Best Spray Drying Machine
The world leading R&D solution for Spray Drying

Pilotech Spray Drying Machine Leading Manufacturer

  • Have been in the field of mini spray drying machine from 2005.
  • 60+ countries,3500+ Usersaround the world.
  • For any application:thermosensitive materials, organic solvents, sugary materials, ceramics, chemical industry, biology etc.

Pilotech Spray Drying Machine

Lab spray dryer

YC-500 Spray Dryer Mini Type For Laboratory, small size, length and width are less than 70MM, can be placed on the test bench, low power, only 1.5KW, single-phase power supply, can be customized 220V or 110V, in line with your laboratory power requirements. It can be equipped with a inert loop system for spray dryers for organic solvents, or a vacuum system for spray drying of heat-sensitive materials.

Nano spray drying machine

YC-015 laboratory spray dryer, simulation of industrial spray drying machine, which went on the market in 2005, has more than 3,000 users all over the world and has been well received by users. Integrated equipment design, built-in air compressor, air compressor storage tank material is SUS304 stainless steel, low noise design. Covering an area of less than 1 square meter, with a user-friendly design and easy operation, we have also recorded high-definition operation videos for you.

YC-1800 laboratory low temperature spray dryer is specially developed for the rapid drying of heat-sensitive materials. The inlet air temperature is as low as 105 °C, and the outlet air temperature is as low as 60 °C. It can be used for spray drying of heat sensitive materials such as enzyme preparations, and sugary materials, which has a good drying effect and no sticking to the wall. The drying chamber adopts a mixed structure of stainless steel and high borosilicate glass, which is good for observing the experimental process and having a long service life.

Vacuum spray dryer

YC-2000 Vacuum Spray Drying Machine For Laboratory, combines the advantages of spray drying and vacuum drying. It has fast drying speed and low drying temperature. It realizes rapid drying of materials under low temperature conditions and is suitable for drying heat sensitive materials. We have a variety of specifications of laboratory vacuum spray dryers, 500ML/H, 1500ML/H, 3000ML/H.

YC501 -Inert Loop Spray Dryer detail

YC-501 is used for the spray drying of water solution and organic solvent. It has a split-type design: the main machine of spray dryer, and the inert loop system. The main machine can be used separately for the drying of water solution, no nitrogen is needed for this. After connecting the nitrogen circulation system, it then can be used for the drying of organic solvent. The equipment covers less than 1 square meter, has a power of 2.5 KW and is easy to operate.

YC018 Ceramic Spray Dryer

YC-018 is a pilot spray dryer, it can deal as much as 4000ML/H. It has a relatively small volume and covers only 1 square meter, 100ML is enough for one experimental, and is suitable for lab and pilot specifications. YC-018 has a broad range of inlet air temperature, from 110°C to 350°C. It can adapt to different materials and has a maximum recovery rate of 92%. The experiment process can be observed through sight glass.

Why Pilotech Spray Drying Machine

  • In China, Pilotech laboratory spray dryer’s market share is over 90%.
  • Pilotech laboratory Spray Drying Machine has been exported to more than 3,500 users in more than 60 countries and regions.
  • From bench spray dryer to pilot scale spray dryer, from aqueous solutions to organic solvents, complete specifications.
  • A lot of papers on the Pilotech laboratory spray dryer can be consulted.

Mark Williams

We purchased YC-015 mini spray dryer from Pilotech in 2009 for spray drying of spirulina extract. At that time, we were most worried about wall sticking. Fortunately, we were very satisfied with the drying effect of YC-015. There is no wall sticking phenomenon that we are worried about and the material recovery rate is very good. YC-015 is still in use in our laboratory, which has been 10 years, and there has been no fault. We are very satisfied. Minimum inlet air temperature is 105 °C, minimum air outlet temperature is 60 °C.

We purchased YC-015 mini spray dryer from Pilotech in 2009 for spray drying of spirulina extract.

At that time, we were most worried about wall sticking.

Fortunately, we were very satisfied with the drying effect of YC-015.

There is no wall sticking phenomenon that we are worried about and the material recovery rate is very good.

YC-015 is still in use in our laboratory, which has been 10 years, and there has been no fault. We are very satisfied.

Minimum inlet air temperature is 105 °C, minimum air outlet temperature is 60 °C.

Spray Drying Machine:The Complete Buying Guide

Are you looking for the spray drying machine? Shanghai Pilotech spray drying machine for laboratory is your ideal choice.

Features of Shanghai Pilotech spray drying machine:

Easy to install. Pilotech spray drying machine adopts the modular design, and only a few parts of the equipment require the manual installation by the user. So the equipment can be easily installed.

Easy to operate. Pilotech spray drying machine features a color touch screen, the PLC control, English operation interface and or customizable language interface. The interface is simplistic in design with the English operation manual, so that you can easily familiarize yourself with each operation step.

Able to dry a variety of materials. Various models of the Pilotech spray drying machine have been designed in order to dry different materials in the laboratory:

1) YC-015 laboratory spray dryer is able to dry most aqueous solutions, and the drying chamber is made of high temperature resistant glass, which makes it easy to observe the whole experiment process;

2) YC-1800 laboratory low temperature spray dryer. It adopts the negative pressure design, with the minimum inlet air temperature of 105 °C and the the minimum outlet air temperature of 60 °C. It is suitable for the spray drying of heat-sensitive materials such as enzyme and sugary materials such as the traditional Chinese medicine extracts. After the drying process, the materials will not stick to the wall, which improves the recovery rate of the materials. YC-1800 laboratory spray dryer can also be equipped with fluidized bed drying function for drying the powder with high moisture content(optional);

3) YC-2000 vacuum spray dryer. Its minimum inlet air temperature is 50 °C, and it is suitable for the spray drying of those materials , which are not heat resistant such as probiotics without inactivation;

4)YC-018 pilot scale spray dryer. Its maximum capacity is 3500ml/h. The inlet air temperature for this model ranges from 110 to 350 °C, the range is relatively wide, and its recovery rate can be as high as 92%.

5) The YC-501, YC-015A and YC-018A inert loop spray dryers. These models can be applied for the spray drying of aqueous solutions and most organic solvent materials;

Low failure rate and long durability. Many users purchased our spray drying machine in 2005 and 2006, and now the equipment is still in normal use, with the drying effect remaining unchanged as if it were newly purchased.

High user satisfaction. We have more than 3,500 users of laboratory spray drying machine to all around the world. A lot of customers have recommended the equipment to our new customers. Tsinghua University, which is the most prestigious university in China, has purchased over 60 spray dryers from us; the Chinese Academy of Sciences, has also purchase over 200 spray dryers from us. Our equipment has been in use by these two clients for years, yet we rarely receive any demand from them for repair. Therefore, many faculty members are willing to recommend our equipment to their colleagues or friends.

Each of our laboratory spray drying machine has undergone rigorous quality tests before delivery, and we dry some standard samples for many times. Shipment is permitted only when the equipment runs stably, so as to ensure that the equipment meets your expectations on the quality and reliability.

We have recorded the operation video for each model of our spray drying machine, which clearly shows the detail of every operation step, so that you can use it well and make the most of it in your researches.

Should you have any further questions, please contact us and we will provide you with the information you need and the best offer as soon as possible.

1.0 Introduction to Pilotech Spray Drying Machine

Many manufacturers who deal with dry products have a hard time looking for a drying machine. But what is spray drying? Drying is the act of removing liquid from solids by evaporation. Many manufacturers dry goods and products for various purposes. Spray drying is a process that allows companies to get a dry powder out from a liquid. So, it helps reduce the transport weight and increase the shelf life of the products they produce.

In the past, spreading products out in open air and letting the sun take over in the drying process did drying. However, with the Innovation of technology, many companies are coming up with different methods and machines to aid in drying products comfortably. One of the devices that have changed product drying is the Pilotech Spray Drying Machine.

2.0 History behind Pilotech Spray Drying Machine

The rise of perfect spray drying equipment and technique took several years from the 1870s to early 1900. First, it was the nozzle atomizer spray dryer before the rotary atomizers came to be several years later. The first dryers did not see much commercial use due to their complicated mode and difficulties in operating in a continuous manner, not until 1920.

In the second decade of the twentieth century, a design that made commercial use practical came to the market with milk drying being the first primary commercial application of the spray dryers. Twenty years down the line, manufacturers came up with different spry driers to dry heat sensitive products, emulsions, and mixtures.

The climax was during World War II when spray dryers were used to reduce transport weight of food and materials to take to several parts of the war fields. The enormous commercial use led to successful innovations and inventions of spray dryers to suit a wide range of products that needed spray drying.

3.0 Working Principle of Pilotech Spray Drying Machine

Like all other spray dryers, Pilotech Spray Drying Machines depend on atomizers or spray nozzles to dispense liquid into a controlled drop size spray.  Also, the type of nose depends on the products to dry and the end particle size. It can be the rotary disc or the single fluid high-pressure swirl nozzle.

The two are common and mostly used because they produce an even particle size from 10 to 500µm after the drying process with a diameter of 100 to 500µm being the common desired one. In some cases, a spray dryer can use an atomizer wheel for more significant particle size results. Alternatively, two-fluid or ultrasonic nozzles can be out to use. The working of the Pilotech takes place in 5 steps, which are:

3.1 Concentration

Concentration is the process of increasing the hard content in the mixture. It helps reduce the amount of liquid that needs evaporation from the product. The feedstock, which is the product to be dried, concentrates before it introduces it in the spray dryer.

3.2 Atomization

A spray dryer works by atomization of the feedstock and bringing in heated air to dry the moister. But what is atomization? Well, atomization is the process of creating an optimum condition that will lead to the evaporation of the moisture and a final product with the desired characteristics. Thus, that is where the nozzle comes to use. A dryer can have one to over 100 nozzles.

3.3 Droplet-air Contact

It happens in the spray dry chamber, which is the core area of a spray dryer. It is where the atomized liquid gets into contact with the hot gas, which usually is air at a vacuum. After that, the introduction leads to evaporation of 95% of moisture in the droplets within seconds. The droplet air contact is a vital process as it influences the drying phase and properties of the final dried product.

The way the droplets get into contact with the hot air depends on the position of the atomizer and the air inlet, in the Pilotech mini dryer, the nozzle header is usually at the top and spray down, so it efficiently dry moisture without hitches.

3.4 Droplet Drying

In the droplet-drying phase, all the moisture in the product evaporates. It usually happens in two steps. In the first phase, the temperature in the saturated air at the surface of the droplet and the wet-bulb temperature of the drying air are equal. Here, evaporation starts taking place by moisture in the drop, replacing the liquid that is evaporating from the surfaces.

The second phase starts when there is no enough moisture to maintain a saturated condition at the surface. That insufficient moisture causes the formation of a dry shell at the surface.

It is good to note that at this phase, evaporation depends on the diffusion of moisture through the shell, which increases in thickness as more shell form.

Unlike the first phase where evaporation is high, the evaporation rate in the second phase drastically falls during the second phase. The dissipation and particle forming characteristics depend on the product that the Pilotech is drying. After evaporation, the end particles can be hollow, sphere, porous, or irregularly shaped.

3.5 Separation

When the whole moisture evaporates, separation marks the end of the drying process. The separation happens by separating the particles of the product from the drying air. There is nothing complex at this stage as the primary separation happens when particles fall at the bottom of the chamber.

To remove remaining particles in the drying air, Pilotech uses specialized equipment. So, it can be a cyclone, bag filters, or electrostatic precipitators. What happens to the air in the spray dryer? All air in the dryer passes through a wet scrubber for purification. After that, it undergoes cooling before releasing it to the atmosphere.

4.0 Advantages of Pilotech Spray Drying Machine

  • The spray dryer has a wide range of use from aseptic pharmaceutical processing to ceramic powder production.
  • The Pilotech mini sprayer is available in any capacity that a manufacturer requires. The feed range can be from a few pounds to over 100 tons per hour
  • It produces the same powder quality during the entire process of drying.
  • The spray dryer runs continuous and can be adaptable to full automatic control.
  • Pilotech Spray Drying Machines are available for different product types.
  • Also, It is available for use in both heat resistant and sensitive products
  • Moreover, it can dry abrasive, corrosive, flammable, explosive, or toxic feedstock in the form of a solution, slurry, paste, gel, suspension or melt type for as long as it is pumpable
  • It produces particles with uniform characteristics
  • There is no contact of the feedstock and the metal surfaces until it is dry, so there is no worry of corrosion.

5.0 Pilotech Spray Drying Machine Buyer’s Guide

As a manufacturer looking forward to buying a Pilotech dryer, how do you find one that suits your purpose? What do you look at in a sprat dryer? There are many products available and finding the right one depends on many things. Here is a guide for you to find the right Pilotech Spray Drying Machine.

5.1 Why Consider Pilotech Spray Drying Machine?

Pilotech manufacturing company has been producing laboratory spray dryer since 2005. The company has grown and become accessible to the point of having 50 patents and over 15-software copyright. Do you know it is the only leading manufacturer in the world that can produce a wide range of spray dryers? Yes! They are the best in making benchtop, vacuum, spray freezing, all in one machine, fluidized granulator, organic solvent, and Nano spray dryers.

But, why go for the Pilotech Spray Drying Machine? Not only is the dryer efficient, cost-friendly, and stable in performance, Pilotech makes spray dryers that are easy to operate, durable, and sustainable. That is why many manufacturers and researchers are going for their products. The following are top reasons why Pilotech Spray Drying Machine is the best:

  • It is a simple and effective lab spray dryer used for product research and development
  • Moreover, there is quality assurance. With over 20 years of continuous research, the quality and reliability of the spray dryer remain to be the best in the industry.
  • From bench to pilot spray dryers, you get a wide variety of dryers to use to dry aqueous solution to organic solvents. The spray dryer is perfect for any commercial use.
  • The Pilotech Spray Drying Machine has outstanding qualities.

5.2 Pilotech Spray Drying Machine Applications

The Pilotech dryer has many applications. Before a manufacturer settles on one, it is good to learn the various ways in which they can use the spray dryer. The following are the diverse use of Pilotech Spray Drying Machine:

Chemical industry

There is an increase in the use of the sprat dryer in the chemical industry. That is because synthetics have become popular in the industry to make plastic. The spray dry suits perfectly in two ways:

  • The emulsion polymerization (E-PVC), where nozzle or rotatory is the only practical way of drying.
  • Suspension polymerization(S-PVC) drying happens in drum dryers, flash/fluid bed dryers, or in dry spray dryers.

In both, the type of atomizer to use usually differs. Melamine, urea-formaldehyde, SBR, and ABS resin use rotary atomizers while polycarbonate resins use atomizers with nozzles.

Ceramic materials

Ceramic manufacturers use spray dryers to make free-flowing ceramic powders that are suitable for pressing and sintering. That is because the spray dryers produce a powder that has even particles for ease when working. Also, the spray dryers used in this field use the rotary atomizers or nozzles, which produces coarse particles.

Detergents, soaps, and surface-active agents

Most people don’t know that washing powders manufacturers are the one that uses spray-drying technology the most. That is because for them to come up with high bulk density detergents, they must use counter-current dryers with nozzle atomization.

The most common dryers used in the detergent making are open cycle dryers, but at times, the self-insert zing designs are suitable to use. When a manufacturer wants to produce lo bulk density detergents, they use co-current dryers.

Pesticides, herbicides, fungicides, and insecticides

The type of spray dry to use in pesticides depends on its nature. So, a manufacturer can use open, semi-closed, or closed cycle dryers. Closed cycles dry toxic pesticides to reduce the risk of intoxication of people around it. Spray dryers for herbicides, fungicide, and insecticides usually uses the rotary atomizers.

Organic chemicals

Do you know manufacturers usually dry cement slurries before the calcining process? The drying process uses spray dryers with either rotary atomizers or pressure nozzles.

Fertilizer

When it comes to fertilizer making, spray cooling is an essential step in the production of ammonium nitrate. That is where the application of spray drying comes into play. It is where a concentrated solution will atomize with the help of a pressure nozzle located at the top of a tower to circulate cold air.

Milk products

As mentioned earlier, milk production saw the use of spray dryers first. With a large volume of products to dry every day, it is the largest spray user in food processing. Also, milk manufacturers who make skim, whole, and fat-enriched milk require drying now and then.

Milk products that also need drying include – infant formula, buttermilk, cream, butter, flavored milk, casein, whey,  whey protein, acid whey, sweet whey, demineralized whey,  cheese, etc.

5.3 Main Components of Pilotech Mini Sprayer Dryer

How do you understand a Pilotech Spray Drying Machine and its components? It is simple and easy to use. That is because every element has its purpose in the drying process. The following are the components that make the spray dryer:

  • Drying chamber
  • Feed supply system where you introduce a product to dry
  • Atomizing device
  • Powder/ fine recovering tool
  • Fine return system

5.4 Inspecting Pilotech Spray Drying Machine

Manufacturers don’t just look at the components hen buying a sprayer. It is also essential to conduct a Spray Dryer Crack Testing & inspection. The test is vital to ensure the spray dry process meets the highest standards during operation in and around the plant. Manufacturers need to have routine examinations and crack testing of spray dryers, cyclones, fluid beds, and bag filters to make sure the drying process takes place swiftly.

6.0 Pilotech Mini Sprayers Models

Pilotech is an expert in making the Spray Drying Machines. Depending on the products you want to dry, there are several designs to suit your needs. The following are some of the models available in the market:

6.1 Pilot Scale Spray Dryer YC-018

This spray dryer is suitable for many commercial uses since it is relatively ide. It has a capacity of processing 3500ml of a product per hour. If a manufacturer requires drying fewer products for one experiment, it can handle at least 100ml material. That makes it suitable for laboratory and pilot plant uses.

The Pilotech YC-018 lab spray dryer has an inlet air temperature of 110 to 350°C and produces particles with sizes ranging from 1-100µm hence excellent for drying ceramic and catalysts.

6.2 Inert Loop Spray Drying Machine YC-501

This spray dryer, which is capable of drying 500ml of feed per hour is suitable for manufacturers working with organic solvents and have a small working space. That is because it is small and occupies less than one square meter of the surface in use. It is easy to operate, as it is a split. What does split type mean?

It means that the spray dryer is into two parts. It has the spray dryer main machine section and the inert loop system with the main machine drying products of an aqueous solution after connection to the nitrogen circulation system.

6.3 Spray Drying Machine YC-015A for Solvents

As the name of dryer implies, it is suitable for quick and safe moisture removal of organic solvents and aqueous solutions. It is safe to use because it has an inbuilt oxygen monitoring system to ensure the oxygen level is according to the preset standards when it is operating. With a capacity to dry 1500ml of product per hour, it can also go as low as 50ml to dry the outcome of one experiment.

6.4 Pilotech Inert Loop Spray Drying Machine YC-018A

What makes it the best is the capacity it can handle and the recovery rate. The spray, which is suitable for drying most aqueous solutions and an organic solvent in laboratory and pilot plant, is capable of drying 4000ml/hour and can handle as low as 100ml for one experiment. Thus, the result out of the YC-018A spray dryer is 92 % full and has high sphericity and mobility.

6.5 vacuum Spray Drying Machine YC-2000

The dryer works by introducing a vacuum system into the spray drying process to reduce the inlet, which is 50°C and outlet temperatures. It has a processing capacity of 1500 per hour though there are same spray dryers available with a capacity of 500 and 3500 ml per hour. Also, they are suitable to use in drying high polymer materials that are not heat resistant.

6.6 Low-Temperature Spray Drying Machine YC-1800

The YC-1800 is ideal for drying heat-sensitive products such as enzymes and sugary products. That is because the minimum inlet and outlet temperate are low enough to accommodate a heat-sensitive material. The drying chamber made of high-temperature resistant glass and SUSU304 stainless steel that makes it durable easy to use and observe while drying and also end-product does not stick on it.

6.7 Spray Drying Machine YC-015 with Glass Chamber

The Pilotech YC-015 comprises of an inbuilt air and storage compressor that is of SUS304 stainless steel. Since the drying chamber, cyclone separator, collection bottle, and collection tube are of high-temperature resistant glass, it is suitable for high-temperature-resistant products, and an operator quickly observes the whole drying process. It has a capacity of 1500ml per hour though it can hold as low as 30ml.

6.8 Benchtop Spray Dryer YC-500

It is a small laboratory spray dryer that can upgrade to an organic spray dryer by adding an inert loop system or downgrade to a vacuum low-temperature spray dryer with a vacuum system. That is because the maximum inlet temperature is 250°C, while the minim is 130°C, with the minimum outlet temperature being 60°C. The YC-500 has a capacity of 500ml per hour though it can hold as low as 20ml.

7.0 Pilotech Spray Drying Machines- FAQs

7.1 Is there a possibility to spray with organic solvents?

Yes, it is possible. With Pilotech YC-018, YC-501, or YC-015A, it is possible to spray and dry organic solvents without the risk of explosion because the model designs work under inert conditions.

7.2 How do you control the outlet temperatures?

The outlet temperatures increase or decrease due to changes in inlet temperatures, sample feed rate, and concentration, and aspirator rate. If you want to change the heat, you have to change one of the above parameters.

7.3 How is the stability and endurance of Pilotech products?

The company has been around for 20 years, with many colleges and universities using Pilotech products. The first products bought by customers are still in use, meaning they are durable. We have a good reputation, that is why many old customers recommend new once to come and buy due to the products’ excellent performance and stability.

7.4 What is the main difference between spray dryers for water and solvents?

The difference is the operating temperatures. The solvent one requires a high temperature than the spray dryer for water.

7.5 How to order Pilotech Spray Drying Machine

Acquiring one of the Spray Drying Machines from Pilotech is simple. Visit the company website www.shpilotech.com and place your order after looking at the various products. After that, a representative in charge will quickly get back to you to make sure your order reaches you as per your specifications.

7.6 Can I come to the factory to test Pilotech Spray Drying Machine?

Yes, you can do a factory visit and have a Pilotech Spray Drying Machine test. To arrange your tour, contact our able support team and book a date and time for your visit.

7.7 What is the highest possible viscosity of a sample?

The viscosity of a fluid is a measure of its resistance to deformation at a specific rate. Also, when it comes to a spray dryer, it depends on the peristaltic pump. The sample has to be pumpable, which is possible with a viscosity of up to 300cps.

8.0 Pilotech Spray Drying Machine- Final Thought

Finding Pilotech products is easy. A simple search on papers and google scholar lands you to different Pilotech products in the market. Moreover, the Spray Drying Machine is simple to start and operate as one operator can run it. As a plus, every product from Pilotech comes with a one-year warranty. It means the company provides free repairs to non-human damages for the first year after buying. Contact us through our website and place your order!

Spray Drying Machine: The Ultimate FAQ Guide

I know you’re probably looking for highly efficient, and durable spray drying machine.

Or, you want to learn everything about spray drying technology.

Whichever the case, today’s guide explains everything you need to know about spray drying machines and technology.

So, if you want to be an expert in spray drying equipment, this is the right guide for you.

What is Spray Drying?

This is a technique of passing hot gas through a slurry to form a dry powder.

Spray drying is a convenient method of producing pharmaceutical and food products.

It is suitable for products that cannot withstand direct heating.

 Spray drying process

Spray drying process

What is a Spray Drying Machine?

A spray drying machine is equipment that converts liquid concentrates into different powder forms.

This is by drying the liquid using heated air.

It is a common machine in various applications, such as in the food and pharmaceutical industries.

2 Low temperature spray drying machine

 Low-temperature spray drying machine

What are the Benefits of Spray Dryer?

Using a spray dryer offers the following benefits:

Increases Bioavailability

a spray dryer allows for the mixing of two individual components into one.

This is practical in the medical industry, where you can mix two drug elements to improve your medicine taste.

Aseptic Production

Spray drying minimizes harmful bacteria in your products, making them safe for human consumption.

This has the effect of improving the usage of your products.

You, therefore, don’t have to worry about the expiry of your product.

This reduces losses within your business.

Reduces Cost

The use of spray drying reduces the overall cost of handling your products.

Such costs include transportation and storage costs.

What are the Limitations of Spray Drying Machine?

You will experience a few limitations when using a spray drying machine.

These limitations include:

· Cost

The initial purchasing cost of this machine are relatively high compared to other drying methods.

This requires you to budget properly before purchasing your spray drying machine.

· Product Limitations

There is a limit as to the kind of products you can dry using this machine.

You cannot use this machine to dry solid products.

This means you have to look for an alternative source of drying your solid products, which may be costly.

· Fire Hazard

There is a need to operate your spray drying machine in a secure place.

This is due to the halogen gas that dries your products, which can easily catch fire.

Ire occurrence can result in losses to your business.

· Heat and Energy Loss

The thermal efficiency of this machine is low.

This implies you have to spend an of heat and energy to dry a given quantity of products.

This is in contrast to other drying techniques.

The higher the energy and heat you use translate to higher power bills and an increase in your products’ selling price.

What is Spray Drying Process?

A spray drying process refers to the conversion of a fluid product into a solid.

This is by converting the fluid through several stages that remove the fluid part and retains the liquid part.

The key stages that a complete spray drying process goes through are:

  • Atomization
  • Spray-air mixing and evaporation of moisture
  • Separation of the dry product

3 Inert loop spray dryer

Inert loop spray dryer

Does Spray Drying Kill Bacteria?

Spray drying greatly reduces the number of bacteria present in your products.

However, it does not eliminate these bacteria.

This increases the risk of destroying your products and causing human poisoning.

Is Spray Drying Process Safe?

Spray drying is a safe process if you carry it out in an enclosure.

You need to ensure there is no leakage, especially in the spray nozzle area.

The evaporation procedure creates powder, which can be a fire hazard hence putting your facility at risk.

How does Spray Drying compare to Freeze Drying?

Freeze-drying is a process of preserving perishable products, while Spray drying is a process of preserving manufactured products.

 Freeze dryer

Freeze dryer

Freeze-drying involves reducing the temperature of the product beyond the freezing point, reducing its pressure and heating.

The purpose of heating is to sublimate the freezing water.

Dry spraying involves passing hot gas through a slurry to form a dry powder.

It is a convenient method of producing pharmaceutical and food products that are thermally sensitive.

Freeze drying has three phases, freezing, sublimation, and adsorption phases.

The phases of dry spraying are atomization, spray-air mixing, evaporation of moisture, and separation of the dry product.

Why do you need Spray Drying Machine in Food Industry?

There are several reasons why you need a spray drying machine in the food industry, including:

· Reduces Bacteria

The spray drying process reduces the bacteria present in food, some of which are harmful for human consumption.

This ensures the production of quality and healthy foods.

· Extends the Shelf Life of Products

The action of minimizing the number of bacteria in products helps in extending their lifespan.

This is because of the removal of certain bacteria that are responsible for the decay of products.

This is important, especially in perishable foods or those whose transportation to the market takes long.

· Food Modification

Spray drying helps in improving the taste of certain foods, such as confectioneries.

You, therefore, have different tastes on one product.

This process also helps in improving the appearance of certain products by giving them an appealing color.

How can Spray Drying Machine Increase Particle Size

Your spray drying machine can increase the powder particle size by letting the inlet operate at a low temperature.

You can alternatively lower the humidity level of the outlet.

This increases the particle size while lowering the quantity of powder that you have to recycle.

Particle formation during spray drying

 Particle formation during spray drying

What is Spray Drying used for?

The main purpose of spray drying is to minimize the bacteria and to remove fluid present in products.

This has an effect of increasing the lifespan of your products.

Spray drying can also serve the purpose of enhancing the appearance and taste of your product.

This is by Spray the product with different enhancements of your specifications.

What determines Spray Drying Machine Price?

Among the various factors that affect the price of your spray drying machine includes:

· Type of Spray Drying Machine

A spray drying machine is available in two types: a single effect and multiple effect spray drying machine.

Each of these types has its unique characteristics that you can select.

However, a multiple effect dry spray machine is expensive compared to a single effect spray drying machine.

This is due to the superior features that they have.

· Size and Drying Capacity

When you are purchasing a spray drying machine, you have to consider its drying capacity.

The one you select should meet your production capacity and also e of the right size to install on your space.

However, you need to note that the different sizes and drying capacity cost differently.

· Manufacturer

Different manufacturers prize their spray drying machine differently depending on various factors.

It is up to you to check for an ideal price from a particular manufacturer before buying.

However, you have to check on various factors in a particular manufacturer before choosing them.

Some of these factors include quality standards and the after-sale service that they offer.

Which Types of Feed can you Introduce in Spray Dryer Machine?

The main type of feed you can introduce in a spray dryer machine is a liquid food concentration.

This allows for proper spray drying resulting in a quality product.

Liquid concentrate is the best due to the drying process that requires heated air to mix with the product.

Ceramic spray dryer

Ceramic spray dryer

What are the Parts of Spray Drying Machine?

A spray drying machine consists of the following critical parts:

Parts of spray dryer machine

Parts of spray dryer machine

Pressure Pump

The function of the pressure pump is to introduce the liquid concentrate into the drying chamber.

Feeder

It is here that you place your liquid food concentrate.

This allows for the flow of the fluid down the drying chamber.

The feeder can take either a conical or a cylindrical shape.

Spray Nozzle

A spray nozzle plays a critical role in spraying the liquid concentrate with a heated gas.

There are several spray nozzles in the drying chamber read to dry spray your product.

Heat Source

The heat source is responsible for heating the air necessary for drying your product.

Different heat sources are depending on the design of your machine.

For instance, you can have electricity, natural gas, methane, or ethanol as your heat source.

Each of these heat sources has unique characteristics and benefits for your machine and the final product

However, you need to avoid the use of natural gases since it easily contaminates your products.

Ethanol is highly combustible; this means you have to use it in an enclosed environment and take necessary precautions when using it.

Heat Exchanger/Cooler

Air escaping via the outlet is still hot, affecting the environment by releasing it that way.

Therefore, you have to cool it down or have a way through which you can recycle the heat.

A heat exchanger helps in transferring the heat from the hot air to the cold air.

Having a heat exchanger is economical since you save on the cost of heating the air.

You have a cooler in some types, which reduces the air temperature before releasing it to the environment.

Collection Vessel

There are two types of collection vessels present in a dry spray machine.

The first is for collecting the powder after the drying process.

This is usually on the lower side of your spray drying machine.

The second collection vessel is next to the drying chamber.

The function of this is to collect fine powder and direct them back for recycling.

Drying Chamber

This is where the actual drying process takes place.

It consists of a series of spray nozzles that forces heated air to ooze out, drying your products.

How does Spray Dryer Machine Work?

The working principle of a spray dryer machine involves the following steps:

Heating of Air

This is the initial step that involves the use of heat exchangers.

Heating of air takes place at a temperature of around 175-degree Celsius and a pressure range of 9 bars.

The hot air is a result of heating either methane or ethanol.

You can also heat oil to obtain hot gas.

Other methods of heating air include electric heating and natural gas.

However, you need to avoid using natural gas for heating air since it contaminates the powder.

Concentrated Air Atomization

This step uses a spinning disk to atomize the liquid.

As the disk spins, the liquid exits it horizontally and radially, heading into the drying chamber.

The drying chamber features a wide enclosure that minimizes from reaching the chamber walls causing fouling.

Recent development involves the use of spray nozzles to minimize this occurrence.

These nozzles are along with the chamber, making the droplets flow in a downward manner.

You will find an air inlet at the middle of the nozzles and has its opening facing downward.

The diameter of the drying chamber is usually small but with a large height.

This ensures there is a maximum spraying process.

The drying chamber’s design is such that there is no mixing of the droplets and air within it.

This produces tiny droplets which dry quickly using either the pressure nozzle or the spinning disk.

Mixing of Atomized Liquid and Hot Air

This is where drying takes place.

Liquid and airflow to the drying chamber simultaneously, and mixing takes place.

The air cools rapidly, thereby drying your liquid.

The drying process is within the outlet’s temperature, while the air inlet is higher.

This results in the drying air spinning downwards in a spiral motion.

Separation of Drying Air and Powder

This process takes place within cyclones.

As the air rotates strongly, the lower part of the drying chamber creates a cyclone from the powder’s discharging.

Once the discharge of the powder is complete, cooling takes place before packaging.

Tiny size powder flow back to the drier, which is around the atomization region.

The next process involves cleaning the cool air before releasing it into the environment.

This is to minimize air pollution.

The cleaning process takes place through bag-shaped filters or via a wet washing process.

Wet washing involves passing the air through the water spray.

Air flowing via the outlet is still hot.

In certain types, you can have a heat exchanger between the outlet and the inlet.

This reduces the cost of heating the air while releasing safe air to the atmosphere.

Powder Particle Aggregation

The fine powder from the separation process needs to aggregate.

This is through nozzle spraying or recycling the powder where there is still liquid.

You can also rewet the fluid bed for the aggregation process to take place.

The aggregation process causes the collision of the sticky particles.

Are there Drying Systems that you can use as an Alternative to Spray Drying Machine?

Yes. There are alternatives to dry spraying machine that you can use to dry your products.

They include:

Freeze Dryer Machine

This is a type of machine that dries your products by reducing its temperature below the freezing point.

Once you freeze the product, you remove the ice through sublimation.

It is an expensive method compared to other methods.

Drum Dryer Machine

This is a cheaper option for drying your products compared to other methods.

You can conveniently use it for drying low-value products.

The final product is in the form of flakes.

Pulse Combustion Dryer Machine

This is the best method to use if you have high viscosity and solid products.

The results are a free-flowing freeze-dry powder.

Common applications of this method are in industrial waste drying.

How does Spray Dryer Machine compare to Fluid Bed Dryer Machine?

Fluid bed dryer

Fluid bed dryer

Both machines function by removing moisture content in products.

However, a spray dryer machine deals with liquid substance while a fluid bed dryer machine deals with solid products.

A spray dryer machine functions by letting the liquid concentrate flow in a drying chamber where it comes into contact with pressurized hot.

In a fluid bed dryer machine, the working involves introducing pressurized air via a perforated bed.

The bed consists of moist solid particles.

What Materials can you Dry in Spray Dryer Machine?

A spray dryer machine is an effective method of drying thermally sensitive products.

Such products include foods and pharmaceutical products.

Types of foods you can dry using this method include coffee, milk, flavoring, cereals, and spices.

You can spray dry pharmaceutical products such as additives, antibiotics, and medical ingredients.

These products need to be in a concentrated solution before Spray drying them.

What is a Single Effect Spray Dryer Machine?

This type of machine has one spraying point that is on the top part of the drying chamber.

It is a cheaper type of spray drying machine though it has its limitations.

For instance, the drying process is longer, resulting in a poor flow and dusty powder.

How does Multiple Effect Spray Dryer Machine compare to a Single Effect Spray Drying Machine?

Both types of machines allow for the effective drying of different products.

The main difference between a multiple effect spray dryer machine and a single effect spray dryer is the drying point.

A single effect spray dryer has one point of drying air on the topmost part of the drying chamber.

A multiple effect spray drying machine has two stages.

Where the liquid dries on the topmost part and the other one along the integrated static bed, which on the lower part of the chamber.

The powder in a single effect drying machine has a poor flow and is dusty compared to multiple drying machines.

A multiple drying machine allows for recycling the fine powder while a single drying machine does not.

How do you Increase the Efficiency of a Spray Drying Machine?

There are various ways you can use to increase the efficiency of a spray drying machine.

For instance, you need to control the outlet air temperature.

This temperature needs to be higher compared to that of your inlet.

You can achieve this by changing the feed flow rate and changing the inlet’s temperature.

What are the Applications of Spray Dryer Machine?

You can use a spray dryer machine in various applications, which includes:

· Food Industries

A spray dryer machine plays a vital role in drying various food products such as milk, coffee, and eggs.

A spray dryer extends the lifespan of these products by drying them.

The cost of transporting dry powder is less compared to the actual product.

This reduces the transportation cost

In certain cases, the application of spray drying enhances the taste and color appearance of different products.

This translates to increased sales and improved profit margins.

· Pharmaceutical Industry

The use of spray drying in the pharmaceutical industry is to enhance the taste of certain drugs. This makes it easy to use by patients.

It is alps useful in injection drugs, which have to be in powder form.

This reduces their weight and extends their shelf life.

· Industrial Usage

Industrial working requires the use of a spray dryer to reduce the weight of certain chemicals.

Common industries that use this machine include paint manufacturing and ceramic material industries.

This machine is also useful in waste treatment for separating waste and liquid.

This process allows for the recycling of liquid and using the waste in manufacturing manure.

How can Spray Dryer Increase Business Profitability?

 Vacuum spray dryer

Vacuum spray dryer

· Product Lifespan

Spray dryer minimizes the number of bacteria present in your products.

Bacteria are responsible for the decomposition of different products.

By reducing bacteria, you extend the lifespan of your products. This reduces wastage due to disposal.

· Enhances Taste

Spray dryer enhances the taste of different products through encapsulation.

This is critical in the production of certain drugs and confectioneries.

This increases sales, which translates to higher profits.

· Reduces Cost

A spray dryer reduces the transportation cost of your products.

This is by converting them to powder form.

How can you Test Spray Dryer?

You need to subject your spray dryer to various tests to ascertain their quality.

These tests include:

  • Factory Acceptance Tests (FAT)
  • Visual inspection test
  • Initializing test

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

The main quality standards that you need to check in an effective spray dryer machine are:

  • ISO standards
  • GMP standards
  • RoHS
  • FDA standards
  • International Conference on Harmonization (ICH) standards

Which Features should you Consider when Buying Spray Dryer Machine?

You need to consider the following factors when purchasing your spray dryer machine:

Organic solvent spray dryer

Organic solvent spray dryer

· Drying Capacity and Size

The drying capacity dictates the volume of output you are going to produce.

Having the right one maximizes your production, which translates to higher sales.

Therefore, you need to check on the drying capacity and select one that suits your requirements.

The size you select should fit the installation space.

While considering the size, you need to leave a space for maintenance purposes.

That is, one can maneuver easily during maintenance.

· Type of Dry Spray Machines

There are two types of dry spraying machines available in the market: a single effect dry and multiple effects dry spraying machine.

Each of these types has unique performance characteristics that you can consider.

However, multiple effect dry spraying machine has superior qualities.

This makes their price higher compared to the single effect dry spraying machine.

It is important to select the type of machine that fits your requirements.

· Power Output

Power output is essential in helping you balance the energy requirement of your production unit.

This is to avoid inconsistent drying performance and also facilitate the working of other machines in your factory.

The ideal power output for your spring drying machine should not exceed the total output of your entire factory.

· Ease of Maintenance

It is important to consider how easy it is to maintain your spray dryer machine before purchasing it.

This is in terms of sourcing for spare parts and skilled personnel to do that.

You can avoid this by ensuring you purchase your spray drying machine from a reputable manufacturer.

Such fabricators usually have spare parts for your machine, and you can consult them when carrying out the maintenance.

· Quality Standards

Checking on the quality standards assures you that a particular dry spraying machine function effectively.

An easy way of getting a machine that certifies all the quality standards is purchasing it from a reliable manufacturer.

· Cost

You should be able to purchase the dry spraying machine you select.

These machines costs differently depending on various factors, such as manufacturer and type.

However, you should consider cost alongside the other factors.

This is because a cheaper machine tends to be of low quality compared to an expensive one.

What are the Common Problems with Spray Drying Machine?

There are several problems you will experience when using your spray dryer machine.

Such problems include:

· Powder Inconsistency and Low-quality Powder

Powder build-up is the main cause of this problem. The build-up is a result of the wrong dryer configuration.

It may also be due to using wide spray angles or having a problem with the nozzle design.

Over time, the build-up deposits on the drying chamber affecting the quality of the powder.

· Low Production

Nozzle bearding may be the cause of this problem—bearding results from improper dryer configuration.

This has the effect of increasing the frequency of cleaning the machine resulting in increased machine downtime.

· High Production Cost

The cause of an increase in the production cost is having a challenge disassembling the nozzles.

Also, the use of impact tools like hammers only increases the damage and wearing of the parts.

This has the effect of increasing the replacement cost.

· Low Hygiene Standards

Hygiene is vital in the working of your spray drying machine.

The main causing of reduced cleaning standards is having difficulties cleaning the inner parts of your machine.

Such areas include corners and around the caps.

· Safety Problems

Safety problems affect those operating your machine.

The cause of this is having non-functional parts and failure to tighten the bolts and nuts.

What Process Layout can you have for Spray Drying Machine?

You can have a different process layout for your spray drying machine, depending on your factory layout.

However, the common layouts available are:

  • Open mode layout
  • Closed cycle layout
  • Two-stages layout
  • Semi-closed layout
  • Combination layout

How do you Control Spray Drying Process?

There are various ways you can control the spray drying process.

For instance, you can alter the feed rate or change the temperature of the inlet.

Doing this increases the temperature of the air outlet, thereby changing the size of the powder particle.

Alternatively, you can increase the atomizing pressure while minimizing the viscosity.

This causes the powder particles to dry faster.

How do you Maintain Spray Dryer Machine?

Proper maintenance of your spray dryer machine is by cleaning it frequently.

You also need to check on the different parts and ensure they are in the right condition.

You also have to lubricate all the moving parts to minimize wear and tear on your machine.

Why Atomization Important in Spray Drying Process?

Atomization is important in spray drying since it allows for converting the liquid substrate into a fine powder.

This is by separating the liquid from the substrate and leaving tiny droplets.

What Determines Residence Time within the Drying Chamber?

The concentration of the substrate determines the residence time within the drying chamber.

A highly concentrated substrate takes longer compared to less concentration.

Which Types of Atomizers can you use in Spray Drying Machine?

The common types of atomizers that you can find in a spray drying machine are:

  • Wheel/Centrifugal atomizers. This method uses a rotating wheel or disc to break the concentrate into tiny droplets.
  • Two-fluid/Pneumatic atomizers. In this type, the interaction is between two fluids, which is a liquid and compressed air.
  • Sonic atomization. This type uses ultrasonic energy to vibrate the liquid as it passes over the surface. It is an ideal method for producing fine powder particles.
  • Nozzle atomization. This type uses pressurized fluid via a pump to break the concentrate into tiny droplets.

With the information in this guide, am sure you can definitely choose the best spray drying machine.

At Pilotech, we have a range of spray drying equipment, depending on the specific needs of your material processing needs.

Our spray drying machines range from lab spray dryers to mini spray dryers, with different capabilities.

Contact us now for a complete catalogue of our spray drying machines.

Send Inquiry Now!

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