Spray dried tetrahydrocannabinol and cannabidiol powders

Abstract

Methods to produce a spray dried cannabidiol, tetrahydrocannabinolic acid, or active tetrahydrocannabinol powder are described and include spray drying a liquid mixture followed by a two-step separation process including cyclones, filters, or an electrostatic precipitator, the liquid mixture includes treated water, and alcohol or an oil, and the powder has a particle size ranging from between 5 nanometers to 750 microns. The liquid mixture may be spray dried into a powder using a rotary atomizer, a spray nozzle, or a plurality of spray nozzles within a counter-current spray dryer or a co-current spray dryer and then sifted.

What is claimed is: 
     
         1 . A method to produce a cannabidiol, tetrahydrocannabinolic acid, and/or active tetrahydrocannabinol powder, the method includes:
 (a) spray drying a liquid mixture to produce a powder, gas, and vapor mixture;   (b) after step (a), separating at least a portion of the powder from the powder, gas, and vapor mixture to produce a first powder depleted gas and vapor mixture, the first powder depleted gas and vapor mixture has a reduced amount of powder relative to the powder, gas, and vapor mixture; and   (c) after step (b), separating additional powder from the first powder depleted gas and vapor mixture to produce a second powder depleted gas and vapor mixture, the second powder depleted gas and vapor mixture has a reduced amount of powder relative to the first powder depleted gas and vapor mixture; and   wherein:   in step (a), the liquid mixture includes water and one or more selected from the group consisting of cannabidiol, tetrahydrocannabinolic acid, active tetrahydrocannabinol, and combinations thereof;   in step (b) and in step (c), the powder and the additional powder include one or more selected from the group consisting of cannabidiol, tetrahydrocannabinolic acid, active tetrahydrocannabinol, and combinations thereof.   
     
     
         2 . The method according to  claim 1 , comprising:
 in step (b), separating at least a portion of the powder from the powder, gas, and vapor mixture with a first separator; and   in step (c), separating the additional powder from the first powder depleted gas and vapor mixture with a second separator;   wherein:   the second separator includes a different type of separator relative to the first separator.   
     
     
         3 . The method according to  claim 1 , comprising:
 in step (b), separating at least a portion of the powder from the powder, gas, and vapor mixture with a first cyclone; and   in step (c), separating the additional powder from the first powder depleted gas and vapor mixture with a second cyclone, a filter, or an electrostatic precipitator.   
     
     
         4 . The method according to  claim 1 , wherein:
 in step (a), the water includes treated water, wherein the treated water includes one or more selected from the group consisting of activated carbon treated water, adsorbent treated water, membrane treated water, ultraviolet unit treated water, and combinations thereof.   
     
     
         5 . The method according to  claim 1 , wherein:
 in step (a), the liquid mixture includes an alcohol and/or an oil.   
     
     
         6 . The method according to  claim 1 , wherein:
 in step (b) and/or in step (c), the powder and/or the additional powder includes a particle size ranging from between 5 nanometers to 750 microns.   
     
     
         7 . The method according to  claim 1 , wherein:
 in step (a), the gas includes nitrogen, air, and/or carbon dioxide.   
     
     
         8 . The method according to  claim 1 , wherein:
 prior to step (a), heating the gas; and   in step (a), introducing the gas and the liquid mixture to an interior of a spray dryer, and spray drying the liquid mixture to produce the powder, gas, and vapor mixture.   
     
     
         9 . The method according to  claim 1 , comprising:
 providing a water removal system configured to remove water from the gas prior to step (a), the water removal system includes one or more systems selected from the group consisting of a dehumidifier, 3 Angstrom molecular sieve, 3 Angstrom zeolite, 4 Angstrom molecular sieve, 4 Angstrom zeolite, activated alumina, activated carbon, adsorbent, alumina, carbon, catalyst, clay, desiccant, molecular sieve, polymer, resin, silica gel, an air conditioner, a cooling tower, a plurality of adsorbers, a cooling tower followed by an adsorber, a cooling tower followed by a plurality of adsorbers, a moving bed of adsorbent, and combinations thereof;   prior to step (a), removing the water from the gas with the water removal unit; and   in step (a), introducing the gas and the liquid mixture to an interior of a spray dryer, and spray drying the liquid mixture to produce the powder, gas, and vapor mixture.   
     
     
         10 . The method according to  claim 1 , comprising:
 providing a fan configured to introduce the gas to the spray dryer and prior to step (a);   prior to step (a), introducing the gas to the spray dryer via the fan; and   in step (a), introducing the gas and the liquid mixture to an interior of a spray dryer, and spray drying the liquid mixture to produce the powder, gas, and vapor mixture.   
     
     
         11 . The method according to  claim 1 , comprising:
 in step (a), spray drying the liquid mixture within a spray dryer by introducing the liquid mixture into the spray dryer through a rotary atomizer, a spray nozzle, or a plurality of spray nozzles.   
     
     
         12 . The method according to  claim 1 , comprising:
 (d) after step (c), the powder and/or the additional powder are combined and then sifted with a sifter; wherein the sifter includes a one or more sifters selected from the group consisting of a vibratory screener, a centrifugal sifter, a circular vibratory fluid bed processor, and combinations thereof.   
     
     
         13 . The method according to  claim 1 , comprising:
 in step (a), spray drying the liquid mixture in a counter-current spray dryer or a co-current spray dryer.   
     
     
         14 . The method according to  claim 1 , comprising:
 (d) after step (c), introducing the second powder depleted gas and vapor mixture to a condenser and/or a vacuum system.   
     
     
         15 . The method according to  claim 1 , comprising:
 (d) after step (c), mixing the powder and/or the additional powder with pectin.   
     
     
         16 . The method according to  claim 1 , comprising:
 (d) after step (c), producing a multifunctional composition including the powder and/or the additional powder and two or more materials selected from the group consisting of a fiber-starch material, a binding agent, a density improving textural supplement, a moisture improving textural supplement, insects,  cannabis , combinations thereof; wherein:   (i) the fiber-starch material includes one or more selected from the group consisting of a cereal-grain-based material, a grass-based material, a nut-based material, a powdered fruit material, a root-based material, a tuber-based material, a vegetable-based material, and combinations thereof;   (ii) the binding agent includes one or more selected from the group consisting of agar, agave, alginin, arrowroot, carrageenan, collagen, cornstarch, egg whites, finely ground seeds, furcellaran, gelatin, guar gum, honey, katakuri starch, locust bean gum, pectin, potato starch, proteins, psyllium husks, sago, a sugar, a syrup, tapioca, vegetable gums, xanthan gum, and combinations thereof;   (iii) the density improving textural supplement includes one or more selected from the group consisting of extracted arrowroot starch, extracted corn starch, extracted lentil starch, extracted potato starch, extracted tapioca starch, and combinations thereof;   (iv) the moisture improving textural supplement includes one or more selected from the group consisting of almonds, brazil nuts, cacao, cashews, chestnuts, coconut, filberts, hazelnuts, Indian nuts, macadamia nuts, nut butters, nut oils, nut powders, peanuts, pecans, pili nuts, pine nuts, pinon nuts, pistachios, soy nuts, sunflower seeds, tiger nuts, walnuts, and combinations thereof; and   (v) the insects include one or more selected from the group consisting of Orthoptera order of insects, grasshoppers, crickets, cave crickets, Jerusalem crickets, katydids, weta, lubber, acrida, locusts, cicadas, ants, mealworms, agave worms, bees, centipedes, cockroaches, dragonflies, beetles, scorpions, tarantulas, termites, insect lipids, insect oil, and combinations thereof and combinations thereof.   
     
     
         17 . The method according to  claim 16 , wherein:
 in step (d), the multifunctional composition includes one more selected from the group consisting of:   a fiber-starch mass ratio ranging from between 100 pounds of the fiber-starch per ton of the multifunctional composition to 1800 pounds of the fiber-starch per ton of the multifunctional composition;   a binding agent mass ratio ranging from between 10 pounds of the binding agent per ton of the multifunctional composition to 750 pounds of the binding agent per ton of the multifunctional composition;   a density improving textural supplement mass ratio ranges from between 10 pounds of the density improving textural supplement per ton of the multifunctional composition to 1000 pounds of the density improving textural supplement per ton of the multifunctional composition;   a moisture improving textural supplement mass ratio ranges from between 10 pounds of the moisture improving textural supplement per ton of the multifunctional composition to 1000 pounds of the moisture improving textural supplement per ton of the multifunctional composition;   an insect mass ratio ranges from between 25 pounds of the insects per ton of the multifunctional composition to 1500 pounds of the insects per ton of the multifunctional composition; and   a  cannabis  ratio ranges from between 25 pounds of the  cannabis  per ton of the multifunctional composition to 1800 pounds of the  cannabis  per ton of the multifunctional composition; and   combinations therof.   
     
     
         18 . The method according to  claim 16 , comprising:
 (e) after step (d), producing a foodstuff from the multifunctional composition, the foodstuff includes one or more foodstuff selected from the group consisting of ada, bagels, baked goods, biscuits, bitterballen, bonda, breads, cakes, candies, cereals, chips, chocolate bars, chocolate, coffee, cokodok, confectionery, cookies, cooking batter, corn starch mixtures, crackers, crêpes, croissants, croquettes, croutons, dolma, dough, doughnuts, energy bars, flapjacks, french fries, frozen custard, frozen desserts, frying cakes, fudge, gelatin mixes, granola bars, gulha, hardtack, ice cream, khandvi, khanom buang, krumpets, meze, mixed flours, muffins, multi-grain snacks, nachos, nian gao, noodles, nougat, onion rings, pakora, pancakes, panforte, pastas, pastries, pie crust, pita chips, pizza, poffertj es, pretzels, protein powder, pudding, rice krispie treats, sesame sticks, smoothies, snacks, specialty milk, tele-bhaja, tempura, toffee, tortillas, totopo, turkish delights, and waffles.   
     
     
         19 . A method to produce a foodstuff comprising cannabidiol, tetrahydrocannabinolic acid, and/or active tetrahydrocannabinol, the method includes:
 (a) spray drying a liquid mixture to produce a powder, gas, and vapor mixture, the liquid mixture includes water and one or more selected from the group consisting of cannabidiol, tetrahydrocannabinolic acid, active tetrahydrocannabinol, and combinations thereof;   (b) after step (a), separating at least a portion of the powder from the powder, gas, and vapor mixture to produce a powder depleted gas and vapor mixture, the powder depleted gas and vapor mixture has a reduced amount of powder relative to the powder, gas, and vapor mixture, the powder includes one or more selected from the group consisting of cannabidiol, tetrahydrocannabinolic acid, active tetrahydrocannabinol, and combinations thereof; and   (c) after step (b), producing the foodstuff including the powder and one or more material selected from the group consisting of a fiber-starch material, a binding agent, a density improving textural supplement, a moisture improving textural supplement, insects, and combinations thereof;   
       wherein:
 (i) the fiber-starch material includes one or more selected from the group consisting of a cereal-grain-based material, a grass-based material, a nut-based material, a powdered fruit material, a root-based material, a tuber-based material, a vegetable-based material, and combinations thereof; 
 (ii) the binding agent includes one or more selected from the group consisting of agar, agave, alginin, arrowroot, carrageenan, collagen, cornstarch, egg whites, finely ground seeds, furcellaran, gelatin, guar gum, honey, katakuri starch, locust bean gum, pectin, potato starch, proteins, psyllium husks, sago, a sugar, a syrup, tapioca, vegetable gums, xanthan gum, and combinations thereof; 
 (iii) the density improving textural supplement includes one or more selected from the group consisting of extracted arrowroot starch, extracted corn starch, extracted lentil starch, extracted potato starch, extracted tapioca starch, and combinations thereof; 
 (iv) the moisture improving textural supplement includes one or more selected from the group consisting of almonds, brazil nuts, cacao, cashews, chestnuts, coconut, filberts, hazelnuts, Indian nuts, macadamia nuts, nut butters, nut oils, nut powders, peanuts, pecans, pili nuts, pine nuts, pinon nuts, pistachios, soy nuts, sunflower seeds, tiger nuts, walnuts, and combinations thereof; 
 (v) the insects include one or more selected from the group consisting of Orthoptera order of insects, grasshoppers, crickets, cave crickets, Jerusalem crickets, katydids, weta, lubber, acrida, locusts, cicadas, ants, mealworms, agave worms, worms, bees, centipedes, cockroaches, dragonflies, beetles, scorpions, tarantulas, termites, insect lipids, insect oil, and combinations thereof, and combinations thereof; and 
 (vi) the foodstuff includes one or more foodstuff selected from the group consisting of ada, bagels, baked goods, biscuits, bitterballen, bonda, breads, cakes, candies, cereals, chips, chocolate bars, chocolate, coffee, cokodok, confectionery, cookies, cooking batter, corn starch mixtures, crackers, crêpes, croissants, croquettes, croutons, dolma, dough, doughnuts, energy bars, flapjacks, french fries, frozen custard, frozen desserts, frying cakes, fudge, gelatin mixes, granola bars, gulha, hardtack, ice cream, khandvi, khanom buang, krumpets, meze, mixed flours, muffins, multi-grain snacks, nachos, nian gao, noodles, nougat, onion rings, pakora, pancakes, panforte, pastas, pastries, pie crust, pita chips, pizza, poffertj es, pretzels, protein powders, pudding, rice krispie treats, sesame sticks, smoothies, snacks, specialty milk, tele-bhaja, tempura, toffee, tortillas, totopo, turkish delights, and waffles. 
 
     
     
         20 . A method to produce a multifunctional composition including cannabidiol, tetrahydrocannabinolic acid, and/or active tetrahydrocannabinol, the method includes:
 (a) spray drying a liquid mixture to produce a powder, gas, and vapor mixture, the liquid mixture includes water and one or more selected from the group consisting of cannabidiol, tetrahydrocannabinolic acid, active tetrahydrocannabinol, and combinations thereof;   (b) after step (a), separating at least a portion of the powder from the powder, gas, and vapor mixture to produce a powder depleted gas and vapor mixture, the powder depleted gas and vapor mixture has a reduced amount of powder relative to the powder, gas, and vapor mixture, the powder includes one or more selected from the group consisting of cannabidiol, tetrahydrocannabinolic acid, active tetrahydrocannabinol, and combinations thereof; and   (c) after step (b), producing the multifunctional composition by mixing the powder with one or more material selected from the group consisting of a fiber-starch material, a binding agent, a density improving textural supplement, a moisture improving textural supplement, insects, and combinations thereof;   
       wherein:
 (i) the fiber-starch material includes one or more selected from the group consisting of a cereal-grain-based material, a grass-based material, a nut-based material, a powdered fruit material, a root-based material, a tuber-based material, a vegetable-based material, and combinations thereof; 
 (ii) the binding agent includes one or more selected from the group consisting of agar, agave, alginin, arrowroot, carrageenan, collagen, cornstarch, egg whites, finely ground seeds, furcellaran, gelatin, guar gum, honey, katakuri starch, locust bean gum, pectin, potato starch, proteins, psyllium husks, sago, a sugar, a syrup, tapioca, vegetable gums, xanthan gum, and combinations thereof; 
 (iii) the density improving textural supplement includes one or more selected from the group consisting of extracted arrowroot starch, extracted corn starch, extracted lentil starch, extracted potato starch, extracted tapioca starch, and combinations thereof; 
 (iv) the moisture improving textural supplement includes one or more selected from the group consisting of almonds, brazil nuts, cacao, cashews, chestnuts, coconut, filberts, hazelnuts, Indian nuts, macadamia nuts, nut butters, nut oils, nut powders, peanuts, pecans, pili nuts, pine nuts, pinon nuts, pistachios, soy nuts, sunflower seeds, tiger nuts, walnuts, and combinations thereof; 
 (v) the insects include one or more selected from the group consisting of Orthoptera order of insects, grasshoppers, crickets, cave crickets, Jerusalem crickets, katydids, weta, lubber, acrida, locusts, cicadas, ants, mealworms, agave worms, worms, bees, centipedes, cockroaches, dragonflies, beetles, scorpions, tarantulas, termites, insect lipids, insect oil, and combinations thereof, and combinations thereof.