Formulation optimisation for pilot-scale honey powder production: A response surface methodology and central composite design approach

This research aimed to optimise a pilot-scale formulation for seamless scale-up, considering critical variables such as the honey-to-maltodextrin ratio, temperature, and drying time. Employing response surface methodology with a central composite design approach, the investigation systematically assessed the impact of four key factors within predetermined upper and lower limits: honey volume (90–900 g % dry basis), maltodextrin (60–600 g), drying temperature (60–70 °C), and drying time (180–300 min). Subsequently, these factors were randomised and optimised using the Design Expert software system. The analysis of variance revealed the significant impact of each drying factor, their interactions, and squared squares on the honey-to-maltodextrin ratio, as well as the effects of drying temperature and time. Validation results underscored the model reliability, exhibiting narrow standard deviations ranging from 0.001% to 1.3%. These outcomes emphasise the efficacy of Response Surface Methodology (RSM) and Central Composite Design (CCD) in refining formulations, offering valuable insights into appropriate product development and a seamless scale-up process.