Laboratory Pharma Spray Drying Manufacturer

Laboratory Pharma Spray Drying

Spray drying plays an important role in pharmaceutical production. Pharma Spray Drying features the following advantages: 1) Finished products have high degree of uniformity: spray drying can realize a uniform production of dried particles. 2) Finished products have good liquidity and solubility; 3) Simplified production processes: the spray drying can achieve compression and drying at one step, and takes relatively short time, which can effectively maintain the effects of heat sensitive medicines; 4) Clean production: airtight spraying environment can effectively avoid bacterial pollution and reduce dust pollution.

Pilotech produces lab scale Pharma Spray Drying products. It simulates industrial production processes in the lab or prepare some samples of different capacities, including 500ML/H, 1500ML/H and 3500ML/H.

Pilotech Pharma Spray Drying is compatible with multiple materials, including aqueous solution, organic solvent, heat sensitive materials, high temperature materials, vacuum low-temperature types, and so on.

We have over 15 years’ experience in producing Pharma Spray Drying products. At present, our products are widely used by over 500 pharmaceuticals companies across the globe and play important role in enterprises’ R&D departments and research institutes such as colleges and universities.

Pilotech Pharma Spray Drying adopts PLC control and touch screen operations. The OS language is English. It is also available for custom language according to your needs. PLC and touch screen are supplied by Delta, which have set up service points across the globe. If you have any questions on the PLC and touch screen, Delta is always ready to help you out.

Pilotech Pharma Spray Drying consists of different components including the blowers, air compressors, peristaltic pumps, and so on, which we purchase from famous brands to ensure stable equipment operation. Many users bought our spray dryer products over 10 years ago and their equipment still function stably to date.

Pilotech Pharma Spray Drying is also extensively used in many other industries such as food, chemical engineering, biology, ceramics, enzymic preparations, energy, materials, battery, and so on. Now over 3000 Pilotech spray dryers are being used around the world.

We have recorded detailed tutorial videos for each Pharma Spray Drying models. The tutorials will teach you how to properly use our equipment.

If you are looking for best Pharma Spray Drying equipment, contact our engineer for more information and quick quote now.

Laboratory Pharma Spray Drying: The Ultimate FAQ Guide

I know you’re probably looking for an efficient, accurate and reliable laboratory Pharma spray drying machine.

That’s why this guide will answer all questions you have been asking about this lab spray drying machine.

By the end of this guide, you will be an expert in laboratory Pharma spray drying machine.

Keep reading to learn more.

What Is Laboratory Pharma Spray Drying?

Laboratory pharma spray drying is an elaborate procedure that thoroughly and meticulously dries heat-sensitive fluid/ liquid or slurry into powder form.

Once the process is complete, the spray drying mechanism guarantees you uniformly dried powder material.

Now, you do have to ensure that the feed into the machine is in the form of either a solution, an emulsion, slurry, or suspension.

Equivalently, the resultant product could either be in the categories of granules, powder, or agglomerates.

Worth noting is that this mechanism is only viable with thermally sensitive materials specifically prevalent in the pharmaceutical and food industry.

For such materials, no other method is viable except spray drying.

The process takes place in a state-of-the-art spray drying equipment with a chain of equipment parts.

Laboratory pharma spray drying

What Are The Advantages Of Laboratory Pharmaceutical Spray Drying?

Spray drying is most extensively applied in pharmaceutical sectors with numerous ever-emerging applications than any other industry.

Producers regard it as the ever-flexible formulation technique for facilitating active pharmaceutical ingredients (API) and more significant biomolecules.

And better still, these are the reasons for their general application in the pharmaceutical sector.

• Uniformity, spray drying technique results in the production of purely uniform dry particles.
• Enhanced bioavailability: once the drying process is complete, the resultant particles would have improved dispersions, and this also applies to even poorly soluble APIs.
• Fast and straightforward continuous process: the drying mechanism only entails three significant stages: simple and consistently rapid while delivering quality solutes from the solution.
• Hygienic production; the drying compartment of the equipment is usually air-tight and sealed, thereby providing no chances whatsoever for external emission of the products. Therefore, it eliminates the possibilities of neither bacterial nor dust pollution.
• Solutes have improved liquidity and solubility. The ultimate products after the spray drying technique usually have enhanced liquidity and solubility.
• The equipment has higher drug loading, thereby enabling you to have larger output.
• The ultimate products have improved therapeutic efficacy, tolerability, safety, patient compliance, and tolerability.
• The procedure extends the product life cycle and shelf life.
• Suitable for the preparation of compressible powder and ideal for processing the products into a wide variety of dosage forms.
• The spray dryers are available in a wide range of designs to certify several products specs.
• Spray drying system is suitable for use with both heat sensitive and heat tolerant products.
• The system is easily customizable to meet your unique product specifications and needs. For instance you can acquire pharma lab spray drying system of any capacity.

Which Materials Can You Spray Dry Using Lab Pharma Spray Drying Machine?

A major significance of the lab pharma spray drying is in the formulation and drying of various materials. These materials may include the following:

• Directly compressible powder e.g., lactose, cellactose,
• Organic solvents
• Aerosols
• Non replicating vaccines
• Complex structures e.g., nanoparticles, nanosuspensions, virosomes, nanoemulsions
• Biologics eg large complex proteins peptides, monoclonal antibodies/ fragments
• Enzyme formulations
• Antibiotics

How Does Open Cycle Laboratory Pharma Spray Drying Vs. Closed Cycle Pharma Spray Drying Compare?

An open-cycle laboratory pharma spray drying entails injecting air drawn from the atmosphere then heating it either in a burner or electrically.

Afterward, the air gets channeled through the chambers then finally exhausted back to the atmosphere.

By far, the open cycle type is the most prevalent type of spray dryer.

The already atomized feed and drying air simultaneously enter the drying chamber from one direction for this design.

Whereas a closed cycle drying typically involves recycling and reusing the air/ heating medium used for drying.

An ideal gas for use, in this case, is an inert type such as nitrogen gas.

Vacuum spray dryer

Closed cycle type drying is preferable whenever you are processing toxic materials, flammable solvents, or oxygen-sensitive materials. You can also pick it when you need to extract the solvent completely.

Nevertheless, both the systems mostly use air as the definite drying medium.

What Is The Ideal Spray Drying Time Of Laboratory Pharma Spray Drying Machine?

The ideal time is a few minutes though not specific because it all depends on a few parameters, which may include the following:

The machine’s specifications; always verify the machine’s specs concerning power output, transmission, and configurations.

Level of concentration of the substrate; highly concentrated type would take longer to process compared to a less concentrated one.

Which Are The Different Types Of Laboratory Pharma Spray Drying Equipment Based On Type Of Stage?

In this category, the dryers can either be single-stage or two-stage types.

Single-stage Pharmaceutical Spray Dryer

Single-stage dryers; in this kind of machine, just bypassing the feed once through the dryer, the moisture gets eliminated. Usually, the moisture content reduces through to the desired proportion of about 2-5% by weight.

Two-stage Pharmaceutical Spray Dryer

Two-stage dryers; in this machine, the drying process takes place through two distinct steps. Therefore, the product leaving the chamber has higher moisture content than that of the final product, usually 5-10%.

After that, the second stage, drying, occurs in a fluidized or vibrating bed dryer.

Remarkably, the implementation of the two-step dryers makes it possible to utilize low temperatures in the process.

And as such, the two-stage dryers are suitable for use with thermally sensitive products.

What Are The Advantages Of Laboratory Pharma Fluidized Spray Drying?

The laboratory pharma fluidized spray drying combines the spray dryers’ attributes and fluid bed granulation to achieve high-quality granules.

The most common advantages of this spraying technique are:

• Production of dust-free, free-flowing and coarse products with high re-dispersibility.
• It results in an effortless drying of most thermoplastic or hygroscopic products.
• The procedure is suitable for use with granulated or agglomerated products.
• Available in versions with aseptic and closed cycle.
• Viable for drying without degrading thermally sensitive and aromatic products.
• Its compact design guarantees economical energy consumption.

Where Are Nozzles Positioned In The Vertical Laboratory Pharma Spray Drying Machine?

The positions of the Nozzles in the machine would depend on the type of flow in the machine. For instance, Spray nozzles would be at the top of the chamber for a co-current flow type.

In contrast, the nozzles are at the bottom of the chamber if the flow is counter-current or mixed.

Spray dryer nozzle design

What Feature Of Semi-Closed Cycle Laboratory Pharma Spray Drying Equipment Is Best For Pharmaceutical Materials That Cannot Be Subjected To Oxygen?

The dryer recycles the gas.

Fortunately, recycled gas would have reduced or low levels of oxygen content, therefore, becoming ideal for materials that are susceptible to oxidization hence degradation.

Why Is Horizontal Laboratory Pharmaceutical Spray Drying Equipment One Of The Best Option For Producing Small Particle Products?

The horizontal spray dryer has a rectangular-shaped chamber in the form of a box.

The nozzles in this box chamber would then spray horizontally while the particles directly fall into the floor before being removed by the action of a sweep conveyor.

These types of dryers, therefore, due to their small dimensions, have low flow nozzles.

Thus, the advantage of their small sizes is in the decrease in residence time of the particle and ultimate production of small particles products.

What Are The Major Components Of Laboratory Pharma Spray Drying Machine?

Components of laboratory spray dryer machine

A standard laboratory pharma spray drying machine would comprise of the following parts unless customized.

1. Feeder; this is a reservoir that holds the liquid in readiness for flow into the drying chamber. It is usually conical or cylindrical. It is at this point that you pour your liquid.
2. Pressure pump/ feed pump; it pushes or transmits the liquid concentrate or slurry into the drying chamber.
3. Spray nozzle: it directs and disperses the heated gas onto the slurry to eliminate the moisture content. There are usually several spray nozzles at the drying chamber.
4. Process gas/ air heater; this heating device rapidly and thermally increases the temperature of the gas/ air for drying.
   You can always select your preferential heating source depending on the design of your machine. Typical examples of these heating sources include electricity, ethanol, natural gas, or methane.
   Additionally, you have to take into consideration the precautions that come with each of the heating sources. For instance, ethanol is highly combustible and therefore only advised to be used with a closed-loop system. And also, natural gas contains tiny contaminants.
5. Heat exchanger; interchanges the heat from the hot air to the cold air. The heat exchanger hence saves you the bustle of having to re-heat low-temperature air.
6. Collection bowl/ vessel; the major collection vessel is at the end of the spray dryer. It collects the final powder after undergoing the drying process.
   The next one is a minor vessel located beside the drying chamber to retain more delicate powder and redirect them for recycling.
7. The drying chamber; is the primary compartment in which the actual drying undergoes. The chamber has a series of nozzles that sprinkle hot gas/ air into the solvent to dry.
8. Other components include air filter, intake fan, heat source, exhaust fan, cyclone separator, etc.

Which Are The Main Stages Involved In Laboratory Pharma Spray Drying?

Atomization

This is the initial process for spray drying whereby the feed solution under the atomizers’ influence transforms it into tiny droplets.

This procedure is critical in enhancing the functioning of the subsequent processes.

The numerous droplets would increase the surface area under which the drying gas transfers heat to the droplets for drying.

The prevailing conditions in the atomizers, such as pressure, ultrasonic energy, electrostatic energy, and centrifugal, enhance the process.

Some of the conventional atomizers effective in spray drying include rotary, hydraulic nozzle, and pneumatic nozzle atomizers.

Droplet – Particle Conversion.

Following the successful atomization, the next procedure entails the conversion of droplets into particles.

This conversion process involves two significant steps: droplet spray drying and droplet drying step.

Ultimately, the droplets transform into dried particles free from solvents. Here are a brief outline of the sub-steps.

Droplet spray drying; in the drying chamber, the atomized droplets shall be exposed to the drying gas.

Remember that the drying gas could be an inert type of atmospheric gas. The droplets should at least take a considerable time in the drying chamber for effective drying.

Consequently, you have to consider the chamber’s size and shape (smaller or taller).

Droplet drying (evaporation); when sufficiently exposed to the drying gas, the slurry droplets would then undergo moisture evaporation.

The solvent turns into vapor, leaving behind the solute component.

A combination of the balance between heat transfer and vapor pressure between the two mediums (gas and solvent droplets) results in dried particles.

Particle Retrieval

With the conclusion of the particle formation, next, we need to collect the particles.

And this procedure entails the separation of the particles from the drying gas.

The particle-drying gas disassociation occurs in two main stages, ie. Primary and secondary separation.

Primary separation is the collection of the settled particles right at the bottom of the conical chamber.

Usually, the densest particles will be the ones to settle at the bottom.

Secondary separation is the collection of the smallest and finest particles with the help of auxiliary devices.

To effectively separate the particles, consider using any of the following separators depending on the desired products’ level of efficiencies and final traits.

Cyclone separator; It has a cylindrical upper part, barrel body, and conical bottom part. This device separates the particle by the action of centrifugal force.

Final separation results in the emission of the gas from the top and settling of the particles at the collection chamber in the bottom part.

Electrostatic precipitator; this device operates based on electrostatic forces. It is very efficient even though rarely used due to the high costs of equipment.

Bag filter; this separation occurs by filtration via bags. Here the machine directs the streamline to the bags under high pressure.

The bag then retains the particles while permitting passage of the gas.

Further, the particles retained would be collected by the action of pulses of compressed air passed through the bag.

The flow of the air is in counter-current motion.

Wet scrubbers; the scrubbers come last after the collectors – usually installed at the end.

The scrubbers trap the particles that would occasionally pass the collectors trapped in the air stream.

The scrubbers, therefore, guarantee particle-free or odorless gas emission into the atmosphere.

What Are The Applications Of a Lab Pharmaceutical Spray Dryer?

Most pharmaceutical products have to undergo spray drying either at a high capacity or low capacity level. Such typical products include antibiotics, enzymes, vaccines, plasma, yeasts, and vitamins.

Besides, most of them require the usage of either two-fluid or pressure-nozzle atomizers.

How Do You Choose The Appropriate Atomizer For Laboratory Pharma Spray Drying?

Your choice of atomizers will always be down to three varieties, i.e., rotary atomizers, hydraulic nozzle atomizers, and pneumatic nozzle atomizers.

Usually you would initially peg your choice of any atomizer based on the following specs outlined below.

Consider The Kind Of Atomization Energy You Need

Rotary atomizer – centrifugal energy

Hydraulic nozzle atomizer – pressure

Pneumatic nozzle atomizer – kinetic energy.

Review The Specifications Of The Atomizers

Rotary atomizer – easily achieves a disc speed of 10,000-30,000 rpm

Hydraulic nozzle atomizer – nozzle pressure of between 250 psi – 10,000 psi.

Pneumatic nozzle atomizer; nozzle pressure of between 250 psi – 10,000 psi.

Specify The Kind Of Spray

Rotary atomizer – fine, medium, coarse

Hydraulic nozzle atomizer – coarse, less homogenous

Pneumatic nozzle atomizer – medium coarseness, poorly homogenous.

Consider The Average Droplet Size That You Require

Rotary atomizer – 10μm – 200μm

Hydraulic nozzle atomizer- 20μm – 600μm

Pneumatic nozzle atomizer – 10μm – 200μm

Review The Pros And Cons Of Each Rotary

Rotary atomizer; pros.

• Can handle high rates of feed without clogging.
• Operates at low pressure
• Highly efficient and forms particles of uniform sizes.

Cons; highly-priced and not favorable with a viscous feed.

Hydraulic nozzle atomizer; pros

• Has low initial cost price
• Forms less dense particles
• Enhances the adoption of narrow drying chambers

Cons; unsuitable with highly viscous feed

Pneumatic nozzle atomizers, pros

• Has improved control over particulate sizes compared to hydraulic nozzle type
• Better of with high viscous feeds
• Suitable for use in the laboratory due to its small-sized drying chamber.

Cons; attracts high operational costs because of the much-needed compressed gas used in atomization.

What Is The Working Principle Of Rotary Atomizer Of Laboratory Pharma Spray Drying Machine?

The rotary atomizer operates on the principle of application of centrifugal energy.

Besides, the atomizers comprise horizontal wheels and discs.

The feed solution, whenever injected, would then collects at the center.

Moreover, the subsequent motion of the rotary atomizers then generates high centrifugal force, which then disperses the solution to the periphery of the atomizer as it forms droplets.

For better performance, there are grooves within the discs of the atomizer which regulate the dispersion of the solution.

How Does The Size Of Drying Chamber Affect The Efficiency Of Laboratory Pharma Spray Drying Process?

The dimensions of the drying chamber are somewhat directly proportional to the efficiency of the machine.

Firstly, the size of the chambers needs to conform to the type of spray dryer.

Specifically, your size selection should be consistent with the kind of atomizer in place. Besides, the size should adhere to the particulate nature of the products.

Secondly, the drying chamber should be sizeable enough to ensure that the particles have adequate residence time within the chamber.

That said, we have got two different sized drying chambers, i.e., smaller and taller drying chambers.

What Are The Factors Affecting The Properties Of Final Dried Product Of Laboratory Pharma Spray Drying?

The final dried products may have varied characteristics such as dimensions, morphologies, and moisture contents depending on a few critical factors. Below is an illustration of these issues.

1. Pressure in the atomizer; nozzle atomizers do impart a lot of pressure to the process, which is crucial to the particulate sizes—high-pressure results in smaller or finer particles and vice versa.
2. Rate of feed flow; at constant atomizer pressure, an increase in fluid flow rate leads to an increase in sizes of droplets.
3. Feed viscosity; feed viscosity is directly proportional to the particle size.
4. The surface tension of feed; remember that atomization occurs due to the breakdown of the feed surface tension. Thus feed solution with increased surface tension decreases the effectiveness of atomization. Consequently, emulsification and homogenization of the feeds are essential in reducing the surface tension.
5. Inlet temperature; refers to the temperature of the incoming drying gas. The temperature of the drying gas directly affects the extent of particle moisture elimination.
6. Outlet temperature; refers to the temperature of the mainstream of air containing all the particles before particle collection.
7. Drying gas flow rate; there should be a moderately low drying gas flow rate to ensure sufficient particle moisture expulsion, yet it needs to be adequate for the following stages.
8. Residence time in the drying chamber should be adequate to guarantee maximum moisture expulsion from the particles. Take precaution because an extended duration may lead to particle degradation for the heat-sensitive products. The still shorter duration may produce particles with high moisture content.

Which Are The Suitable Materials For Mixed Flow Lab Pharmaceutical Spray Drying System?

Mixed flow laboratory pharmaceutical spray drying machine combines both the co-current and counter-current flow mechanisms.

You will supply your atomized droplets from the chamber bottom in a counter-current direction to the drying gas supply from the top in this setup.

Eventually, both the drying gas and dried particles exit from the bottom.

If you work with dry-coarse droplets, then the mixed flow system would be ideal for you due to the longer residential time in the chamber.  Besides, this system is necessary for thermally sensitive materials.

What Is Residence Time Of Laboratory Pharma Spray Drying?

Benchtop spray drying machine

The residence time refers to the duration of the exposition of the atomized droplets while inside the drying chamber.

This period is critical in determining the extent of moisture content of the particles. Remarkably, you need always to find it correct.

Arguably, this time could range in between a few seconds, say 10 – 15 seconds, in the drying chamber.

How Does The Atomization Pressure Impact The Laboratory Pharma Spray Drying Droplet Size?

Atomization pressure is specifically significant in the nozzle typed atomizers. The pressure in there would therefore be directly proportional to the droplet size.

With a constant feed solution and the same atomizer, an increase in the pressure would subsequently decrease the droplet size.

Why Is It Important To Install Wet Scrubbers After The Powder Collection System Of Laboratory Pharma Spray Drying Equipment?

Usually, a standard spray drying mechanism would result in the emission of particles even in the air streamline surpassing the entire dry collection particle channel. As such, the wet scrubbers come in handy to trap and retain such passable particles.

Ultimately, the combination of the wet scrubbers leads to clean and purer emitted air free from particles or odor.

Can Other Industries Use Laboratory Pharma Spray Drying Machine?

Several other industries would benefit from the lab pharma spray drying machine, as outlined below.

Chemical industry; inorganic chemicals, organic chemicals, spray concentration, dyestuffs, pigments, detergents, soaps

Food industry: Milk products, egg products, fruits, vegetables, carbohydrates, fish products, plant products, slaughterhouse products.

Agro-chemical industry: fertilizers, fungicides, herbicides, pesticides, and insecticides.

What Is The Laboratory Scale Pharma Spray Drying Equipment Price?

Well, the equipment costs vary depending on the type of spray drying system.

Considering the standalone equipment, then arguably rotary atomizer would cost the highest amongst the three atomizers.

Nevertheless, additional factors such as the manufacturer, size and dimensions, drying capacity would also shift the equipment costs.

Why Are Pressure Nozzles Preferred in Pharma Spray Drying?

Pressure nozzles are a great addition since they produce coarse and yet free-flowing powders compared to rotary atomizers. Specifically, such pressure nozzles installed in the spray drying system are unique because they are the vortex type.

They make the fluid passing through them undergo some form of rotational motion.

A significant advantage of the pressure nozzle is that it can be applied over a large variety of flow rates. Still, the nozzle could be combined into multiple installations to produce a considerable flow rate and flexibility in particle sizes.

Lastly, the pressure nozzles can achieve highly high operational pressure range between 250 psi to 10,000 psi.

What Are The Quality Standards For Laboratory Pharma Spray Drying Machines?

Like any other pharmaceutical machine, the lab pharma spray drying machine must undergo rigorous quality standardizations.

Below is a list of typical quality standards your machine should adhere to.

• ISO certification standards
• GMP certification standards
• RoHS
• ICH (International Conference on Harmonization Standards)
• FDA standardization marks.

What Are Some Of The Emerging Trends In Laboratory Pharma Spray Drying Technology?

With the recent advancements in pharmaceutical equipment technology, we are sure to see some of these advancements.

Firstly, the Development of a non-heat spray drying technology has been in place just recently. The non-heat mechanism would be the best option for quite a heat-sensitive, valuable product.

Secondly, the production of nano-sized powders has taken center stage while also maintaining its unique properties.

Thirdly, there is advancement in the application of steam drying mechanisms to sterilize products amidst spraying.

Next, manufacturers have been concerned about the inclusion of poorly soluble drugs due to the rapid use of amorphous products.

As such, we are likely to see this specific application in biopharmaceuticals, including the separation and preparation of proteins and peptides.

A fundamental development is in the aseptic spray dryer, which will likely soon hit the market. This equipment would perfectly blend in the aseptic powder filling as a compliment.

Initiation of spray drying in fortification.

Spray drying could probably be used to fortify some of the nutrients that may or may not be directly consumable.

For instance, the technique could come into play in the incorporation of vitamin D3 in products.

That would be achievable by dissolving vitamin D3 crystals in an oil phase. Mixing with a carrier such as a maltodextrin then follows.

Finally, spray drying would eliminate the moisture content, thus resulting in thoroughly dried vitamin D3 powder.

The ultimate result would then be the conversion of the crystals into powdery form for subsequent usage. The powder would then be easy to fortify with other products.

At Pilotech, we help you design and manufacture the best laboratory Pharma spray drying machine for your specific needs.

Whether you need bench top spray dryer, mini spray dryer, or pilot scale spray dryer, we offer a perfect solution for all your material processing needs.

Contact us today for all your laboratory Pharma spray drying machine.