Pilotech Lab Spray Dryer Manufacturer
- Efficient, LCD touch screen & PLC controlled lab spray drying of any application, especially for temperature sensitive products.
- Designed specifically for lab spray dryer and pre-production trials (pilot scale spray dryer).
- Aqueous only (YC-500/YC-015/YC-018/YC-2000/YC-2100), Aqueous and solvent (YC-501/YC-015A/YC-018A) based solutions.
- Pilotech lab spray dryer have 3,500 satisfied users in the world.
Pilotech Lab Spray Dryer
YC-500 has a bench design. The equipment can be installed on the laboratory furniture or can be put on ground, as needed. The power of YC-500 is only 1.5KW, it is only 80mm high, and the minimum material amount is 20ML, so it is very convenient for material preparation. YC-500 has a good expandability. You can add vacuum module and nitrogen circulation system module based on your needs in later stage, thus to adapt the spray drying of organic solvent and heat-sensitive materials.
Shanghai Pilotech Instrument Equipment Co., Ltd. began to produce YC-015 lab spray dryers in 2005. So far, more than 3,000 YC-015 lab spray dryers have been used in laboratories around the world. The equipment is durable. The YC-015 lab spray dryer produced in 2005,2006 can still operate very well. You can search for many papers about YC-015 lab spray dryer on Google Scholar.
YC-015A has nitrogen circulation system inside, its treatment capacity is 1500ML/H, and 30ML is enough for one experimental. It is a lab scale organic solvent spray dryer, and can be used for the drying of water solution and organic solvent. YC-015A has PLC control, touch-screen operation, English screen interaction. Clips are used to connect the cyclone separator in the drying chamber, so it is easy to assemble.
The lowest inlet air temperature of YC-2000 Vacuum Spray Dryer is 50°C. It can be used for drying materials that cannot be dried by traditional spray dryer, such as probiotic enzyme. Materials after drying can remain biological activity. It can also be used to dry heat-sensitive materials such as polymer materials.
Why Pilotech lab spray dryer?
- Pilotech have been manufacturing lab spray dryers for over 20 years.
- Pilotech lab Spray Dryer has more than 3,500 satisfied customers in more than 60 countries.
- From bench spray dryer to pilot scale spray dryer, from aqueous solutions to organic solvents, complete specifications.
- You can discover our lab spray dryer outstanding efficiency and flexibility.
Hello Cathy! I am doing well. Spring Festival is over in China now? Back to work…, we are learning more and more with our new spray dryer. We are getting a lot of use out of the spray dryer as we attempt to create a powder from our oil in water nanoemulsions, and it seems to be working quite well. By the way, we love this new baby spray dryer!!
Lab Spray Dryer :The Complete Buying Guide
Pilotech has 15 years of experience in spray drying technology. According to your different requirements (capacity, temperature, particle size), Pilotech has developed different types of lab spray dryer to achieve the goal of your experiments.
Pilotech lab spray dryer covers a widely range of applications for food, pharmaceutical, chemistry and other industries, and it can be used for drying of aqueous solution or organic solvent material. We have exported our lab spray dryer to over 60 countries, like US, Canada, UK, German, Italy, Russia etc.
Pilotech Lab spray dryer body material is 304 stainless steel (316 stainless steel is optional), atomizer is made of SUS 316 stainless steel.
LAB SPRAY DRYER NOZZLE WITH SUS316L STAINLESS STEEL
Each Pilotech lab spray dryer is equipped with the large touch screen of the world-famous brand Delta, easy to operate.
LAB SPRAY DRYER TOUCH SCREEN WITH DELTA
All Pilotech lab spray dryer produces low noise, create a comfortable laboratory environment.
Pilotech lab spray dryer’s max. capacity can be up to 4L/H, and a minimum of 30ml sample can be handled per batch, both the pilot test and lab test.
Detailed instruction manual will be provided, teach you how to operate the lab spray dryer step by step. Until now, all our foreign customers successfully installed and operated our lab spray dryer with a great reputation.
All means of transportation are acceptable, by sea, air or land.
Pilotech lab spray dryer warranty is one year, if any part is broken during the warranty period, Pilotech will delivery one new part for free(Except for the damage coursed by human factors). Meanwhile, if you have any questions during operation, feel free to contact us, our after-sales service team will contact and help you within one working day.
If you are looking for one set suitable lab spray dryer, we have YC-015, YC-018 and YC-500 general lab spray dryer for aqueous solution, YC-1800, YC-2000 and YC-3000 low temperature lab spray dryer for heat-sensitive material, YC-501, YC-015A and YC-018A for organic solvent materials.
Welcome your inquiries for Pilotech lab spray dryer, we will reply you in 12 hours.
- Types of lab spray dryer
Spray dryer can be divided into centrifugal spray dryer, pressure spray dryer and airflow spray dryer, which differ in their method of atomization. Centrifugal spray dryer is most common in laboratory at first, then pressure spray dryer become popular, but both show great limitations for laboratory use.
POWDER DRIED BY PILOTECH LAB SPRAY DRYER
1) Large size, most of them cover an area of about 3 square meters;
2) Noisy, most of them have a noise level of above 100DB, causing a significant impact on the working environment of the laboratory;
3) High power consumption, most of them have a capacity of over 13KW;
4) Large sample volume, at least 2L of sample is required for each test, material preparation is troublesome.
In recent years, airflow spray dryer have become more and more widely used in laboratory because of its small size, low noise, low power consumption, and ease of use.
- How a spray dryer works?
1) How centrifugal spray dryer works?
Liquid material is pushed by a peristaltic pump to a high-speed rotating atomizing disk, due to the centrifugal effect, a film of the liquid is formed and moves to the edge of the disk, where the liquid atomizes into small droplets and rapidly dries into powder in heated air flow in 3-5s.
2) How a pressure spray dryer works?
Liquid material is pushed into the spray dryer by a pressure up to 2-20MPa where it atomizes into small droplets. Such droplets have a big surface-to-volume ratio and can be dried in heated air flow in 10-30s. Most of the particles are collected through the discharge slot at the bottom of the tower, and the finer particles are separated from the exhaust air with a cyclone separator and collected with a collection bottle at the lower end of the cyclone separator as fine powder products.
LAB SPRAY DRYER AIR COMPRESSOR(SUS304 STAINLESS STEEL TANK)
3) How an airflow spray dryer works?
Liquid material is pushed by a peristaltic pump into a dual-flow atomizing nozzle, and is atomized under the action of compressed air. The atomized droplets are dried within 1-2 seconds in heated air flow. The powder particles are taken down and separated from the air flow by a cyclone separator and collected with a collection bottle, while the exhaust air is expelled or recycled.
- The advantages and disadvantages of lab spray dryer and vacuum freeze dryers
Both spray dryer and vacuum freeze dryers are widely used in laboratories, and both have their specific advantages – spray dryer are fast, use less power, and can adapt to a wide range of material concentration; while vacuum freeze dryers impart higher solubility to the products, and can meet the strict conditions required for some heat-sensitive materials.
- Applications of lab spray dryer
Lab spray dryer are widely used in food, pharmaceutical, energy, chemical, battery, mineral, life science, material science, clothing, paper, ceramic and other industries.
Food: Lab spray dryer are widely used in production of dairy products, food additives, flavors, spices, condiments, protein powder, instant tea powder, instant drink, lipid powder, fruit and vegetable powders and functional foods;
Pharmaceutical industry: spray drying can be widely used in the production of bulk drugs and traditional Chinese medicine, such as Amoxicillin, Ampicillin, Aspirin, Dihydrostreptomycin, Kanamycin, Ampicillin, Penicillin, Tetracycline, Streptomycin, Chloramphenicol Succinate, Sulfathiazole, Vitamin A, Vitamin E, Vitamin B12, aluminum hydroxide, aluminum sulfate, glycolipid, amylase, barium sulfate, calcium lactate, calcium pantothenate, hormones, L-lysine, niacin, protease, rutin derivative, liver essence, Chinese medicine extracts, etc.
Materials science: spray drying is also used in large scale for production of lithium batteries, nano materials, ultra-fine powders, lithium iron phosphate, graphene, modified starch, metals, polymer materials, composite materials, ceramics, building materials, electronic materials, etc.
- The history of Shanghai Pilotech Lab Spray Dryer
Shanghai Pilotech Co., Ltd. began producing lab spray dryer since 2005, and our products are now used by more than 3,000 universities, research institutes and R&D departments of enterprise around the world. Shanghai Pilotech regularly contacts users to understand their needs and pain points, and successively developed laboratory organic solvent spray dryer, negative-pressure low-temperature spray dryer, vacuum low-temperature spray dryer, integrated spray granulation and coating machine, vacuum freeze spray dryer. Our products have greatly simplified rapid drying of heat-sensitive materials such as enzyme preparations, sugar-containing materials, and heat-labile polymers in laboratories, and dry-granulating of ceramics and catalysts that require a particle size of about 80 microns. Shanghai Pilotech has developed concentric spray nozzle in 2016, solving the long-existing problem of eccentric spraying.
- Major components of Pilotech lab spray dryer
All major components of our lab spray dryer are from world-renowned brands. The touch screen and PLC module are from DELTA, Taiwan, the world’s largest manufacturer of touch screen and PLC, which has service outlets all over the world. If you encounter any problems in touch screen or PLC, in addition to contacting us, you can also directly contact DELTA’s local outlets.
The fan of our machine is from HENGFENG, Taiwan; the peristaltic pump is from RS or JIEHENG; and the compressor is from Panasonic.
LAB SPRAY DRYER DIGITAL PERISTALTIC PUMP
The spray nozzle is made of SUS316 stainless steel; the body of the machine is made of 1.5mm-thick SUS304 stainless steel. The YC-015 lab spray dryer has a build-in oil-free air compressor, whose compressed air tank is also made of SUS304 stainless steel to prevent corrosion of the tank due to long-term exposure to water vapor.
- Which lab spray dryer is best for you?
7.1 Materials with high sugar content, such as Chinese herbal medicine extract or fruit and vegetable powder;
For these materials, our low-temperature spray dryer, such as YC-1800 and YC-018, may be the choice.
Sugar may melt and become very viscous at high temperature, so material with high sugar content may stick to the wall of the drying room when heated. To solve this problem, our low-temperature spray dryer apply some level of vacuum to assist drying, so that the inlet air temperature can be reduced to 105°C. At this temperature, the sugar in the material will not melt and will not stick to the wall.
7.2 Heat-sensitive materials, such as enzyme preparations, probiotics, heat-labile polymers, etc.;
For these materials, our vacuum spray dryer may be the choice, which are available in three specifications: 500ML/H, 1500ML/H, 3000ML/H.
These materials may experience chemical or biological changes at high temperature, and our vacuum spray dryer can operate with an inlet air temperature of 50 ° C to prevent these changes.
7.3 Materials in organic solvent;
Due to the flammable and explosible nature of organic solvents, a nitrogen cycle system(inert loop system) and a solvent recovery system are required to avoid explosion during the drying process. Our closed-cycle spray dryer, equipped with inert gas circulation system, are well suited for such materials, and are available in 500ML/H, 1500ML/H, 3000ML/H and 5000ML/H capacities.
7.4 Materials that should form large particles after drying, such as catalysts, ceramics, etc.;
Catalysts and ceramics sometimes need to be larger particles with a size of 50-80 microns for better performance – many catalysts must be over 50 microns for better catalytic effect and ceramic tablets need particles with a size of 50-80 microns for better molding. However, the average particle size of spray-drying products are often 1-25 microns. Our YC-018 laboratory-scale and YC-019 pilot-scale spray dryer can produce 50-100-micron particles, which meet the requirements of ceramics and catalysts.
7.5 Materials that need granulation or coating after drying;
For some materials, the desired particle size can hardly be achieved simply by drying, so you need further granulation and coating processes. Our YC-1000 spray granulator achieves all three functions seamlessly.
- Customers of Shanghai Pilotech
Our laboratory scale spray dryer, has more than 2000 customers in China, including Tsinghua University, Peking University, Chinese Academy of Sciences, University of Science and Technology of China, Zhejiang University, Nanjing University, Wuhan University, Tianjin University, Sun Yat-sen University, Nankai University, China Agricultural University, Chinese Academy of Agricultural Sciences, Chinese Academy of Fishery Sciences, Jiangnan University, Fudan University, Shanghai Jiaotong University, Xi’an Jiaotong University, Shandong University, and Hunan University. Our products are also exported to more than 70 countries and regions, including the United States, the United Kingdom, France, Germany, Italy, Russia, Singapore, Chile, Japan, South Korea, Malaysia, Australia, users including Princeton University, Harvard University, University of Singapore, Hong Kong University of Science and Technology, Chinese University of Hong Kong, and Stanford University. There are now more than 3,500 users around the world using our lab spray dryer.
- Factory inspection of our lab spray dryer
All our spray dryer must pass strict test before leaving the factory. After production of each spray dryer, we’ll first conduct a strict visual inspection to ensure that there are no problems in its appearance; then run the spray drier with no load for 24 hour to test the touch screen, PLC, temperature probe, fan, air compressor, heater and other components; and at last use a standard sample to test functionality of the equipment. If all test results are OK, the equipment will then be cleaned and packed for shipment.
- After sales service
We offer a one-year warranty for the whole machine, which covers any non-artificial damage to the machine within 12 months after receipt. Our equipment is highly modularized, and all modules can be easily replaced. Our experienced engineers can quickly pinpoint the problems based on the error description and help customers solve the problem.
Lab Spray Dryer: The Compete FAQ Guide
This guide will answer all questions you have been asking about the lab spray dryer system.
First, you will know the benefits of the lab spray dryer, understand the limitations and the working principle.
Second, it will explore efficiency, drying speed, maintenance to troubleshooting lab spray dryer, among other critical aspects.
So, if you want to be an expert in the lab spray dryer system, read this guide.
- What is Lab Spray Dryer?
- Why should you Invest in Lab Spray Dryer?
- What is the difference between Lab Spray Dryer and Pilot Spray Dryer?
- Are there Limitations of using Laboratory Scale Spray Dryer?
- What is the Average Lab Spray Dryer Price?
- What are Lab Spray Dryer Specifications?
- Which Material is Laboratory Spray Dryer made of?
- Where can you use Lab Scale Spray Dryer?
- How do you Determine Lab Spray Dryer Capacity?
- What should you Consider when Buying Lab Spray Dryer?
- Which Types of Lab Spray Dryers do you have?
- What are the Components of Lab Spray Dryer?
- Which Type of Feeder can you use on Lab Scale Spray Dryer?
- How does Spray Drying Process compare to Other Drying Techniques in Laboratory?
- How does Lab Spray Dryer Work?
- What Affects the Efficiency of Laboratory Spray Dryer?
- Which Raw Materials are suitable for Spray Drying Process?
- Which Problems will you Experience when using Laboratory Scale Spray Dryer?
- What are the Quality Standards of Lab Spray Dryer?
- How do you Maintain Laboratory Scale Spray Dryer?
- Does Lab Scale Spray Dryer have a Warranty?
- How do Increase Particle during Spray Drying Process?
- What is the Effect of Altering the Nozzle Size in Laboratory Spray Dryer?
- How do you Troubleshoot Lab Spray Dryer?
- How do you Power Lab Spray Dryer?
What is Lab Spray Dryer?
Lab spray dryer
A lab spray dryer is a machine that is common in the laboratory process.
Its function includes drying various products such as soap powder, fuel, intermediates and inorganic salts.
Why should you Invest in Lab Spray Dryer?
Investing in a lab spray dryer offers various benefits to your application. These benefits include:
· Drying Time
The use of a lab spray dryer reduces the drying time for your product.
This increases the production process, which enhances your output.
· Different Designs
There are different designs for lab spray dryers that you may choose for depending on your product specification.
This allows you to dry your products to the exact drying condition without having to worry about the machine.
· Increases Products’ Lifespan
The use of this machine helps in eliminating the most harmful bacteria.
By doing this, the lifespan of your product is extended, reducing loss due to wastage.
· Cost Reduction
Among the cost that you reduce through the use of this machine is the transportation cost.
This is by reducing the weight of your product hence reducing space and weight.
You also save on storage cost since most of the products do not have harmful bacteria; hence no need pf adding preservatives.
Cost reduction also comes in when there is reduced loss; as a result, f product wastage due to harmful bacteria.
Through this process, you can save the most while reducing the overall operational cost.
What is the difference between Lab Spray Dryer and Pilot Spray Dryer?
The main difference between a lab spray dryer and a pilot spray dryer is in their design.
In a lab spray dryer, two-fluid nozzles facilitate the operation.
A pilot spray dryer consists of 2 fluid co-current nozzle, a rotary and a 2-flid fountain nozzle.
Pilot spray dryer
Are there Limitations of using Laboratory Scale Spray Dryer?
Yes. There are a few limitations to the use of a laboratory-scale spray dryer.
Such limitations include:
· Large and Bulky Equipment
The size of a lab-scale spray dryer is large and bulky.
This reduces its flexibility when operating it.
You also have to find ample space to install this equipment in your factory.
This is a limitation, especially when such a space is not available.
· Product Limitation
The use of this machine is limited to liquid product.
You, therefore, have to find another source of drying your solid products.
This increases your operating cost, especially if you are drying a variety of products.
The high price of this machine makes it out of reach if you are working on a budget.
You, therefore, have to budget appropriately before purchasing it.
Other costs that you experience when using a lab-scale spray dryer include maintenance and operating cost.
These costs increase its overall price.
You require a skilled professional to operate this machine.
This is a limitation, especially in areas where such skills are not readily available.
· Fire Hazard
The use of air is dangerous since it may cause a fire outbreak when you are drying fire-sensitive products.
This results in a loss on your part, which limits the use of this machine.
It is essential to install this machine in a secure location.
Such location should include proper ways of handling fire outbreaks to prevent massive loss to your business.
What is the Average Lab Spray Dryer Price?
To get the average price of a lab spray dryer, you have to consider the following:
· Type of Lab Spray Dryer
The different types of lab spray dryers have a separate drying effect on your product.
This affects their selling price in the market.
Knowing the exact type of dryer, you want helps in understanding the minimum price you can purchase them.
Different manufacturers compete in the same market.
They also use other manufacturing processes for the fabrication of these sprayers.
These factors affect the price of an individual manufacturer.
You have to check for the different prices before selecting one that you can afford.
However, you have to ensure that a given sprayer meets all the specifications before you purchase it.
Different lab spray dryers can handle different amounts of products per given time.
This affects the purchasing price of these dryers.
When estimating the price, it is essential to know the exact capacity that you need for the efficient functioning of your factory.
This is by checking your maximum output.
What are Lab Spray Dryer Specifications?
Lab spray dryer specifications are the parameters that you need to check in a particular dryer before selecting it.
Such specifications facilitate the operation of your dryer, ensuring you have maximum product output.
Remember, the specifications may vary depending on the design and configuration of the lab spray dryer.
Some of the main specifications include:
- Power consumption
- Atomizer type
- Working temperature
- Atomizer type
- Airflow rate
- Nozzle type
- Residence time
- Mode of operation
- Noise level
- Safety features such as thermal protection
Which Material is Laboratory Spray Dryer made of?
Aluminium is the primary material of a laboratory spray dryer.
Stainless steel is an alternative material for a laboratory spray dryer.
These materials are ideal due to their unique characteristics like anti-rust and anti-corrosion.
These materials are also easy to clean and maintain.
Where can you use Lab Scale Spray Dryer?
The use of a lab-scale spray dryer is every day in the following areas:
The chemical industry uses it in making detergents, color pigments, pesticides, insecticide and inorganic chemicals.
Other areas include the manufacturing of organic spray concentration and milk product concentration.
Industrial application. Here, typical uses include coffee and milk manufacturing, starch extraction and making polymers.
How do you Determine Lab Spray Dryer Capacity?
Lab spray dryer
To determine the capacity of a particular lab spray dryer, you have to check on the manufacturer’s manual.
A reliable manufacturer usually indicates the capacity of a specific dryer to facilitate in your selection.
Understanding the capacity of your lab spray dryer helps in determining your production capacity.
What should you Consider when Buying Lab Spray Dryer?
You need to consider the following when purchasing your lab spray dryer:
Checking on the capacity of a particular lab spray dryer helps in understanding the output of your factory.
A low capacity spray dryer is ideal if your production is low.
For efficiency purposes, the lab spray dryer you select should be of a higher capacity than the factory’s production capacity.
The dryer you select must meet all the quality standard specifications.
Such a dryer guarantees you proper functioning for long with no need for maintenance.
Price determines if you are purchasing a particular dryer or not.
There are different prices in the market, depending on several factors such as capacity.
An excellent price for your lab spray dryer is one which you can afford.
However, while considering cost, you have to consider other aspects of your dryer like the capacity and quality standards.
· Ease of Maintenance.
A lab spray dryer of bound to breakdown during its lifetime.
How easy it is to maintain such a dryer determines its effective performance.
You have to select a dryer that is easy to maintain.
Such maintenance should take into consideration the availability of spare parts and professionals to do that.
The easiest way you can purchase such a dryer is by purchasing it from a reputable manufacturer.
Which Types of Lab Spray Dryers do you have?
There are different ways you can classify your lab spray dryer.
That is, by the flow type, the stage numbers and the cycle type.
Organic spray dryer
· Co-current Lab Spray Dryer
In this type of dryer, the flow of the particles and the hot air flows in the same direction.
The spray evaporation rate in this dryer is high.
Vaporizing water preset reduces the high temperature of the drying air.
It is an ideal method for drying heat sensitive products since the heat does not come into direct contact with the product.
· Counter-current Laboratory Spray Dryer
This type of dryer involves the introduction of the air and spray in opposite ends of your dryer.
The atomizer is at the top of your dryer while the air flowing through is at the bottom.
This type of dryer offers rapid evaporation of your product due to its high energy efficiency compared to co-current type.
It is not, however, not the best method to use for heat sensitive products.
This is because the dry particles get in contact with the hot air.
· Mixed Current Laboratory Spray Dryer
This type consists of both counter-current and co-current flow.
In this type of flow, air flows from the top while the atomization process takes place at the bottom.
The drying process involves exposing the dry particles to hot air.
This type of lab spray dryer is not ideal for products that are heat sensitive.
Another way of classifying these dryers is by checking on the stage numbers.
Here you can have a single or multiple stage dryer.
A single-stage is a cost-effective and straightforward method of spray drying your products.
This type reduces the moisture content on your product by between 2-5%.
A multiple-stage la spray dryer is relatively expensive compared to the single-stage one.
However, it reduces the moisture content of your product by between 5 and 10%.
This type lets you use a low temperature for the drying process.
You can also have different types of lab spray dryers based on the cyclone type.
That is, you can have either closed or open cyclone lab spray dryers.
In an open cyclone type, the hot air flowing out of the drying chamber goes through a cleaning process before releasing into the environment.
In a closed cyclone, hot air goes through a treatment and drying process before recycling it into the machine.
A closed cyclone dryer is an energy-efficient type of dryer since it helps in reducing your overall energy bills.
What are the Components of Lab Spray Dryer?
A practical lab spray drying equipment has the following components:
Based on the flow type, you have the following types of lab spray dryer:
Parts of spray drying machine
This is the top part of your lab spray dryer.
It takes various shapes depending on the design of your dryer, that is, cylindrical, square or triangle.
It is here that you place your product for it to flow through the drying machine.
It is crucial to control the rate of feeding your product into the system.
This ensures there is uniformity in the particle droplet formation.
· Control Panel
This consists of an easy to operate interface where one can control the activities of the machine.
It consists of buttons and switches that you press and allow the system to function.
It is from this point that you can control the airflow and particle speed.
· Heating Unit
The heating unit is responsible for heating the air or inert gas that facilitate in the particle droplet formation.
There are two types of heating unit that you can have for your machine.
That is a direct heating unit, where the heating unit heats the inert gas or air.
The other type involves heating air or inert gas through the use of a heat exchanger.
The second method involves checking on different parameters.
Such parameters include temperature, physical and thermal properties of air.
You also have to consider the air flowing through the hating section.
The function of the nozzles is to facilitate the flow of the solution and the hot air either into the drying chamber or atomization unit.
There are different types of nozzles available for your drying machine, depending on your specifications.
· Drying Chamber
This is where spray drying takes place the aim of spray drying s to reduce our solution into tiny particle droplets.
It consists of several nozzles along its walls which facilitate the drying proceed.
Spray drying involves removing the water content of your solution to form tiny water droplets.
· Inlets and Outlets
Inlets are essential in allowing air or inert gas to flow into the system.
The inlets are usually at the top of the same level as your drying chamber.
The outlet allows for the flow of the hot air out from the drying unit.
This outlet is generally at the bottom of the evaporating unit.
There is also another outlet where the tiny droplets flow from the drying unit.
This outlet is also at the bottom of your drying chamber.
· Recovery Unit
The atomization unit is where the separation of tiny particles from hot air takes place.
Various parameters influence the efficiency of the separation process.
Such factors include the inlet design, cyclone dimension and number.
The shape of the hot air inlet here is usually wrap-around and tangential.
This shape enhances the volume of air flowing into this unit which increases the efficiency of the machine.
· Heat Exchange System
This is an optional component of your lab scale spray dryer.
It aims at reducing the cost of heating air or inert gas flowing into the system.
It does this by removing heat from the hot air exiting the system before releasing the air into the atmosphere.
The heat exchange system also helps in reducing environmental waste by cooling the air.
Which Type of Feeder can you use on Lab Scale Spray Dryer?
You can use a conical or horizontal type of feeder in a lab-scale spray dryer.
How does Spray Drying Process compare to Other Drying Techniques in Laboratory?
Spray drying is an ideal option for drying fluid products or solutions.
Other drying techniques such as freeze-drying are suitable for drying already manufactured products.
Lab freeze dryer
Spray drying is a cost-effective method of drying your products compared to other drying techniques.
It is for these reasons that are increasingly becoming a standard method of trying different products.
However, the use of a spray dryer is limited due to the type of product it can work with and its bulkiness.
It is heavy and large, which requires ample installation space.
How does Lab Spray Dryer Work?
The working principle of your lab spray dryer involves a series of steps right from the start to the finishing point.
These steps are:
· Feed Preparation
This step involves preparing the products that you will place on the feeder.
Such products are usually in a semi-liquid state.
The main challenge you experience here is the addition of little water as you stir the product to dissolve entirely.
It is essential for the mixture not to be vicious.
The highly viscous product makes it hard for atomization to take place.
You also have to ensure the viscosity of the mixture is uniform.
Mixture uniformity ensures uniformity in the droplet sizes.
Atomization is the separation of water from the tiny droplets.
Different types of atomizers exist for your selection.
However, each of these atomizers disperses uniform droplet sizes during the process.
The drying rate of a given particle squared is proportional its radius.
You can control the efficiency of the drying process by controlling certain variables.
These include; dryer dimension and the airflow rate.
The particle size should be reasonable to avoid drying problems.
That is, tiny particles may over dry hence affecting their performance.
Large particles don’t dry properly hence reducing tend to stick on the walls.
This reduces the total output of your product.
The different types of atomizers available in the market for your selection include.
They include ultrasonic, pressure nozzle and rotating disks.
Each of these nozzles uses different principles to operate.
For instance, rotating disk work by introducing the feed into the centre of rapid rotating disks.
These disks consist of vanes which help in directing the flow of the feeds.
Liquid flows from the edges of the disks breaking into droplets.
Rotating disks are best for use if your feed consists of entrained solids.
This is because it aims at reducing water contents.
The use of rotating disks is rare due to their high cost compared to the other types of nozzles.
Also, the functioning of a pneumatic nozzle involves mixing inert gas and the liquid feed.
This facilitates the formation of the droplets. These nozzles are complex compared to the other nozzles.
They also have a frequency of plugging, which slows down the functioning of the dryer.
Pressure nozzle consists of tiny orifices where streams of feed flow breaking into droplets.
These nozzles are relatively cheaper though they tend to plug.
The plug has the effect of increasing back pressure, thereby destroying the flow pattern of the particles.
Ultrasonic nozzle breaks liquid stream using rapid vibration into tiny droplets.
You can have multiple nozzles in one dryer depending on its capacity.
· Heating Air
The next step involves heating either an inert gas or air.
This is either through combustion or the use of either electricity or steam.
The use of inert gas is preferred if the solvent is not water and is flammable.
You may introduce the hot air or gas concurrently with your liquid concentrate or counter currently depending on the design of your dryer.
The critical consideration here is to minimize the particles from hitting and sticking on the walls.
Such affects product quality.
What Affects the Efficiency of Laboratory Spray Dryer?
Several factors that affect the efficiency of your laboratory spray dryer.
Common ones include the volume of hot air flowing through the drying unit, the size and design of the nozzle.
Other factors include the duration of heat exposure and product concentration.
Which Raw Materials are suitable for Spray Drying Process?
The raw materials that you can use in a spray drying machine should be one that is in a liquid solution.
That is, you have to mix your product to obtain a uniform solution.
Which Problems will you Experience when using Laboratory Scale Spray Dryer?
Among the various problems you will experience when using your laboratory scale spray dryer include:
- Low powder quality and inconsistency
- Misalignment of wear parts
- Low productivity
- Hygiene standards
- High production cost
- Safety issues
What are the Quality Standards of Lab Spray Dryer?
The primary quality standards for a lab spray dryer are:
- GMP standards
- FDA standards
- UL Standards
- ASTM Standards
How do you Maintain Laboratory Scale Spray Dryer?
Vacuum spray dryer
There are various ways you can maintain your laboratory scale spray dryer.
For instance, you have to lubricate the moving parts of your dryer frequently.
This reduces the wear and tear of your machine, ensuring it functions properly.
You also have to clean your machine often.
Cleaning removes dirt which can block the effective functioning of your machine.
Having a regular maintenance schedule for your machine reduces the chances of it breaking during operation.
You need to replace the broken parts of your machine with genuine spares.
This is only possible by purchasing spare parts from a reliable manufacturer.
Does Lab Scale Spray Dryer have a Warranty?
Yes. Purchasing a lab-scale dryer is the surest way of getting a warranty.
Having warranty assures you of the proper functioning of your lab scale spray dryer.
In case of a breakdown on your machine during the warranty period, you can get in touch with your manufacturer for maintenance.
How do Increase Particle during Spray Drying Process?
You can increase the particles during the spray drying process by increasing the nozzle size.
However, large particles don’t dry properly hence affecting the quality of your powder.
What is the Effect of Altering the Nozzle Size in Laboratory Spray Dryer?
The effect of altering the nozzle size is that it affects the particle size of your product.
This can lead to sticking of the particles, or the particles may not dry well
How do you Troubleshoot Lab Spray Dryer?
Troubleshooting your ab spray dryer depends on the type of problem it is experiencing.
Among the ways, you may troubleshoot your lab spray dryer based on given issues include:
· Low Powder Quality and Inconsistency
The leading cause of having a low powder quality and inconsistency is product buildup.
The product buildup is due to the design of your nozzle.
The effect of product builds up is over time the particles deposit on the sides affecting the quality of your powder.
To solve this, you need to use a flat cap design that offers a low outer face design hence minimizing product buildup.
· Misalignment of Wear Parts
Misalignments of wear parts cause inconsistency in the powder formation resulting in low-quality powder.
Solving this involves aligning all the wear parts to be in perfect shape to perform effectively.
· Low Productivity
The main problem of low productivity is nozzle bearding which is as a result of dryer configuration.
Alternatively, it may be due to using wide spray angles or nozzle profile.
Low productivity increases the frequency of your cleaning schedule due to the amount of dirt deposited.
You also have to stop production from cleaning the machine effectively, thus reducing the output.
The best way of solving this problem is by using a flat cap profile.
This offers a low outer face design which reduces bearding.
· Hygiene Standards
Proper hygiene is essential, especially for related human products.
Several factors reduce the cleanliness of your machine.
For instance, the particle deposits lead to a buildup hence contaminating the powder.
The reasons for such is using the wrong nozzle design.
You need to solve this by regularly carrying out a maintenance schedule and checking if there is any particle leakage.
You may also have to replace the design of your nozzle and use a flat structure.
A flat design reduces particle buildup, which reduces the amount of dirt deposited on the walls.
· High Production Cost
High production cost may be as a result of having an improper connection.
It may also be due to the use of wrong spare parts.
Another cause of high production cost is If your machine is outdated.
You can solve this problem in various ways.
For instance, when replacing a worn-out part, always ensure you use an original spare part.
You also need to check if there is a short circuit within your machine and repair it.
A closed cyclone dryer is more energy-efficient and dries quicker compared to open cyclone lab spray dryer.
You have to compare the energy and operational costs of the different types and select an ideal one for your use.
· Safety Issues
Safety issues may arise if those operating the machine do not have the qualifications to use your machine.
It may also be due to a damaged part within your machine.
Those who must operate the machine have the necessary knowledge of operating your machine.
Such knowledge should include repair and maintenance procedures.
You may check if there is a damaged part within the machine that poses a safety concern to your machine and those operating it.
Those operating the dryer should stand at designated points where they can see the entire machine working.
An ideal place is within the controlling unit.
This reduces body damage.
How do you Power Lab Spray Dryer?
There are different ways of powering your lab spray drying machines.
The common one is using direct current like electricity is the preferred option due to its availability and relatively low cost.
Other ways you can power your lab spray dryer is by using alternating current.
The primary type of this form is the use of a generator.
However, it is an expensive option since you have to purchase fuel frequently.
Alternatively, you can use both methods to power your dryer.
This is by allowing the generator to be a backup form of electricity.
Now, we would like to hear from you.
Whether you need a new lab spray dryer or you intend to upgrade lab spray dryer, Pilotech offers a perfect solution for all your needs.
Contact us today for a complete catalog with all our spray dryer machines.