Choosing the Right Size Spray Dryer

Spray drying technology is helping organizations of all sizes improve product quality, increase efficiency, expand product portfolios, and gain a competitive advantage.

Whether to invest in a new spray drying machine is a big decision involving a lot of business variables and capital. Prior to purchasing a new machine, it is important to consider:

• Capacity: How much do you plan to process?
• Space: How much space do you have?
• Ease of Operation: Will this dryer be easily integrated into our operations?
• Budget: How much can you invest?

There are three commonly used spray dryers: Lab Scale, Pilot Scale and Full Scale. Each is designed for varying capacities and uses. To help you make your decision we’ve put together a quick guide for understanding the three levels of spray dryer machines.

Lab Scale Spray Drying Machines

Lab scale dryers are generally small, compact and self-contained units that fit on top of a table. They are best suited for when you need to process a couple pounds of product per day. They are ideal for basic research and experimentation or small batch operations because they are low cost and easy to run. Of course, because these units are small, output is low and cleaning isn’t always easy.

Pros

• Simple Operation Easy to Run
• Semi-Portable
• Excellent For Testing and Development
• Low Investment

Cons

• Lower Yield
• Limited Control Capabilities
• Difficult to Clean

Pilot Scale Spray Drying Machines

Leveling up, a pilot scale spray dryer can produce several pounds of finished product per hour. Pilot scale spray dryers are designed for process development and optimization. They also offer more advanced controls over parameters such as temperature, airflow, and feed rate.

Pros

• Bridge the gap between benchtop experiments and full-scale commercial production
• Higher  Yield Performance
• Advanced Control Options
• Continuous Duty Design
• Flexible Reporting Capabilities
• Flexible Design Options

Cons

• Requires Upfront Investment
• Limited Portability
• Industrial Utility Requirements
• Training Needed to Achieve High Performance (Provided by EnviroStar with install)

Industrial Scale Spray Drying Machines

Full scale spray dryers are best-suited for organizations interested in producing large batches of product and achieving higher yields. These dryers can produce thousands of pounds of finished product per hour. Full scale spray dryers are more automated and they often feature advanced process control systems, such as real-time monitoring, feedback loops, and automated adjustments, which help to ensure consistent quality and high throughput.

While they require a higher upfront investment, they typically yield returns in the short-term by cost-effectively running large batches of product.

Overall, selecting the right size spray dryer requires a thorough understanding of your production needs, input materials, and available resources. It’s essential to work with an experienced supplier, like EnviroStar, who can help you choose the right size dryer for your application.

End to End Solutions

When you’re ready to make a spray drying equipment investment, EnviroStar can help you evaluate the right equipment for your project, develop a superior formula that results in high-quality consumer products, and get your products to market faster with tolling services. EnviroStar also offers budget friendly, easy-to-use, high efficiency, pilot scale and full scale spray drying machines. From ingredient preparation to final packaging, we’re here to help.

Not ready for a purchase, but still want spray drying technology? Check out EnviroStar’s tolling services.