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Cakingphenomenain
Caking of free-flowing powders during storage is a deleterious
phenomenon that is ubiquitous in the feed, fertilizer and
pharmaceutical industries, and of economical importance for amorphousfood powders
low-moisture foods. Among other subjects related to caking
of amorphous powders, the following aspects are reviewed
in this article: (1) physical and morphological changes, and Jos~M. Aguilera,Jos~M. dd Valle
quantitative procedures to assesscaking; (2) proposed mech-
anisms of caking phenomena; (3) examples of caking in food
and MarcusKa~l
materials; (4) the relationships between storage-induced cak-
ing and other phenomena and the glass transition of amorph-
ous powders; (5) methods for estimating the evolution of between particles, without a measurable decrease in sys-
caking with time from the physical prol~rties of powder tem porosity. At the onset of caking, small i n t e ~ l ¢
bridges may even disintegrate under mild shaking.
samples and environmental conditions; and (6) measures to
Agglomeration, a later stage, involves an irreversible
minimize the occurrence of caking phenomena. consolidation of bridges but the high porosity of the
particulale system is maintained, resulting in particle
clumps with structural integrity. The mechanisms of
interparticle bonding have been reviewed by Rutlandz
Caking is a deleterious phenemenon by which a low- and SchuberP. Compaction, an even more advanced
moisture, free-flowing powder is first transformed into stage in caking, is associated with a pronounced loss of
lumps, then into an agglomerated solid and ultimately system integrity as a result of thickening of interparticle
into a sticky material, resulting in loss of functionality bridges owing to flow, reduction of intetpanicle spaces,
and lowered quality. The problem is ubiquitous in the and deformation of panicle clumps under prcsstu-¢. In
food, feed, fertilizer, pharmaceutical and related indus- the final stage of caking, i n g l e bridges disappear
tries 1-3. This review deals, in the main, with an import- as a result of sample liquefaction and extensive flow
ant form of caking in foods, namely that of amorphous owing to the high moisture conteut. This stage usually
powders by viscous flow. Caking may also occur as a involves the solubilization of low molecular weight
result of recrystallization, either after fat melting or after fractions and the presence of hygroscopic behavior 6.
solubilization at crystal surfaces; surface wetting fol- Although most publications state only whether caking
lowed by moisture equilibration or cooling; or electro- is observed and under what conditions, quantitative
static attraction between particles4.
A s ~ c t definition of caking is difficult to formulate,
because changes in a particulate system depend on P(t)/Po Do,~/Dp~,kr, Morphology
temperature, moisture and position within the powder,
and involve many different stages, including bridging, 1 0
agglomeration, compaction and fiquefaction (Fig. 1). At
any given stage, lumps may be few or numerous, of dif-
ferent sizes and of varying degrees of hardness.
In practice, a quantitative measure of caking is highly
desirable for following changes in the condition of a Bridgin 8
powder over time. The 'caking index' (a termed coined
by the authors) is defined as the state of the system at
any time relative to an initial state. Two morphological
indicators of the state of the system are: the ratio of in- Agglomeration <1 >0
stant system porosity to initial system porosity, p(t)lpo;
and the ratio of interparticle bridge diameter to particle
diameter, D~dg,IDp=~(see Fig. 1).
Because of the diversity and inconsistency of the Compact on -->0 --)1
terms used to describe caking, some definitions are pro-
posed based on their most common use in the literature.
Bridging, the initial stage in caking, occurs as a result of
surface deformation and sticking at contact points Liquefaction o t ~
JO~ M. Aguilera(correspondingauthor)and le~ M. dd Valle are at the
Departmentof Chemicaland BioprocessEngineering,PontificiaUniversidad
Cat61icade Chile, PO Box 306, Santiago22, Chile (fax: +562-552-4054; Stagesduring ~ typical caking process,indicating the changesin
e-maih jmaguile@ing.puc.cl).Marcus Karel is at the Departmentof Food systemporosity.[p(t)/poland the ratio of interparticlebridge diameterto
Science,RutgersUniversity,New Brunswick,N] 08903,USA. particle diameter [/:~,~/D,~I at each stage.
L%
tremely hygroscopic, to exhibit a
bridge diameter to particle diameter, high tendency to caking at ambient
determined using microscopical techniques conditions of 25°C and 60% RH,
and to cake even at low water ac-
r~.z tivities's. The solids in dehydrated
Quantitativemethodsutilizedto characterizecakins phenomena. fruit juices comprise mostly fructose
°t
0.2
/ A 10":
A m
3T ~I0"
o.t2
~o 0.08 10-
0 -
," . . . . .
- lo- , = , k i | t t i
0 10 20 30 40 50 60 70 0.00 0.04 0.08 0.12 0.16 0.20 0.24 2o 4o 6o 8o too
Equilibrium RH (%) w (g watedg dry matter) &T = r - r, (°cI
FgS
Data requiredto predictthe advanceof cakingin fishproteinhydrolyzatepowdersamples.(a),~ f i o n is~3~%~m:(~),ext~memai data from
Aguilerael'al.tT; (--), modelusingHenderson'sequation~3(/~qn3). (b), Phasediagramplot:(n),experimentaldata fromAguihraet al?7; (--), model
usingthe Gordno-Taylorequation28(Eqn4). (c),Williams-Landel-Fea'y(WLF)plotof relaxationtimesfor caking:(n),exl~meatal data fromAguiletaand
del Valle~; ( - - ) , universal WLF plot for viscosity of polymers (Eqn 2); (--), model using a WLF-lype relationship3owith adjustableC~and Czcooffa:ients
(Eqn 5). Condition ~)indicates the stability of powder samplesagainstcaking; condition ( ~ signalsthe onset of caking phenomena(just perceptible in a
few days);and condition ~ indicates that powder samplescake fast enough to allow the easy identifa-.ationof the defect. Seetext for further details.
In the fish hydrolyzate example, caking started to be observed extensively. Similar .microstmctural obser-
apparent as samples reached average moisture contents vations were made for spray-dried powders of whole
of 0.04-0.08 g water/g dry matter, corresponding to a milk supplemented with lactoses .
delay factor of - 6 h. This reveals nothing about the Microstructoral changes in lyophilized samples of fish
actual moisture content on the surface of the particles. myofibrillar protein hydrolyzate were also observed
Hence, factors that should be controlled when establish- using SEM ~. Samples equilibrated for three weeks to
ing actual caking kinetics include water vapor transmis- _<44% RH retained their original highly porous structure
sion rate and uniform exposure of particles to the vapor with fine walls. At 56% RH, pore walls were observed
phase. to thicken, whereas at 67% RH they had fused into thick
and continuous masses, reducing considerably the po-
Microslmctural aspects of caking rosity of the system. The sample equilibrated to 75%
Morphological changes in a powder undergoing cak- RH presented evidence of crystaUine-Ilke structures.
ing can be best visualized using microscopical tech- Image processing by digitization can be used to cor-
niques~*. Thus, it is surprising that microscopical analy- rect defects in the original microstractural image (e.g.
sis has not been used to any great extent to characterize non-informational noise), enhance or suppress data,
caking, but it is likely that quantitative information select important features, extract numerical data (e.g.
related to caking phenomena and the determination of particle area or characteristic size) and perform statisti-
a caking index (see Fig. 1) will be easily derived by cal analysis. Figure 6 depicts three images from the
microscopy and the aid of computational image analysis SEM micrograph of milk powder in an agglomerated
in the future. state that can be used to characterize stages in caking
Amorphous components in spray-dried powders are in and caking kine:ics by the analysis of geometrical
the met~table amorphous state and exposure to high features.
relative humidity results in an irreversible transition to
the crystalline state. Amorphous lactose crystallizes and Prevention of caking
releases water during equilibration at 42-52% RI-I (at As should be evident at this point, the strict control of
25°C). Scanning electron microscopy (SEM) was used moisture content and storage at low temperatures, when
to follow caking of skim milk powder stored at 20°C possible, are key factors in. miinimi;zing the effects of
during equilibration at 43-94% RH (Ref. 35). After two caking of powders. However, in many instances, anti-
weeks, changes had occurred only for powder equilib- caking agents are added to hygroscopic food powders to
rated at >54% RH, whereas at ~74% RH lactose crys- improve their flowabifity and/or to inhibit caking; they
tallization as well as bridging between particles were achieve this by one of several mechanisms.
Conclusions
Caking of amorphous powders is a continuous and
complex, time-dependent phenomenon in food powders
and related biomaterials. Surface flow and stickiness,
needed for interparticle bridging and adhesion, occur
when the Ts of the amorphous powder is below the
ambient temperature, 7". As resistance to flow is in-
versely proportional to AT= T - T v caking rates can be
modeled as a function of AT using a WLF-type relation-
ship. Moisture is a critical parameter in caking of ~ -
ous foods through its 'del~essing' effect on Ts, and it is
usually conh-olled by the use of proper packaging and/or
anficaking agents. The modification of Ts as a mechan-
ism for reducing the caking rate needs to be studied.
Microstracture and image analysis may become import-
ant tools in the characterization and quantification of the
caking phenomenon.
fig.6 Admow~
Image processing of a scanning electron micrograph (SEM) The authors appreciate the comments of Dr Micha
of agglomerated spray-dried milk. (a), original SEM image; Peleg, who reviewed the manuscript. The present
(b), digitized gray-scale image with contour of particles; work was partially funded by the National Fund of
Science and Technology of Chile, projects FONDECYT
(c), image with selected objects for measurement and data analysis.
193-0620 and 194-0648. This is a contribution of
Scale bars = 200pro. the CYTED-RIPFADI Ibero American Network on
Physical Properties of Foods.
• By competing with the host powder for available
moistureI. Several of these agents are of a porous References
1 Pele~M. andHollenbach, A.M.(1984)FoodTechnol. 38(3),93-102
nature and exert their protective action in foods by
2 Ru~land,D.W.(1991)Fert. Res.30,99-114
preferentially adsorbing large amounts of water vapor 3 Provent,B.,Chulia, D. andCary, J.(1993)Eur.l. Pharm. Biopharm.
onto specific surface sites with high binding energy. 39, 202-207
Because further increases in moisture cause large 4 Pele~M.(1983)inPhysicalPrupettiesofFoods(Pelc~,M. and
increases in the equilibrium RH, the optimum per- Rasley, E., eds), pp. 293-323, AVI
formance of these agents is observed with short S Schubert,H. (1981) Int. Chem. Eng.21,363--377
exposures to moist atmospheres. 6 Dziedzic, S.L and Kearsley,M.W. (1984) in GlucoseSyrups:Science
Review
Rapid water determination
Water is present in practically all foodstuffs. The water con-
tent is of great significance in determining the physical charac-
teristics, technological processes, microbiological stability,
in foodstuffs
shelf life and sensory properties of foods, as well as having
legal and economic ramifications. Determination of the water
content is one of the most frequent analyses performed on
H-D. Isengard
foodstuffs. To avoid the manufacture of products with an
undesired, unadvantageous or non-permitted water content water, in a product; the difference in mass after drying
and keep the amount of out-of-specification products to a should not, strictly speaking, be referred to as 'water
minimum, water determination methods should not only content' but rather 'mass loss on drying'. Experimental
determinations of mass loss on drying vary according to
yield correct results but also deliver them very quickly, poss-
the conditions employed and do not provide information
ibly even continuously and within the requirements of quality- about an absolute property of the product, but rather
management systems. about its behaviour under certain drying conditions,
which should, consequently, be mentioned as parameters.
This mass loss is sometimes called "moisture', but this
term is problematic too, as it is commonly used to mean
To avoid misunderstanding, it must be clearly stated at water, possibly including other liquids. However, some
the outset that the water content of a product is not necess- of the mass loss may result from in~n~ie gaseous and
arily equivalent to the original mass minus the mass after volatile solid compounds; on the other hand, liquids with
a drying process. Cases where this is true are extremely very high boiling points may escape such detection.
rare, because methods based on measuring the mass of a A further complication is posed by the existence of
product before and after a drying process cannot distin- "free" water molecules and different forms of "bound
guish between water and other volatile substances, water' that are hound more or less strongly to other food
which may even include those produced by and during components, often evading determination.
the process itself. The term 'water content' should be
reserved to refer to all of the water, and nothing but the Primary and secondary methods
Primary methods arc those methods that directly
H-D. Isenganlis at UniversitatHohenheim,Institutfor Lebensmitteltechnologie, measure the true water content. From a scientific point
Garbenslr.25, D-70599Stullgart,Germany(fax:+4%711-397-3935). of view, only primary methods should serve as reference