YC-500 Benchtop Spray Dryer

Benchtop Spray Dryer: The Complete Buying Guide

Sometimes there are few samples in the laboratory, some are expensive, or some are difficult to obtain in the laboratory. However, the spray dryer machine commonly used in the laboratory requires a lot of samples for each experiment. It is troublesome to prepare samples every time, and the expensive samples cannot be used for spray drying experiments.

Pilotech YC-500 benchtop spray dryer offers a good solution to solve this problem.

Compare to a centrifugal spray dryer and pressure spray dryer, Pilotech YC-500 benchtop spray dryer is small in size and works very quietly on the test bench.

Spray dryers commonly used in many laboratories usually require 1000ML of samples for each experiment, and the recovery rate is very low. Pilotech benchtop spray dryer can complete an experiment with at least 20ML of samples, hence suitable for relatively small samples.

Pilotech YC-500 benchtop spray dryer, not only requires less material for a single experiment, but also very low in power (only 1.5KW) consumption, environmentally friendly and energy saving.

Drying chamber and cyclone separator of Pilotech benchtop spray dryer are made of SUS304 stainless steel, which is durable. The drying chamber is equipped with observation holes, you can easily observe the experimental process, and students can study the spray dryer working principle too.

If you need to test sugar-containing samples, YC-500 benchtop spray dryer would also be very suitable for you. The performance of the Pilotech benchtop spray dryer is especially improved. Samples can also be well dried at the lowest air inlet temperature of 130 °C. The air inlet temperature is suitable for spray drying sugar-containing materials, preventing possible material sticking on the wall.

If you need to test organic solvents in the future, you would upgrade to an organic solvent spray dryer by purchasing our inert loop system, which is very convenient.

If you need to test enzymic preparations, probiotics or other heat-sensitive materials, no problem, you would upgrade to a vacuum low-temperature spray dryer by purchasing our vacuum module.

By the way, if your materials are not resistant to high temperature, you can consider using our low temperature spray dryer or vacuum spray dehydrator which has lower inlet and outlet temperatures. If your materials contain organic solvents, you can consider using our inert loop  spray dryer, if you need to process more materials, you can consider using our pilot- spray dryer.

In order to send you best benchtop spray dryer, we will carry out strict testing procedures on each dryer before shipment. The tests include testing the drier without any materials, testing the drier with materials, temperature control accuracy test, and recovery rate test, etc. This is to ensure that each equipment will meet our strict requirements and the reliability of each equipment you bought from us.

We provide you YC-500 benchtop spray dryer English operation handbook and installation & operation video.

If you are looking for the right l benchtop spray dryer and best price for your applications and needs! Get a quote now, we will reply you within 8 hours.

Benchtop Spray Dryer: The Ultimate FAQ Guide

This guide will answer all questions you have been asking about the benchtop spray dryer.

Whether you want to learn about the atomization process, parts, working principle, types of nozzles or features – you will find everything here.

So, keep reading to learn more.

What is a Benchtop Spray Dryer?

A benchtop spray dryer is equipment that produces dry powder from a liquid.

It quickly uses hot gas to dry it.

The mist is sprayed into a chamber that has hot air.

After being sprayed into the hot air chamber, it falls to the bottom in the form of dry powder.

Spray drying process

 Benchtop spray dryer

What are the Components of a Benchtop Spray Dryer?

A benchtop spray drier has several components that all work in the spray drying process.

Some of the components in the benchtop spray dryer are:

 Schematic of spray drying machine

Atomizer or Spray Nozzles

The atomizer does the work of turning the liquid in the chamber into small droplets of liquid.

LED Screen

You will control and monitor the working of the benchtop spray dryer through the LED screen.

The screen displays the necessary parameters like air inlet, temperature, airspeed, air volume, and needle frequency.

A Reliable Sealing

The sealing is vital for the spray drying process.

It forms an airtight seal, meaning you have a suitable environment for the whole spray drying process.

The Power Switches

With the power switches, you can quickly turn on and off the benchtop spray dryer.

Drying Chamber

The drying chamber is made of borosilicate glass.

Borosilicate glass is a high-quality glass that is easy to clean.

Since the glass is transparent, you can easily monitor the whole spray drying process.

Collecting Tube

The collecting tube directs the final product to the collecting chamber or bottles.

Collecting Bottles

The collecting bottles are where the final product is collected and stored.

Peristaltic Pump

The peristaltic pump is used to pump the fluids that are then to be dried.

Air Dispenser

It directs air into the benchtop dryer system.

Air Heater

You can easily control it as a suitable temperature depending on the material you’re drying.

It is the hot air that helps in the drying process.

How does a Benchtop Spray Dryer Work?

A benchtop spray dryer works by drying fine mist into powder.

The following are steps on how a benchtop spray dryer works.

The Wet Process

Before you start the process of spray drying, the material you want to dry should be in liquid form.

Here, you will condition the material that is to be spray dried.

The purpose is to make the spray drying a success and also to optimize the yield.

The wet process involves the following steps:

i. Formulation

The formulation is also referred to as dissolution.

You’ll do this for raw materials that are not in liquid form.

The raw materials are dissolved to make it in liquid form.

After this, the dissolved material is ready for the next stage.

ii. Evaporation

Evaporation can also be referred to as concentration.

In this stage, you are increasing the total solid.

This will result in a better yield for the spray dryer.

iii. Heating

You will then heat the liquid.

Heating will counteract the increase of viscosity that is formed in the concentration stage.

iv. Pumping

After all the above steps, the liquid is then pumped at high pressure.

The pumping directs the liquid to the spray dryer.

Atomization

The liquid to be dried is atomized into tiny droplets.

By atomizing, you ensure that you have a fast-drying process of the liquid.

The humidity in the particles will dry at a rapid rate.

The atomizer is the nozzle or nozzles that will help in atomization.

There are different types of nozzles in the market that you can choose.

Also, the kind of nozzle you choose has to match the material and the flow rate of the liquid.

You will get the best outcome by using the right nozzle.

The types of nozzles available are pressure nozzle, two-fluid nozzle, and pressure nozzle.

Contact of Material to be Dried and Hot Air

The process of drying takes place as hot air gets into contact with the sprayed droplets.

The dry air takes up moisture.

You are to heat the air in the spray drying chamber before the sprayed droplets enter this chamber.

The dry air has low humidity at the inlet.

On the other hand, it has high humidity and low temperature at the outlet.

The hot, dry air can be pumped in two ways:

· Co-currently to the Product

Blowing hot air co-currently to the product means you are blowing it from the top of the tower.

· Counter-current to the Product

Blowing hot air as a counter-current, you are blowing it from the bottom of the tower.

Many applications prefer the counter-current process.

In contrast, co-current spray drying has an exciting appeal.

The exciting part is that the hot, dry air gets into contact with the first particles with the most significant humidity.

This means the particles are protected against overheating.

Drying

The drying process occurs in the spray drying chamber once the particles are inside it.

Moisture is removed sequentially with the help of the heat transfer between the air and the particles.

The drying process is done in three ways:

Constant Drying Rate

Here, the particles are saturated with liquid.

If the surface of the particle is large, the mass transfer happens quickly.

Falling Rate

The drying depends on the capability of the liquid held in the solid particles to diffuse and evaporate.

This process is controlled by diffusion.

Bubble Formation

During the falling rate, the temperature of the particles will increase.

If the temperature gets higher than the boiling point of the liquid in the particle, it may vaporize.

This, in turn, will create a bubble.

Solids Separation

You are then to collect the particles once they are thoroughly dried.

The separation is mostly done in cyclones.

Besides, the cyclone could be equipped with filters to increase their efficiency.

Furthermore, the powder is separated from the air once it is in the cyclone.

That is, once it is collected at the bottom of the benchtop spray drier.

What are the Types of Spray Nozzles a Benchtop Spray dryer uses?

A spray nozzle is equipment that is used to break apart liquid into a spray pattern.

A benchtop spray drier can use various types of nozzles.

Some of the nozzles that a benchtop spray drier can use include:

 Spray dryer nozzle

Flat Fan Nozzle

To produce a line of spray, use a flat fan nozzle.

Flat fan nozzles come in two designs: standard shape and deflection orifice.

Misting Nozzle

To form a mist or fog that is finely atomized with no movement, use misting nozzles.

A homogenous fog is mainly directed by the surrounding airflow and not the nozzle.

The types of missing nozzles are small and impingement orifice.

Hollow Cone Nozzle

A hollow cone nozzle produces a solid circle of spray.

A spray pattern has the smallest drop sizes of all the spray patterns.

Some of the designs of the hollow cone nozzle include tangential whirls, spirals, and axial whirls.

Solid Stream Nozzle

The aim function of a solid stream nozzle is to deliver as much impact as possible.

Solid stream nozzles concentrate fluid into a dot of spray with a high impact.

The two designs for a solid stream nozzle include an enhanced laminar flow and a standard shaped orifice.

Full Cone Nozzle

Full cone nozzle will produce a solid circle of spray.

You can use this nozzle when you want to distribute the fluid over an area evenly.

The designs of a full cone nozzle are tangential whirls, spirals, and axial whirls.

Eductor Nozzle

You will use an educator nozzle to mix and agitate fluids.

Spillback Nozzle

You will use a spillback nozzle for a high turndown rate while maintaining the size and other spray qualities alike.

Can you use Benchtop Spray Dryer to Combine Ingredients?

Yes, you can combine ingredients on specific benchtop spray dryer designs.

When you combine these small particles, you will get a product that dissolves easily.

Generally, combining ingredients improve the quality of the final product.

The materials are chemically and nutritionally equal.

In addition to this, the combination of ingredients makes it have a larger surface area per volume.

With this in mind, it will tend to dissolve.

What is Atomization in a Benchtop Spray Dryer?

Atomization is an essential part of the benchtop spray dryer process.

In the atomization process, the liquid is fed and converted to small droplets using the nozzle or rotary atomizer.

The desired qualities of the final product, such as viscosity and particle size, are developed during this process.

The small droplets have a larger surface area.

Meaning the rate of evaporation of water is increased.

The droplets, through evaporation in the dryer chamber, become individual powder particles in the drying stage.

Spray dryer structure

What Principles does a Benchtop Spray Dryer Use?

The main principle of a benchtop spray dryer relies on removing water.

The quality of the final product depends a lot on how the water is removed.

Your starting point should be to determine moisture content in the product.

Then, the size and type of particles you need.

Remember, this will influence the type of atomizer you will use.

Another factor is the kind of dryer.

You need a large surface area for drying if you are using a tall form benchtop spray dryer.

The surface area affects how you will attain the specifications of the product.

Once you consider all these, there is a possibility that you will get the best products.

How does Benchtop Spray Dryer compare to Mini Spray Dryer?

A benchtop spray dryer is small in size and quiet.

Also, as the name suggests, a benchtop spray dryer is used on a tests bench.

Moreover, a benchtop spray dryer can use 20ml of sample to complete a test.

A mini spray dryer usually requires 1000ml of the sample in every experiment.

A mini spray dryer uses more power than a benchtop spray dryer.

With a low power consumption, a benchtop spray dryer saves energy.

A benchtop spray dryer mostly costs less than a mini spray dryer.

In short, these two types of spray drying machine are similar except for the size and uses.

What is the Importance of a Spray Analysis in a Benchtop Spray Dryer?

You are required to have specific know-how and skills when conducting a spray analysis in a benchtop spray dryer.

You can also hire a spray analysis services if you do not have such knowledge.

Having a benchtop spray dryer that is in good condition will give you a better output and reduce risks.

It is important to note that you should attain the right air to fluid balance.

Failure to achieve this balance, you will get a final product that is not consistent.

The inconsistency may be in the form of particle sizes, ingredient mixture, or moisture content.

You will see visible bands if you are using metallic material or a solid color.

In addition to this, over atomization results in a poor finish.

Knowing the spray pattern is crucial for you to get the correct output.

A common issue is incorrect to paint to air balancing.

This results in a substandard fan shape and material discharge.

Spray analysis in a benchtop spray dryer helps you realize if there is an issue that is happening while spraying.

Furthermore, spray analysis assists you to examine other things that may affect the quality of the final output.

What are the Features of Benchtop Spray Dryer?

Some of the features that a benchtop spray dryer has included:

Benchtop spray dryer

• It is easy to assemble, disassemble, and clean.
• It has a borosilicate glass meaning you can easily monitor the spray drying process.
• It can complete a test with a small sample size of 20 to 30ml of the liquid.
• The air compressor does not use oil and does not contaminate the compressed air.
• It produces sound below 50 decibels.
• Borosilicate glass will resist strong acid, alkali and high temperatures.
• It has a PID that controls the inlet and outlet temperature.
• It has a touchscreen that you can use to control the benchtop spray dryer easily.
• A benchtop spray dryer has an automatic clogging gear that prevents the nozzle from clogging.
• It also has a rotary pump to the feed which adjusts the capacity easily.
• The benchtop spray dryer is self-sufficient requiring no support equipment.

What Determines the Benchtop Spray Dryer Machine Price?

The price of a benchtop spray dryer varies a lot depending on the manufacturer.

Large scale benchtop spray dryers cost more than small scale benchtop spray dryers.

The material used to manufacture a benchtop spray dryer also affects its price.

Besides, the capacity of a benchtop spray dryer also affects its price.

Benchtop spray dryers with a high production capacity cost more than those with a small production capacity.

The price of a benchtop spray dryer can go anywhere between 2500 US Dollars to 30000 US Dollars.

What are the Applications of a Benchtop Spray Dryer?

A benchtop spray dryer is applicable in laboratories, universities, research institutes, chemical enterprises, and more.

A benchtop spray dryer can be applied in the following fields:

• In the food industries to produce:

1. Tea
2. Eggs
3. Cereals
4. Spices
5. Vitamins
6. Colorings
7. Milk powder
8. Stevia
9. Flavorings
10. Blood
11. Starch and its derivatives
12. Enzymes
13. Animal feed

• In pharmaceuticals to produce:

1. Medical ingredients
2. Additives
3. Antibiotics

• In industries to produce

1. Ceramic materials
2. Microalgae
3. Paint pigments
4. Catalyst supports

How can a Benchtop Spray Dryer be used in the Encapsulation Technique in the Food Industry?

The encapsulation technique is used to make dehydrated powders.

These substances have no water to dehydrate.

The material to be encapsulated is homogenized in the form of a suspension in water.

This is known as a slurry.

The slurry is then delivered to a spray drier.

The spray drier is a tower that is heated to temperatures higher than the boiling point of water.

The slurry is then atomized as it arrives in the tower.

Due to the large surface area of the droplets, when atomized, it forms micelles.

The particles also dry quickly due to their large surface area.

What are the Technical Specifications of a Benchtop Spray Dryer?

Some of the technical specifications of a benchtop spray dryer include:

• An outlet temperature of 30 ℃ -140 ℃
• An inlet temperature of 30 ℃ -300 ℃
• An evaporating capacity of between 500ml/h to 2000ml/h
• An average drying time of 1.0~1.5s
• The power consumption is 220-230v and 50-60hz
• Acid-resistant stainless steel and borosilicate glass
• The blower power is 0.1kw/220v
• A standard 0.7mm two-fluid nozzle spray system
• An airflow rate of between 70m3/h to 330m3/h, and pressure of 686pa
• A temperature precision of ± 1° C
• An automatic or manual operation mode
• It has an LCD
• The blower will not stop until the temperature is <90° C since it has thermal protection.

What Quality Standards should a Benchtop Spray Dryer conform to?

A benchtop spray dryer has to adhere to the quality standards set by international bodies.

The quality standards will ensure that the benchtop spray dryer meets all required specifications and is safe for the spray drying process.

Make sure that you purchase a benchtop spray dryer that meets all the required quality standards.

Here are some of the quality standards that a benchtop spray dryer has to conform to:

CE Quality Standard

This mark is widely adopted even though it applies to the European Economic Areas.

Current Good Manufacturing Practice [cGMP] Quality Standard

With this standard, a benchtop spray dryer has its design and working conditions approved.

Food and Drug Administration [FDA] Quality Standard

This quality standard ensures that all benchtop spray dryer products are fit even for human consumption.

Restriction of Hazardous Substances [RoHS] Quality Standard

This quality standard ensures that your benchtop spray dryer will not produce specific hazardous gases.

The safety of plants, animals, and the environment is covered in this quality standard.

What are the Advantages of a Benchtop Spray Dryer?

A benchtop spray dryer has many advantages.

Some of the advantages of a benchtop spray dryer include:

• If pumpable, the feedstock that is in solution, emulsion, paste, melt or slurry form can be dried.
• You can control and maintain the quality and property of the product through the whole drying process.
• You can dry thermolabile and pharmaceutical products at low temperatures and atmospheric pressure.
• You can efficiently operate a benchtop spray dryer via the programmable logic controller [PLC].
• A benchtop spray dryer has minimized corrosion due to the materials used to make it.
• A benchtop spray dryer handles extensive production rates.
• A benchtop spray dryer produces dry powder in various shapes, sizes, moisture content, and shape.

Are there Limitations of Benchtop Spray Dryer?

A benchtop spray dryer also has its limitations.

Some of them include:

• After use, a benchtop spray dryer is challenging to clean.
• You cannot dry solid materials.
• A benchtop spray dryer is heavy and costly to put up.
• A lot of heat is wasted as it has low thermal efficiency.
• A fire can start, or the product can deteriorate when it is deposited in the drying chamber.

What Determines the Nature of the Final Product of a Benchtop Spray Dryer?

The nature of the product achieved by a benchtop spray dryer depends on:

• The operation of the benchtop spray dryer
• The design of the benchtop spray dryer
• The physiochemical qualities of the feed

What are the Pharmaceutical uses of a Benchtop Spray Dryer?

Some of the pharmaceutical used of a benchtop spray dryer includes to:

• Improve drug compressibility
• Minimize capping bias in crystals
• Produce dry powder formulas
• Produce excipients
• Dry pharmaceuticals such as vaccines and penicillin
• Produce microcapsules
• Improve the solubility rate of drugs that are not that soluble

What are the Stages that occur in a Benchtop Spray Dryer?

Three stages occur in a benchtop spray dryer.

These stages are:

• Atomization
• Mixture and evaporation of the spray-air
• The separation of dry product

Is there a difference between Benchtop Spray Dryer and Nano Spray Dryer?

Yes, there is a difference between a benchtop spray dryer and a nanospray dryer.

A benchtop spray dryer produces particles that are relatively large than that of a nanospray dryer.

A nanospray dryer produces small particles whose size is in nanometers.

How does benchtop Spray Drying compare to Freeze Drying?

 Benchtop spray dryers

A benchtop spray drying used hot air in the drying process.

On the other hand, freeze-drying involves using a low-temperature drying process.

Freeze drying is also referred to as lyophilization or cryodesiccation.

In freeze-drying, you are freezing the product, decreasing the temperature, and then removing ice through sublimation.

In freeze-drying, the temperature is usually below 0°C during primary drying and 20-30°C in secondary drying.

The temperature in the benchtop spray drying process is usually above 80°C.

 Freeze dryer

Apart from Spray Drying, Which Other Drying Technique can you use?

There are other drying techniques you can use.

Some of the drying techniques you can use include:

Drum Dryer

This is not a costly drying process.

It is used to process low-value products.

It creates flakes and not free-flowing powder.

Freeze Dryer

This is a costly drying process.

It is used for products that will deteriorate in spray drying.

Pulse Combustion Dryer

This is a less expensive drying process.

You can handle high viscosity products with a pulse combustion dryer.

Sometimes, it gives a freeze-dried powder which is free-flowing.

What Determines the Inlet and Outlet Temperature of Spray Dryer?

The quality of the final product will determine the inlet and outlet temperature of a spray dryer.

For instance, a lower outlet air temperature will lead to higher powder moisture content.

How can you Increase Efficiency of Bench Spray Dryer Machine?

You can increase the efficiency of a benchtop spray dryer machine by conducting regular inspections.

Also, you should repair or replace faulty or broken parts.

You should use genuine parts when replacing worn-out parts.

With this in mind, your benchtop spray dryer will work efficiently and last for long.

What are the Safety Features of Benchtop Spray Dryer?

Some of the safety features of a benchtop spray dryer include:

• The benchtop spray dryer is enclosed to inhibit any leakages?
• Fully automated system integrated with alarms detects a possible failure that may cause damage.
• The benchtop spray dryer is made with robust and durable material to resist a given pressure, thus preventing an explosion.
• The benchtop spray drier injects an inert substance to suppress an explosion.

According to your specific needs, Pilotech offers a range of material processing equipment.

Whether you need spray dryer machines, freeze dryer, spray granulator, extruder spheronizer, and UHT sterilizer, amongst others.

Contact us today for all your material processing machine needs.