The food sector recognizes the value of spray drying, and demand is growing in proportion. How would you select a spray dryer that is appropriate for your food type as a spray dryer supplier? In the food industry, different types of dryers with varying drying stages have various roles. For example, many different types of dryers are used to preserve fruit and vegetable juices in powder form, each with its own set of characteristics to meet the demands of the producer, as inappropriate usage might damage the product’s physiochemical and microstructural properties.
Several variables must be considered when choosing a spray dryer. The simplicity of use, setup, and cleaning needs are all key considerations when buying a spray dryer. The functional element should be investigated once the fundamentals have been addressed. It is preferable to use equipment that is simple to use, modify, and generate optimal conditions. The following are the primary controls that the instrument should provide:
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- Airflow, temperature, and pump speed are all within your control.
- The volume should be the same as the air compressor pressure.
- The quantity of Active Pharmaceutical Ingredient (API) needed for development.
- The API’s sturdiness and functionality
- The necessary amount of dry mix formulation
- The solid content of the active and the amount of encapsulant will determine the overall batch size.
- The sort of drying gas required will be determined by the solvent used to make up the emulsion, which might be air or nitrogen.
How to maintain your Industrial Spray Dryer?
Optimization-
There are three common methods for optimizing the spray dryer. To begin with, it is done in order to increase the quality and yield of the final product. The inlet, exit, and feed temperatures may all be adjusted to achieve this. Second, optimization is necessary to avoid production losses, such as those caused by Clean in Place (CIP). Finally, because the quantity of moisture in the ambient air is larger in the winter, spray dryers work better in that season. The response surface approach was proven as the best appropriate tool for optimizing spray drying conditions in a study published in Trends in Food Science & Technology.
Enhancing your abilities-
The amount of water evaporated by the spray dryer is determined at the moment of wet product loading to determine its capacity. For optimum evaporation, the temperature differential between the input and exit needs to be increased.
CIP nozzle valve’s retractable design-
They do not function at extremely high intake temperatures, even though higher inlet temperatures improve energy efficiency. Because a particular output temperature might cause build-up in spray dryer vessels. Furthermore, the product must not be denatured, burnt, or devoid of nutrients or desirable properties.
Improved run time-
A good optimum production should operate on a well-planned schedule with very little or no unexpected downtime. A feed system that is frequently swapped between products and batches has to be cleaned regularly. However, spray drying for allergens and cleaning between allergen production batches should be closely monitored.
Spray dryers with two feeds that run at full capacity have just become available, making them ideal for automized nozzle systems. An atomizer can be created with a rotary or nozzle, and another nozzle can be used when one feed system is shut off.
Cleaning in place-
For the reasons listed below, planned cleaning should be done daily or between batches.
- To avert a fire or explosion due to a build-up of too much material.
- Cross-contamination and quality issues will arise as a result of the excessive buildup.
- In order to keep the chamber free of microbial development.
- To get rid of any maintenance difficulties that aren’t really essential.
Ambient conditions-
As previously stated, seasonal fluctuation has a significant impact on the spray dryer’s effectiveness. As a result, it’s critical to standardize the entering air for year-round productivity. The total moisture in the air as it exits the chamber limits the dryer’s capacity. For or while manufacturing a stable product, the air exiting the chamber should not be too wet, since this might result in a clumsy outcome. Furthermore, the chamber should be operated at the highest overall moisture level feasible to achieve optimum effectiveness. As stated in the introduction, intake, and outlet temperatures, as well as other parameters, should be adjusted for theoretical maximum production, even during seasonal fluctuations.
Using a few components, it can be controlled. The ambient air moisture content and air volume must first be measured using a hygrometer. Because the spray dryer is equipped with a direct-fired gas burner that works on natural gas or propane, it may account for up to 10% of moisture contribution. In conclusion, the total volume of evaporated water contribution should be determined. Mechanical inefficiency and slippage should be accounted for with the use of a flowmeter for better accuracy. Finally, all operational data must be gathered in order to fully comprehend the machine, determine if it is running at peak efficiency, and determine if the product yield is comparable to theoretical values. Food Research Lab provides food consulting services to help you utilize the finest industrial spray dryer available.
