Spray dryers are essential components in powder production plants, particularly for their ability to efficiently remove excess moisture from liquid feeds. This process transforms liquids into dry powder particles, making them suitable for various applications in industries such as food, pharmaceuticals, and chemicals.

The operational temperatures of spray dryers vary depending on the type of product being processed. For example:

• Whole milk powder is typically dried at temperatures ranging from 170°C to 210°C.
• Skim milk powder requires slightly higher temperatures, between 170°C and 230°C.

In a two-stage drying process, primary drying occurs until the moisture content reaches 4-12% above the desired final moisture level. The remaining moisture is then evaporated using a fluid bed system, ensuring optimal powder quality.

Advantages of Spray Dryer:

Being a leading spray dryer manufacturer in India, our spray dryer delivers various advantages to customers like,

• Wide range of plant capacities – we can supply spray dryer plants with a wide range of capacities from small to commercial scale.

• Helps achieve constant powder quality throughout the entire journey of the feedthrough dryer.

• Provides continuous operation and adapts easily to fully automatic control.

• Our spray dryer plant suits both heat-resistant and heat-sensitive products.

• Can work with abrasive, corrosive, flammable, explosive or toxic feedstock; as long as they can be pumped.

• Processes with feedstock in multiple forms – solution, slurry, paste, gel, suspension or melt form can be effectively dried using the Spray Dryer Process.

• The process can control product density as desired.

• This process can be utilized to produce nearly spherical particles as desired.

• Poses a lesser risk of corrosion as the material being processed does not contact the metal surface until dried.

Computational Fluid Dynamics (CFD):

Technology in Spray Drying:

Computational fluid dynamic (CFD) technology is increasingly used in spray drying to model and optimise the process. CFD simulations can help researchers and engineers understand the complex fluid dynamics during spray drying, including heat and mass transfer, droplet evaporation, and particle formation.

By simulating these processes in a virtual environment, one can test different spray drying conditions and optimize the process for maximum efficiency and product quality. CFD simulations can also help identify potential issues and bottlenecks in the spray drying process, allowing for adjustments to be made before production begins.

Some specific applications of CFD in spray drying include:

• Modeling the fluid flow and heat transfer inside the drying chamber
• Predicting the droplet size distribution and evaporation rates
• Simulating the behaviour of different types of particles during drying, including agglomeration and breakage
• Optimizing the design of the spray dryer, including the nozzle configuration and airflow patterns.

Spray cooling is the process of converting molten liquid material into spherical solid particles (Granules/Beads) using cold air.

• A stream of equally distributed cold air is sprayed with molten liquid.
• The molten material solidifies to form granules/Beads of the necessary specifications.
• The fines generated are separated in a high-efficiency cyclone.
• The spray-cooled granules/Beads are further cooled in a unique Integrated fluidized bed cooler and external vibratory fluidized bed cooler to eliminate lump formation after production and during shipment.
• Two statically and dynamically balanced fans, Delivery and Exhaust Blower, balance the entire system. With the assistance of instrumentation, the system is managed by a locally furnished control panel.

In summary, Spray dryer manufacturers in India play a pivotal role in transforming liquid feeds into high-quality powders across various industries. With advanced designs like those from Sahiba Fabricators, manufacturers can achieve consistent product quality while optimizing energy use and minimizing labor costs. As industries continue to evolve, the importance of efficient and effective spray-drying technology will only grow, making it an indispensable part of modern production processes.