Spray Drying - Issues and Solutions

1. Low Quality Powder & Powder Consistency – Bulk Density Issues

Cause of Problem: Product Build Up

Build-up may be due to dryer configuration, use of wider spray angles and powder formulation, but in many cases, it’s the nozzle design. Product build-up drips on the chamber and becomes scorched particle deposits that compromise powder quality.

Old style weaker seal in cap with heavy build up

Solution: Flat Cap Profile

Click&Dry spray dry nozzles  flat cap design provides a lower outer face profile that greatly reduces build-up. Click&DryTM technology produce powders with 20% less build-up than any other spray dry nozzle. This is achieved by moving the O-rings into the disc orifice.

            lower outer face profile greatly reducing bearding

Cause of Problem: Wear Part Misalignments

Traditional nozzle designs have misalignments between swirl chamber and orifice. Decentralised parts create inconsistent spray performance and affect the powder quality through all drying operations.

Solution: Concentric Clasp Technology

Click&Dry spray dry nozzles align wear parts to produce a uniform spray pattern across all lance sets. Achieving a better performance and powder consistency. Pressure – flow is consistent – outcome predictable

2. Low Productivity

Cause of Problem: Nozzle Bearding

Bearding may be due to dryer configuration, use of wider spray angles and powder formulation, but it is mostly due to deficient nozzle design. This increases the cleaning frequency, which delays production. Stopping production for cleaning and short run times plays a big part in dryers’ low productivity.

Old style cap showing scorched build up

Solution: Flat Cap Profile

Click&Dry flat cap design provides a lower outer face profile, which greatly reduces bearding. This means fewer dryers shut down for clean-up and, therefore, higher productivity. If we reduce build-up, we slow the bearding process and then nozzles can run longer. The Click&Dry system offers longer run times. Moving the O-rings into the wear part helps achieve this result.

Click&Dry cap reduced build up improved quality