.
For the construction of a freeze-drying natural dye production plant in Lima, Peru, it would
be ideal to consider areas with lower humidity levels. Although Lima is known for its humid
climate, with relative humidity that can even reach 100% (SENAMHI, 2019). There are some
areas less exposed to humidity that could be more suitable.
Some of the places in Lima where it would be viable to carry out this project are Chosica and
Chaclacayo, located in the higher parts of Lima, these areas have a drier and sunnier climate
for much of the year due to their location in the Rimac River valley. Relative humidity is
usually lower than in coastal areas. Their average humidity is between 30% and 40%.
(Castro, 2023). Also, Cieneguilla is a good option, this district is known for its dry climate,
ideal for activities that require lower environmental humidity. Being a warmer area away
from the coast, it offers more stable and less humid climatic conditions, with an average
relative humidity that can be between 30% and 50%. (SENAMHI, 2015).
We know that the maximum recommended Relative Humidity is between 20% and 30%
maximum in processing areas (Marín y Mejía, 2012). To regulate the relative humidity of the
aforementioned districts, tools such as Industrial dehumidifiers can be used. These machines
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eliminate humidity from the air through refrigeration or absorption methods. They are often
placed in key areas where strict humidity control is needed. You can also opt for Desiccants,
these are dehumidification systems based on desiccants that absorb moisture from the air
using materials that retain water, such as silica gel or lithium chloride.
Strategic partnerships with food sector companies are crucial for market expansion. For
example, companies producing organic foods or promoting healthy menus may benefit from
incorporating freeze-dried natural colorants into their products. According to Centro
Universitario del Sur (2013), companies already promoting products without artificial
additives are in an excellent position to incorporate these colorants, allowing them to expand
their offerings and attract a broader, health-conscious audience.
Obtaining certifications for organic or sustainable products can provide significant added
value for freeze-dried natural colorants. Certifications like "fair trade" or "organic" are
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particularly attractive to environmentally conscious consumers. According to a report by The
Food Tech (2024), companies that obtain these certifications not only gain consumer trust but
also gain access to more demanding markets like Europe, where consumers are more willing
to pay a premium for sustainable products.
One example of success in the use of natural colorants is Naturex, a French multinational that
has led the natural colorants market, standing out for its ingredients sourced from fruits,
vegetables, and spices. The company has grown significantly by incorporating sustainable
and healthy practices into its production process. This type of success story is crucial for
inspiring Peruvian companies to invest in freeze-dried natural colorants, as it demonstrates
the global demand and viability of such products (Naturex, 2024).
4. CONCLUSIONS
Freeze drying is an invaluable process for preserving products in industries where stability,
sensory quality and shelf life are important. By improving the preservation of the natural dyes
properties, it improves efficiency in storage and transportation, and helps maintain the quality
and safety of pharmaceutical, food and consumer products such as coffee.
The lack of investment by private industry in industrial freeze-drying systems is mainly due
to a combination of high investment and operation costs, the long duration of the process, a
limited demand market, the existence of cheaper alternatives, the complexity and cost
maintenance and risks associated with return on investment. These factors make
freeze-drying a viable technology primarily for specialized sectors, such as the
pharmaceutical industry and some premium food segments, where the benefits justify the
costs. However, for most companies, financial and market barriers make it difficult to adopt
this technology, limiting its use to situations where its added value is essential.
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Referencias bibliográficas
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● The Food Tech. (2021). Natural dyes: innovation for new product categories.
Obtained from:
https://thefoodtech.com/ingredientes-y-aditivos-alimentarios/colorantes-naturales-inn
ovacion-para-nuevas-categorias-de-productos/
● Toneva, M., Grozeva, N., & Memdueva, N. (2024). "Green Solvents for Extraction of
Natural Food Colorants from Plants: Selectivity and Stability Issues." Foods, 13(4),
605. https://doi.org/10.3390/foods13040605MDPI
● Aplicaciones de liofilización. (2022, septiembre 20). Vikumer Liofilizador.
https://vikumer.com/es/aplicaciones-de-liofilizacion/
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