Vacuum Belt Dryer Series
- 20 years experience in Vacuum Belt Dryer(VBD)；
- Has a professional technical R&D team,specialized in researching and developing advanced Vacuum Belt Dryer(VBD)；
- Many patents for Vacuum Belt Dryer(VBD)；
- Over 500 sets Vacuum Belt Dryer(VBD) around the world；
- GMP standards；
Pilotech Vacuum Belt Dryer Series
Compared with other types of dryers, Shanghai Pilotech’s vacuum belt dryer has low drying temperature and low energy consumption, which is 1/3 of the energy consumption of spray dryer. It is suitable for high-viscosity materials, and the dried materials have good fluidity and solubility.
|Vacuum Belt Dryer Model||Diameter|
|Heating Exchange Area||Heating Temperature|
|Moisture Content Of Feeding Material||Moisture Content Of Dried Product||Heating Resource||Water Evaporation|
|Steam or Hot water or|
Pilotech Vacuum Belt Dryer Series
- Realize continuous feeding and continuous discharging under vacuum condition;
- Complete drying and crushing under vacuum condition;
- It can dry high-viscosity materials such as Chinese herbal medicine extract, etc.;
- Start discharging in 30-60 minutes, and the powder discharging rate is 99%;
- Heat sensitive materials will not be deformed;
- Low operating cost, the cost is 1/3 of the cost of spray drying;
- It can be equipped with online CIP system, in line with GMP specifications.
The vacuum belt type continuous dryer has solved the problems which exists in the traditional Chinese medicine industry for a long time: many extracts are difficult to dry, the spray drying temperature is too high and the heat sensitive substances are easily destroyed. The vacuum oven has a long drying time, high energy consumption and intermittent operation. It is easy to contaminate bacteria and absorb moisture, and cannot meet GMP quality standards.
The successful development of the vacuum belt dryer has played a very active role in promoting the drying problems in the industries of traditional Chinese medicine, pharmaceutical intermediates, fine chemicals, food and health products, and is the best product to replace spray drying and vacuum oven drying. Such as traditional Chinese medicine industry: Salvia miltiorrhiza, compound salvia miltiorrhiza, Chuanxiong, Angelica, Andrographis paniculata, Ganoderma lucidum, Sophora flavescens, ginseng, Acanthopanax senticosus, etc.; food and health products industry: coffee, malted milk extract, fruit treasure, instant milk powder, instant tea, etc.;
It has very good application effects to fine chemicals, pigments, pesticides and other industries.
The vacuum belt dryer not only has low drying temperature and continuous production, and also has small loss, less waste and easy operation in the drying process. The most important thing is to reduce labor intensity and save a lot of energy. Compared with vacuum drying ovens of the same output, it can save 65% electricity consumption, 70% steam saving. It can save 75% electricity and 85% steam compared with spray dryers of the same output.
- Vacuum Belt Dryer Principle
The material to be dried is fed into the vacuum chamber of the dryer through a screw metering pump, and is uniformly shoaled on the conveyor belt by the cloth motor. A special roller drive conveyor belt driven by a motor and runs at a set speed. There are independent heating plates and a set of cooling plates under the conveyor belt. The conveyor belt is closely attached to the heating plates and cooling plates, and transfers the heat required for drying to the materials and cooling by contact heat transfer. Set the operating speed of the conveyor belt according to the nature of the material. When the material is transported by the conveyor belt from one end of the cylinder to the other, the material has been dried and cooled. When the conveyor belt is folded back, the dried material cake is peeled off from the conveyor belt. After being pulverized by the pulverizing device, it is discharged through the butterfly valve. The obtained particles can be directly made into capsules or tablets.
The whole equipment adopts PLC control. Operate the equipment through the man-machine interface of the PC. Set up a touch screen operation panel near the dryer and configure a graphical interface, which can display various process parameters, production data and other parameters, which can be modified and adjusted in real time.
- Schematic Diagram of Vacuum Belt Dryer Structure
- Technical Characteristics of Vacuum Belt Dryer
（1）Low drying temperature, low energy consumption, no pollution, continuous production, automatic control, meeting GMP requirements;
（2）Drying at low temperature, and can be adjusted according to different materials (35℃-90℃);
（3）The product has a certain degree of crystallization during the drying process. After crushing, the pellets have good fluidity and can be directly filled into capsules.；
（4）The feeding speed can be adjusted accurately, even when the feeding amount is small, the distributing device can distribute evenly；
（5） Each conveyor belt in the box is individually controlled by a frequency conversion motor；
（6）Automatic granulation, continuous discharge of dry particles into the storage tank under vacuum, the storage tank for dry particles can be replaced during the automatic drying process；
（7）Low energy consumption and low noise；
（8） The movement of the conveyor belt is controlled by a frequency conversion speed motor, with correction and tension adjustment functions；
（9）The preparation tank is equipped with a stirring device and a constant temperature device, which can be heated and mixed when adding auxiliary materials；
（10）PC-based control system, friendly man-machine interface, convenient operation, flexible modification of process parameters；
（11）The conveyor belt has a variety of specifications from 1 to 10 layers, customized according to user requirements.
Note: The equipment can be customized according to customer requirements and product characteristics.
Vacuum Belt Dryer Guide
Over the years, Vacuum Belt Dryers (VBDs) have gained popularity, thanks to their ingenious technology that effectively dries a wide range of liquid and paste materials. Unlike the traditional dryers, VBDs makes it possible to dry thermal-sensitive products (easily destroyed by high temperatures) and high-viscosity raw materials. The viscosity of a liquid corresponds with the concept of “thickness.”
We’ve discussed all you need to know about Vacuum BeltDryers – from its range of application, production process to its market selection techniques.
How a Vacuum Belt Dryer Works
A VBD is a continuous and automated in-feed (liquid & paste) and discharge drying equipment that uses a vacuum to control the drying process. Using a high vacuum, the raw materials’ boiling point (temperatures) reduces, and the moisture sublimes to gas directly.
An infeed pump conveys liquid products into the dryer body. Belts move the heating plates evenly, and this is critical for getting quality end products. What follows is a continuous process –evaporation of moisture, drying, cooling to discharging. All these happen at controlled temperatures, typically decreasing from one cycle to the next.
A vacuum crusher equipment turns the solid raw material into powder or granules of varying sizes (depending on the required specifications and use).
VBD Range of Application
A Vacuum belt dryer finds its application in a wide range of industries – especially for products that are difficult to dry and process using the traditional dryer techniques. These include, but are not limited to: conventional and western pharmaceutical products, biological products, food, health foods, chemicals, and food additives, etc. We’ve highlighted each of these below.
VBDs are used to produce food products such as malt extract, tea powder, corn paste, instant beverage, and cocoa powder. The fineness of the powder and the granules’ size for food products such as coffee can be controlled using specific crusher equipment. Other food products include: Rice protein powder, hops extract, wheat essence, vegetable juice concentrate, meat extracts, chocolate products, instant soup, etc.
Pharma products such as Chinese medicine extracts, embryos, plant extracts, and PVPK products are primarily produced using Vacuum Belt Dryers. Before VBDs came into the market, producing traditional Chinese medicine was a headache. Most of these extracts are difficult to dry while some are thermal-sensitive and should be handled properly to avoid losing their medicinal properties. Other pharma products processed using VBDs are vitamins, fermentation broth, antibiotics, and active medicinal substances, etc.
VBDs are also used to produce chemical products such as emamectin benzoate (an insecticide used in pest control) and the lithium battery used in a wide range of electronic products.
Laboratory VBD applications
Several organizations, learning institutions, and research companies use vacuum belt dryers in their Research and Development needs. Their specific applications often vary based on the type of research and the elements they are using to conduct the study – could be food, chemicals, or pharmaceutical products.
The Step by Step VBD Drying Process
A vacuum dryer is designed more like an industrial boiler or a horizontal silo, with synthetic mesh-like belts on the inside. Depending on the design, the dryer belts sit on hot water or steam-heated elements. All the parts used, from the vacuum chamber to the conveyor belt, are food-grade.
Most vacuum belt dryers will operate at vacuum conditions from 10mbar to around 80mbar. This is designed so it can suit a wide range of production needs. The moving belt surface varies in size, and you can choose one based on your preference. A single vacuum band dryer is used for small-scale production, while a typical ten-belt VBD is used for commercial production.
VBDs offer a continuous working mechanism that’s easily customizable to suit your production applications. The raw materials go through many processes: from feeding the raw materials in liquid or paste form to getting end products as granules or powder.
As highlighted above, these processes include:
The heating temperatures can be adjusted from 30-150 degrees Celsius, depending on the raw material’s nature and expected end-product. The typical moisture content of raw materials would range from 20-80 percent.
The conveyor belt is attached to the heating and cooling plates. These plates transfer the required amount of heat (by contact heat transfer) instantly for the drying and cooling process. All these take place under vacuum conditions. The drying process is continuous and controlled by the Programmable Logic Controller (PLC) module.
Automatic granulation and Crushing
One thing about drying raw materials at relatively low temperatures is that they crystallize, making it easy to crush into a particular grain size. Depending on the expected end-product, crushing is controlled to ensure end-products have the desired feel and fluidity.
A VBD handles liquids, viscous products, and concentrates. Since all the processes are automated, there’s no room for human errors – hence no oxidation or inconsistent quality issues.
Benefits of Vacuum Belt-Dryer continuous process
A vacuum belt dryer comes with several benefits. In itself, the continuous drying process is a bespoke engineering solution that came when the change was more than a necessity. We’ve highlighted some VBD advantages below.
VBD is a combination of advanced tech-solution and practicality. It does an excellent job of retaining the aroma, color, and flavor in its end products; this is something that traditional drying technologies don’t guarantee. An example is the spray dryer that destroys heat-sensitive substances due to the high drying temperatures.
The low energy consumption of VBDs is an added advantage for companies in the commercial processing industry. This translates to low electricity bills and reduced overhead costs, which drives profitability. Unlike the vacuum oven that has a long drying time with high energy consumption, VBDs use 1/3 of the energy consumption of a typical spray dryer.
Retains Critical Elements with enhanced quality
One of the properties of a vacuum belt dryer is enhanced evaporation at reduced pressure. This helps eliminate oxidation while preventing undue damage to the raw material’s integrity – for example, the chemical composition of a product or the plant extract’s effectiveness as a pharmaceutical product. When making powdered sweeteners, VBDs preserve unique product characteristics such as essential amino acids, antioxidants, vitamins, and mineral components.
The solubility of End Products
The solubility of VBDs’ end-products is unmatched. Due to the consistent and high-quality production process, the powder produced is highly soluble in cold liquids.
Temperature zones allow for product-specific feeding with the option to adjust the feeding parameters to suit your individual needs. This is made possible by a PLC control system.
Due to the high-quality processing, continuous drying by VBD meets and even exceeds the Good Manufacturing (GMP) standards. With a Clean-In-Place (CIP) system, you won’t have to worry about the tedious daily cleaning procedures.
The Vacuum Belt Dryer Production Process
Manufacturing a Vacuum Belt dryer takes more than just a one-step process. For efficiency, accuracy, and quality, the production follows a step-by-step procedure. At each step, there’s a quality control inspection to ascertain that everything is proceeding as required. With such a process, it’s easy to increase productivity, which allows for mass production without compromising quality.
Assembling Raw Materials
As with any production line, the VBD production process begins with the sorting and assembly of high-quality raw materials. These include food-grade stainless steel, heating and cooling plate materials, conveyer belt, etc. This process is necessary to ensure the success of the entire project. From here, it’s possible to know which materials to source before preparing for the next production step.
Processing the Parts
When receiving raw materials, they are often in a form that cannot be used immediately. Processing of parts means getting them ready for the job. More often, this involves cleaning the parts, resizing them, etc.
Joining the several metallic parts of a vacuum belt dryer is a challenging task that requires the best of talents, leverage, and experience. More often, the welding process is automated to ensure fast and uniform production. However, this isn’t to say that every part of the welding process is automated. There are those areas where manual welding is necessary to guarantee quality work. Every product goes through inspection before and after manual or machine welding.
After joining the various parts of the VBD, it’s necessary to do some polishing to preserve the adjoined parts’ integrity. This is done to remove heat tints, reshape misaligned parts, and ensure a smooth and even finish. A weld polishing machine will get the job done in most cases, but manual polishing may be required when getting around the corner welds.
The majority of the polished parts need to be assembled before moving ahead with the production process. This isn’t the final assembly, but one that comes before the mirror-polishing of stainless steel casting. The assembly process may or may not require further welding. It all depends on the parts being assembled.
Across major industries, there’s usually an element of casting involved in the production process. Casting polishing needs to be done to remove the sprues and tough skin from the stainless steel. Choosing the right casting polishing tool is key to ensuring a mirror polish while preserving the material’s quality and functionality. This step could involve a sequential polishing process to ensure a subtle and well-blended finish. The tools used include large abrasive flap wheels, interleaved flap wheels, etc.
The major VBD parts enter a final assembly. This process is often automated, with little to no human labor. However, it’s necessary to check that all the pieces click into place and that every element occupies its rightful position. While this step may not be labor-intensive, it’s one that needs accuracy and precision to avoid costly errors that may propagate and affect the products’ lifetime.
Inspection is often done by the quality assurance team that consists of professionals from all the major departments – from control and safety engineers to the top-level management roles. Before a machine is tested, inspection is done to ensure all parts are intact and minimize incidents and probable damage. All the individual products are inspected before testing to ensure only the best machines get to the market.
Electrical Control Inspection
Besides inspecting the various parts of the Vacuum belt dryer, a thorough inspection of the electrical control system is done for advanced safety. The control system is one of the most critical parts of any machinery. If a control unit fails, there’s very little that can be done to bring the machine under control. This makes it a priority to inspect and test the different electrical components making up the VBD.
Pneumatic Control Inspection
VBDs’ pneumatic system comprises all the components that use compressed air to transfer energy from one part of the machine to the other. For example, a compressor used to power all the motors, pumps, and cylinders is an essential part of the pneumatic system that needs proper inspection. Any component that stores, moves, controls, or provides compressed air should also be inspected.
Vacuum Belt-Dryer Buying Guide
Choosing a vacuum belt dryer from the market can be a daunting task. If you’re like many, you would want to invest in a quality, durable, and reliable product that will serve all your needs without incurring extra costs. With the many options from several manufacturers on the market, convenience and quality should always be your top considerations. That said, we’ve covered some of the crucial factors you should consider when buying a VBD.
Vacuum Belt-dryer Features
There are different types, models, and designs of vacuum belt dryers. While the principle of operation remains the same, certain unique features come with each vacuum dryer set. These include the size, heating exchange area, heating source, and heating temperature range. You can always ask for further clarification on what these features mean and their importance as far as continuous drying is concerned.
When choosing a VBD that will suit your production needs, you always want to prioritize both the present and future needs. You don’t want to buy a small capacity VBD that won’t be relevant in the next five years or so. Always have your priorities right and invest in a model that’s both scalable and sustainable.
A great manufacturer will specify the size and production capacities in ranges that make sense to the customer. That means the customer should have an easy time making a choice based on their needs, and not based on what the manufacturer offers.
Many people don’t give a product’s warranty the attention it deserves. While a warrant is an assurance of quality and trust between the manufacturer and the customer, there’s more to having a long-term warranty than just the number of years your VBD remains covered.
A warranty product’s period is often an assurance of quality. A confident manufacturer will offer nothing less of a 1-year warranty. This gives you enough time to use the vacuum belt dryer and test every aspect of it before using it for the long term.
When buying such a high-investment product, the purchasing process should be procedural, legal, and professional. Purchasing good practices begin with a show of interest and a request to purchase/requisition. What follows is the customer selection, purchase order, fulfillment, receipt, invoicing, and payment.
Many times, when the customer isn’t knowledgeable enough about the product, it’s essential to begin with a consultation process, which could involve technical scheme determination and testing to ensure everything works as you would expect. Business negotiation follows, after which the procurement process can begin.
The purchasing process is crucial as it allows you and the manufacturer to communicate effectively and share vital thoughts about the product.
Trust in business is hard to come by. The manufacturer’s reputation is one of the critical factors to consider when buying a Vacuum belt dryer. While the manufacturer’s years of experience in the industry is one of the determining factors, it’s not the only recipe for success in selecting and buying a VBD. Here’s why:
- The technology used in the production process is of greater importance
- Quality often begins in the product design and material selection process
- Customer satisfaction speaks volumes – this is often a measure of the quality of services, from customer support to troubleshooting and other services.
An excellent way to measure the company’s reputation is to look around and see who is using the product. More often, a product used by institutions for learning and research purposes, large production companies, or government facilities is enough to convince you of the product integrity and the manufacturer’s reputation.
If you’re on a budget, you want to purchase a product that fits your needs. Several factors determine the cost of a product, from internal factors such as the cost of production to external factors such as the market dynamics and government policies. You always want to do your research and make sure you’re not making decisions based on the pricing alone and ending up buying what you don’t want.
Why Choose Pilotech Vacuum Belt Dryer?
At Pilotech, there’s more than meets the eye. Your search for a vacuum belt dryer ends here as you find a wide range of high-quality vacuum belt dryers to suit your unique needs. Below are some of the reasons why choosing us is the best investment you can make:
Quality Products and Services
Buying a high-quality product is not enough. You want to purchase it from a manufacturer that cares about you and wants to solve your problems and everything that may arise along the way. At Pilotech, we evaluate your unique needs and provide just the perfect product for your specific production requirements.
Not only are our products of high quality, but our customer support is also exceptional. We are intentional about this – since a quality product without effective customer support remains a significant source of frustration to the end consumer.
With more than 20 years in the VBD industry, we fully understand what it takes to amaze our customers. More than 3,500 scientific institutions use our products across the world.
This is a big deal for us, and our work is to ensure consistency and unmatched support services to all of them.
As a leader in the vacuum belt dryer technology, we believe that your production needs are unique, and there’s no one-size-fits-all solution. When you come to us, we keenly listen to understand what you need. We then weigh the options to see if there’s a ready product in the market to meet your requirements. If there’s none, we’ll proceed to customize a product to match your needs and product characteristics.
A great team of exceptional talent
As a manufacturer specializing in high-tech products, acquiring a team of outstanding talent is part of our top priorities. This is what we have done over the years – investing heavily in our Research and Development. We are always striving to keep up with ever-changing technology to keep developing advanced market products.
Besides the above reasons, below are the other advantages you get by working with us:
- You get a variety of options to choose your perfect VBD model
- All the VBDs meet the GMP standards.
One of our greatest perks is that we built our products to last a lifetime. Thus, our products serve more than 70% of China’s market, with exports to more than 60 counties and regions worldwide.
Wrapping It Up
Vacuum belt dryers are becoming the go-to option for industries looking for a continuous drying machine that guarantees automated processing and high-quality end products. The vacuum technology isn’t only a game-changer, but an innovative solution that has helped solve several industry problems.
Not long ago, it was almost impossible to dry heat-sensitive products without deforming them. Now, even the difficult to dry traditional Chinese medicine has seen a significant production in the market.
When buying a vacuum belt dyer, it’s recommended you do your research and weigh the options before making a purchase a decision. Hopefully, this guide has been of great importance on your journey to selecting a VBD for your production needs.
If you would love to inquire more about our Pilotech Vacuum belt dryer, contact us today, and we’ll be glad to be of help.