AVEKA's extensive spray drying capabilities and experience serve multiple industries at all scales.

spray drying machines
Process

Spray drying is a continuous process used to manufacture free-flowing dry powders from a liquid feedstock. The liquid feedstock is atomized into a heated air stream where the droplets rapidly dry to form individual particles. The resulting product is a free-flowing powder. Particle size, morphology and moisture content can be controlled by adjusting dryer parameters, nozzle configuration and feed properties. Spray drying is widely used across many industries and can efficiently dry commodity material as well as create value-added, designer particles.

AVEKA utilizes both tower and horizontal box dryers equipped with two-fluid and hydraulic spray nozzles to process a variety of aqueous systems. AVEKA’s full-service analytical laboratory allows for rapid process adjustments during trials and excellent quality control for production operations. Spray dried products can be characterized by measuring particle morphology, size distribution and moisture content. Additionally, extensive pre- and post-processing capabilities contribute to the turnkey experience AVEKA provides.

Capabilities and Equipment Specs

*Spray Drying Equipment:

  • Two food grade horizontal box dryers (up to 2000 kg of water evaporation per hour)
  • Three food grade tower dryers (ranging from 3 kg to 2000 kg of water evaporation per hour)
  • Four industrial tower dryers (ranging from 3 kg to 90 kg of water evaporation per hour)

Pre- and Post-Processing Capabilities:

  • Liquid silo storage
  • Liquid batching tanks (many available options)
  • Homogenization
  • Decanting
  • Filtration and separation
  • Evaporators (up to 1400 kg water evaporation per hour)
  • Screening and classification
  • Reconstitution of dry raw materials
  • Reactions, ph adjustments
  • Packaging

*Rates are dependent on materials and drying conditions.

Factors to Consider

 

  • What is the percent solids going to the spray dryer?
  • What is the target particle size?
  • What is the desired finish product moisture content?
  • Is the finished powder hydrophilic, flowable or tacky?
  • What is the viscosity of the liquid slurry?
  • Is the liquid feed material a solution or dispersion?
  • What is the temperature profile?
  • Is any additional liquid handling needed: pH adjustment, blending materials, heat treating, etc.?
  • Are there any specific conditions or limits for storage/handling of the raw material or finished goods?