YC-015 Nano Spray Dryer

Nano Spray Dryer

When doing experiments, researchers often use nano-materials. However, it’s difficult to obtain nano-materials or micron-materials by quickly drying nano-solutions in the laboratory.

Pilotech YC-015 nano spray dryer is very suitable for particles, whose diameter ranges from 0.5 to 25 microns. That’s why our nano spray dryer is widely used in various industries, including pharmacy, bioscience, food, material science, metal, and ceramics.

The drying chamber of YC-015 nano spray dryer is made of either high borosilicate glass or SUS304 stainless steel. Each of these two materials has its own advantages: high borosilicate glass is heat-proof and easy to observe, while SUS304 stainless steel is durable.

Components of our nano spray dryer include PLC controller, a touch screen, a drying chamber, a cyclone separator, and a receiving bottle, which are connected through clamps, bringing great convenience and easy to install.

Pilotech YC-015 nano spray dryer adopts a patented heating technology. So, it’s heating process is uniform and steady. The heater will never be burnt even if it runs for a long time.

Pilotech YC-015 spray dryer adopts an innovative concentric spray head, which will not be deviating from one side in the process of atomizing. Thus, materials will not be sprayed onto the wall. Pilotech YC-015 spray head is more suitable for materials with high viscosity and easy to disassemble and clean, and spray nozzle is made of SUS316L stainless steel.

The capacity of YC-015 nano spray dryer is 1500ML/H. However, for a small amount of materials, 30ML of solution is enough to finish an experiment. Thus, YC-015 nano spray dryer reaches a balance between the laboratory’s needs for processing a amount of materials and a small amount of materials.

If necessary, YC-015 nano spray dryer can be equipped with a tail gas dust removal device, which is optional to improve the recovery rate of material and to reduce impacts on the environment.

We have produced nano spray dryer since 2005. YC-015 Nano Spray Dryer is of high stability, excellent controllability, high recovery rate, and low failure rate. That’s why it is highly recognized by 1,500 users across the world.

YC-015 nano spray dryer is provided with an HD tutorial video, in which its every detail is given. This tutorial video explains in detail how to install, disassemble, clean, maintain and preserve YC-015 nano spray dryer.

If you enter “YC-015 spray dryer” into the search box on Google Scholar, you will see a lot of relevant papers.

And If your materials contain sugar, our low temperature spray dryer may be more suitable, then the material won’t stick onto the tank wall due to high temperature.

If you are looking for nano spray dryer manufacturer in China or the best quote, please contact us now without any hesitation.

Nano Spray Dryer: The Ultimate FAQ Guide

This guide will answer all questions you have been asking about nano spray dryer such as process optimization, parts, working principle, process parameters, atomization, and particle size, amongst others.

Keep reading to be an expert in these spray drying machines.

What is a Nano Spray Dryer?

A nano spray dryer is equipment, which dries particles in the nanometer range.

You will produce particle powder of minute sizes when using a nano spray dryer.

With a nano spray dryer, you can make a particle to be as small as 300 nanometers.

You can also achieve a yield of up to 90% when you use a nano spray dryer.

Nano spray drying machine

When should you use Nano Spray Dryer?

You will need a nano spray dryer when you want to produce very small particle sizes.

Other spray drying machines are not able to produce particles in the size of nanometers.

Researchers are always using nano materials to do experiments in the laboratory.

Spray drying machine

Which Industries use a Nano Spray Dryer?

Various industries use a nano spray drying machines.

These industries use this machine to produce small particle sizes.

Some of the industries that use a nano spray dyer include:

· Pharmaceutical Industries

Pharma industries are one of the industries that widely use a nano spray dryer.

This is because you can use a small sample size yet achieve a high yield.

You will use a nano spray dryer to spray dry expensive substances when doing research.

You can use a nano spray dryer in the pharmaceutical industries to produce:

1. Nano capsules that contain biodegradable polymers.
2. Produce absorptive drug carriers to make nanoparticle suspensions.
3. To make inhalable drugs from the dry powder inhalers.
4. Microencapsulation and nanoencapsulation of liposomes.
5. Encapsulating nano particle drugs to make them highly bioavailable.
6. Stabilizing heat-sensitive vaccines, growth hormones, and insulin.
7. To make excipients that you will use when controlling drug release studies.

· Bioscience Industries

Some of the applications in bioscience industries include:

1. Drying heat sensitive proteins.
2. Drying heat sensitive enzymes.

· Material Science Industries

The following are examples of how the material science industries use a nano spray dryer:

1. To make additives such as carbon nanotubes.
2. To make nanoparticle agglomerate from silicon oxide.
3. To manufacture fine magnetic powder.
4. Agglomerating nanoparticle suspensions.
5. To manufacture particles from titanium oxide.
6. To manufacture fine pigments for coatings and paints.
7. To manufacture fine metal particles that you will use for a novel catalyst.

· Metal Industries

Some of the possibilities in the metal industries include:

1. Processing minerals.
2. Manufacturing carbide powders.
3. Manufacturing iron powders.
4. Manufacturing thermal spray powders.

· Ceramic Industries

Some of the possibilities in ceramic industries include:

1. Manufacturing anti-corrosion powders.
2. Manufacturing powder for industrial and civil coatings.
3. Manufacturing fire proof powder.
4. Manufacturing high-resistance substances.

· Food Industries

You will use a nano spray dryer in the food industry especially in the present field of functional food.

Some of the possibilities in the food industry include:

1. To make functional additive nano foods.
2. To make encapsulations of flavors, perfumes, or fruit aromas.
3. To make food additives such as vitamins.
4. To spray dry fine powder aroma that you will use for pet foods.
5. To make encapsulations of fish oil to protect the smell.

How does a Nano Spray Dryer Work?

A nano spray dryer and the conventional spray dryer dries powder using similar concepts.

However, a nano spray dryer has instruments such as:

• The cylindrical drying chamber.
• The atomizer that produces the spray.
• The permeable metal form which produces laminar flow in the drying of the gas.
• The electrostatic particle collector.

Here is how a nano spray dryer works:

i. Material Wetting Process

The wet process is the very first step when using a nano spray dryer.

You will mix up all the materials that you are to feed in the machine.

It has to be in liquid form so that you can extract the powder from the liquid solution.

ii. Atomization Process

You will then direct the liquid solution to the spray head.

A piezoelectric actuator will generate a fine spray of droplets from the liquid solution.

You will use a vibrating mesh in the nano spray dryer.

The mesh system contains small caps that have an exact arrangement of micrometer-sized holes.

Stainless steel is the material that makes up the small caps.

You can control the vibration frequency of the cap to produce moderate to high droplet size.

The piezoelectric actuator vibrates between 60–140 kHz.

This high frequency of vibration produces millions of droplets every second.

The distribution of the droplets is in a homogeneous size.

The size of the droplets depends on:

1. The viscosity of the solution.
2. The surface tension.
3. The size of the holes in the stainless-steel membrane.

For instance, a spray mesh with 4 µm will produce droplets in the range of 3–8 µm.

The size of the mesh is directly related to the size of the droplets.

This in turn affects the particle size and physiochemical properties of the final product.

iii. Contact Between the Air and the Liquid

The particles now enter the drying chamber from the top.

The drying gas will also enter from the top of the cylindrical drying chamber.

This is known as co-current flow since both the drying gas and liquid enter from the same direction.

iv. The Drying Process

The heating system in a nano spray dryer will produce laminar flow.

Laminar flow happens when the air passes via a compact porous metal foam.

Laminar flow is unique to nano spray dryers since conventional spray dryers use turbulent flow.

The design of the heating system provides hot gas entry flow in the renowned Reynold number regime (Re < 2300).

When using a laminar flow, the particles move in a unidirectional manner.

This limits the path of travel which minimizes the contact of the droplets with the wall of the dryer.

Besides, since the drying process happens close to the spray head, the heating process happens early.

This will reduce the residence time and developing the conservation of heat-sensitive items.

Hot air will dry the particles while directing them to the collector at the bottom of the drying chamber.

The length of the cylinder can affect the drying of different substances.

The length will affect the residence time.

For fine sprays of tiny droplets, a short drying chamber is recommended.

This is because the residence time is low (1–4 seconds) and the droplets would reach a complete drying state.

In contrast, large particles require a long cylinder to increase the residence time for them to dry completely.

For dry solid particles, a short drying cylinder is good for achieving fine particle sizes.

On the other hand, a long drying chamber is good for achieving large particle sizes.

v. Collection Process

A nano spray dryer uses an electrostatic particle collector to achieve a high collection performance.

The machine uses a cylindrical anode, two electrodes, together with a grounded cathode.

All this makes up the electrostatic system.

The machine applies an electrostatic field in the drying process and applies a high voltage amidst the electrodes.

This will quicken the particles that have a negative charge and attract them to the surface of the electrode.

Once they discharge, the particles will separate from the wall.

The particles then fall inside the electrostatic particle collector where you will collect them.

What Heating System does a Nano Spray Dryer use?

 Nano spray dryer

A new heating system produces particles in a nano spray dryer.

In a nano spray dryer, heat flow is laminar and nor turbulent as is in conventional spray dryers.

The laminar flow has an advantage in that the particles fall straight down upon leaving the spray head.

This makes it possible for the particles not to stick to the glass wall.

A nano spray dryer produces laminar flow by pressing air via a porous metal foam.

What is the Evaporating Capacity of a Nano Spray Dryer?

A nano spray dryer has an evaporating capacity of 1.5 liters per hour when you use water.

However, you can use a small quantity of solution to perform an experiment.

You can use a small capacity of 30ML to conduct an experiment.

This means you can use a nano spray dryer for large and small samples depending on your needs.

This variation reduces wastages when doing experiments as you only use what you need.

How does an Automatic and Manual Nano Spray Dryer compare?

An automatic and manual nano spray dryer has many differences.

This is even though they will all provide you with nano particles during spray drying.

· Cost

Generally, an automatic nano spray dryer will cost you more than a manual spray dryer.

The budget you have will determine the type of nanospray dryer you will purchase.

·  Level of Supervision

An automatic nano spray dryer will do the most task by itself requiring no supervision.

On the other hand, a manual spray dryer requires some supervision during its operation.

This means you will require more human labor when using a manual nano spray dryer.

· Production Capacity

An automatic nano spray dryer has a high production capacity than a manual nano spray dryer.

This is because an automatic nano spray dryer will perform its task with little to no supervision.

· Accuracy of Production

An automatic nano spray dryer is more accurate at drying particles than a manual nano spray dryer.

This is because a nano spray dryer will do all the tasks with no human involvement once the drying process starts.

· Consistency in Production

When it comes to repeating the drying process, an automatic nano spray dryer is efficient than a manual nano spray dryer.

This means your production process will not have mistakes and quality is a guarantee.

· Time-saving

An automatic nano spray dryer performs the drying process way quicker than a manual nano spray dryer.

This means you can accomplish more in less time thus meeting your production needs.

· Ease of Use

An automatic nano spray dryer is easy to use than a manual nano spray dryer.

An automatic nano spray dryer has easy to use and monitoring panels.

This makes it easy for one person to oversee and change parameters.

· Level of Automation

An automatic nano spray dryer has more automation than a manual nano spray dryer.

This is because the automatic version has in-built hardware and software to do all tasks by itself.

What Particle Size Range can you produce with a Nano Spray Dryer?

A nano spray dryer can produce a variety of particle sizes.

The particle size can vary from 1 µm to 25µm.

This makes it possible for you to produce particle sizes that meet your specific production needs.

 Nano spray drying machine

What are the Advantages of a Nano Spray Dryer?

A nano spray dryer has many advantages making it beneficial for your industry.

Some of the advantages of a nano spray dryer include:

· Time-saving

When using a nano spray dryer, you will save a lot of time especially when it is the fully automatic version.

This means you will meet your production needs and fulfill your client demands.

· Production Capacity

A nano spray dryer will increase your production capacity.

You will be able to process more nano particles within a short time.

This is mostly true when you have a fully automatic and not a manual nano spray dryer.

· Particle Sizes

You can get a variety of particle sizes by using a nano spray dryer.

A nano spray dryer can give you particle sizes ranging from 1 µm to 25µm.

This means you can meet your specific production needs.

· Ease of Operation

A nano spray dryer is an easy machine to operate.

You can easily use the automatic version once you fully understand how it works.

You can monitor and make changes with the programmable logic controller [PLC] and touch screen.

· Profitability

A nano spray dryer will increase your profits.

You can make more nano particles for experiments within a short time.

You will also have a high production capacity that meets your demands.

This leads to more sales hence more profit.

· Consistency and Efficiency

A nano spray dryer can meet production needs over and over again.

The machine is also efficient for the drying process.

· Sample Capacity

You can use a range of sample capacity with a nano spray dryer.

You can use large samples or small samples for experimental purposes.

Are there Limitations of a Nano Spray Dryer?

The limitations of a nano spray dryer should not make you not purchase it for your industrial needs.

Some of the limitations of a nano spray dryer include:

· Price

This is a major factor to consider when purchasing a nano spray dryer.

The fully automatic nano spray dryers cost more than semi-automatic or manual nano spray dryers.

The budget you have will determine the kind of machine you will buy.

It is a good practice to always purchase the machine that will meet your production needs.

Besides, the high initial price will be offset in the long run.

This is because the machine will serve you for years without any major failures.

Also, the fully automatic nano spray dryers will require no to minimal human involvement meaning you will cut your recurring costs.

· Production Capacity

The production capacity depends on the type of nano spray dryer you purchase.

Generally, the more expensive nano spray dryers have a high production capacity due to the level of automation in them.

The cheaper nano spray dryers will have a low production capacity.

You should always go for a nano spray dryer that will meet all your production needs.

· Human Labor

A manual nano spray dryer will need some level of human involvement.

This is because the machine cannot do all the tasks by itself.

The workload of a manual nano spray dryer is higher than that of an automatic one.

How can you Improve the Recovery Rate of a Nano Spray Dryer?

You can equip a nano spray dryer with a tail gas dust removal device.

This device improves the recovery rate and it also minimizes the environmental impact that the machine may cause.

Also, the tail gas dust removal device is optional meaning you can decide to use it or not.

What Technologies does a Nano Spray Dryer use?

A nano spray dryer uses several technologies that improve its efficiency and production.

These technologies include:

Nano spray drying system

· Heating System

A nano spray dryer uses laminar heat flow and not a turbulent heat flow that is common in conventional spray dryers.

The laminar flow makes the particles move straight down making them not stick to the glass wall.

The machine achieves laminar flow through a porous metal foam.

· Electrostatic Particle Collector

The electrostatic particle collector will charge the dry particles and deflect them using an electrical field.

Also, the machine produces a high voltage of 16 kV around the collection tube.

The electrical field increases between the inner walls of the collection tube and the star electrodes.

Once the particles get deflected, they stay within the inner walls of the particle collector and the charge reduces.

This technology is efficient allowing you to collect 99% of all particles that enter the system.

·  Spray Head

The spray head of a nano spray dryer is one unique component that makes nano spray drying possible.

It has a piezoelectric device that vibrates accurately to produce a fine mesh.

The vibrations produce fine droplets with their distribution having a narrow size with the help of spray caps.

What are the Typical Organic Solvents used in Nano Spray Drying of Pharmaceuticals?

You can use a nano spray dryer with several organic solvents in the pharmaceutical industries.

The selection of these organic solvents depends on the solubility of the drug and the material that you will use for encapsulation.

Also, organic solvents generally produce smaller droplets that water because:

• They have low surface tension.
• They have a low viscosity.
• They have a low density.

Also, you can use lower drying temperatures with organic solvents due to their low boiling points.

Some of the solvents you can use include:

• Dichloromethane (DCM)
• Acetone
• Ethanol
• Methanol
• Acetonitrile
• Ethyl acetate
• Mixtures that have water

What are the Parts of a Nano Spray Dryer?

A nano spray dryer has several parts that work together to achieve the drying process.

The parts of a nano spray dryer include:

· PLC Controller

PLC stands for a Programmable Logic Controller.

This is a computer that you can reliably use under extreme industrial environments such as:

1. Extreme temperatures.
2. Wet environments.
3. Dry environments.
4. Dusty environments.

A PLC has a power supply, central processing unit [CPU], memory, operating software [OS], input, and output [I/O].

·  Touch Screen

The touchscreen allows you to operate the machine from a central point.

You can enter commands and control the machine easily.

· Drying Chamber

The drying chamber is where all the drying happens.

Also, the drying gas and the droplets enter this chamber from the same direction [co-current].

In the drying chamber, the droplets do not get in contact with the glass wall.

· Cyclone Separator

The cyclone separator removes charges from the particles that you are to collect.

·  Receiving Bottle

You will then collect all the neutral dry nano powder on a bottle.

What are the Adjustable Process Parameters of a Nano Spray Dryer?

The adjustable process parameters of a nano spray dryer are:

• The rate of flow of the drying gas.
• The spray rate.
• The inlet temperature.
• The composition of the feed.
• The concentration of the solids.

Is Nano Spray Drying safe?

Yes, nano spray drying is safe.

Nano spray drying is a physical-chemical process that transforms liquid into dry powder.

Where there is powder or dust in a nano spray drying plant, there is a chance of an explosion or fire.

The way to reduce these risks is to reduce the chance of seal extrusion and leakages in the nano spray nozzle.

A spray nozzle that has a good design reduces the chances of fire or explosion in a nano spray drying process.

How does the Spray Head of a Nano Spray Dryer Work?

A nano spray dryer spray head is innovative and concentric.

This means it will not move from side to side during atomization.

The advantage of this is that the material will not stick to the glass wall.

What Parameters Influence the Quality of Product in a Nano Spray Dryer?

Here are some of the parameters that influence the quality product in a nano spray dryer:

· Atomization pressure

The pressure that you apply will influence the size of the droplets.

· Feed Flow Rate

Maintaining a constant atomization pressure increased the size of droplets by increasing the feed flow rate.

· Feed Viscosity

You need high atomization energy when you increase the viscosity of the feed.

· Feed Surface Tension

Atomization happens when you disrupt the surface tension of feed.

This disruption influences the size of the droplets hence you need to emulsify and homogenize the feed.

· Inlet Temperature

A high inlet temperature makes it possible for moisture to evaporate rapidly.

· Drying Gas Flow Rate

A high gas flow rate will increase how particles move inside the drying chamber.

The flow rate should be suitable to facilitate the separation process of the nano particles.

· The Residence Time within the Drying Chamber

Residence time is the period that the droplets stay in the drying chamber.

Ensure adequate residence time for complete drying of particles.

What is Atomization in a Nano Spray Dryer?

Atomization is the process of producing fine droplets from bulk liquid.

Atomization will influence the particle size

What is the Price of a Nano Spray Dryer?

The price of a nano spray dryer depends on the production capacity and technology.

Generally, fully automatic nano spray dryers will cost more than semi-automatic or manual nano spray dryers.

The price of a nano spray dryer will range from 1,000 US Dollars to 1,000,000 US Dollars.

How does Conventional Spray Drying compare to Nano Spray Drying?

A nano spray dryer uses vibrating mesh technology to produce an ultra-fine spray.

You cannot use conventional spray drying to produce nano particles.

A nano spray dryer uses laminar heat flow.

Conventional spray drying used turbulent heat flow.

Conventional spray drying produces large droplets than nano spray drying.

Particles in nano spray drying do not stick to the drying chamber due to the laminar flow.

Nano spray dryer

How does Mini Spray Dryer compare to Nano Spray Dryer?

Mini spray dryer

A mini spray dryer is much smaller than a nano spray dryer.

A nano spray dryer produces nano particles.

A mini spray dryer can process 1500ML per hour while a nano spray dryer can process 2000ML per hour.

A mini spray dryer produces larger particles than a nano spray dryer.

What are the Quality Standards Nano Spray Dryer Machine Must Conform to?

A nano spray dryer has to conform to quality standards due to safety and health purposes.

Some of the quality standards a nano spray dryer has to conform to include:

· Current Good Manufacturing Practices [cGMP] Quality Standard

This quality standard ensures that a nano spray dryer employs the best designs and working techniques.

· CE Quality Standard

All companies worldwide accept this quality standard.

CE Quality Standard applies to European Economic Areas.

· Food and Drug Administration [FDA] Quality Standard

FDA ensures the nano spray dryer meets the basic health standards.

Remember, every machine must conform to the set industry standards within a geographical location.

Now, it’s your turn – we would like to hear from you.

Whether you’re planning to upgrade, or in case you have any inquiry about nano spray dyer, Pilotech team is here to help – contact us now.