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The Spray Drying Process

Spray Drying Equipment

In the realm of food preservation, spray drying stands as a versatile and effective method for transforming liquid substances into dry powders. With an outstanding track record of innovation and proven success, Dahmes has established itself as a leading expert in dryers and evaporators. Whether it's enhancing shelf life, improving portability, or concentrating flavor, spray drying has revolutionized the food industry. So what it is?


Understanding Spray Drying


Spray drying is a technique used to convert liquid or semi-liquid substances into powders by rapidly drying them with hot air. The process involves four fundamental stages: product feed, atomization, droplet-air contact, drying, and powder separation.




Dahmes Spray Drying

Product Feed

The beginning of the spray drying process is the product feed system. The product feed system generally consists of a balance tank, feed pumps, strainers, and many times a high-pressure pump. The product is often very viscous upon delivery to the atomization system, and proper care must be given to the design of each component to ensure that the product is fed consistently to the atomization system.



Atomization

The product feed system supplies the atomization system to turn the liquid feed into small droplets. This can be achieved through various methods such as high-pressure nozzles, rotary atomizers, or three-fluid nozzles (all equipment that we provide LINK). As a product is atomized, the surface area per mass is greatly increased, creating a large surface area to efficiently interact with the hot air.


Drying

The atomized droplets are immediately introduced into a chamber where they come into contact with hot air. This air is the drying medium, rapidly evaporating the free moisture from the droplets. The temperature and airflow rate are carefully controlled to ensure optimal drying conditions without causing thermal degradation of the product. When you’re in the food business, this is a critical part of preservation. We have the right solution for you at Dahmes and we can test it at our state-of-the-art R&D center.


As the droplets travel through the drying chamber, bound moisture continues to evaporate from the particles, eventually leaving behind dried particles. Adequate residence time in the chamber is critical to achieve the desired moisture content in the final product. Monitoring parameters such as inlet temperature, outlet temperature, feed rate, and airflow is crucial to maintaining product quality and consistency. Our equipment is carefully designed to control the process requirements for various products.


Powder Separation

Once dried, the powder is collected at the bottom of the dryer, and any particles entrained in the air are separated from the drying air using cyclones or a baghouse. This equipment removes the dried particles from the air stream, allowing for the collection and addition back with the other powder to package for the final product. Often times, the largest challenges in spray drying present themselves in this part of the process, so having a powder separation process that suits the product is critical.



Applications of Spray Drying


Dairy Products

Spray drying is used in the production of dairy powders such as milk powder, whey and milk protein, whey and milk permeates, cheese powders, and infant formula. By removing moisture, spray drying extends the shelf life of dairy products while preserving their nutritional value and flavor.


Powder from Spray Drying
Instant Beverages

Instant coffee, tea, and fruit juices are often produced using spray drying technology. The process allows for the conversion of liquid concentrates into easily reconstitutable powders, providing convenience and longer shelf life. That’s what our equipment does.


Flavorings & Seasonings

Food manufacturers utilize spray drying to create powdered flavorings and seasonings, including spices, herbs, broths, bullion and other savory extracts. The powdered form enhances the dispersibility and flavor intensity, making it ideal for different applications.


Functional Ingredients

Spray drying is employed to encapsulate bioactive compounds, vitamins, and minerals, enhancing their stability and bioavailability. These functional ingredients find use in dietary supplements, fortified foods, and pharmaceutical formulations.


Advantages of Spray Drying


The spray drying process offers several advantages that contribute to its widespread adoption in the food industry. If you’re not spray drying for food preservation, you may be missing out on several key advantages.


Preservation of Nutritional Value

Unlike traditional drying methods that may involve high temperatures and prolonged exposure, spray drying allows for rapid drying at lower powder temperatures, minimizing heat damage to sensitive nutrients.


Improved Solubility & Dispersion

Powders created on spray driers can be manipulated to form agglomerates that exhibit excellent solubility and dispersibility in liquids, facilitating reconstitution and incorporation into food and beverage formulations.


Enhanced Shelf Life

By removing moisture, spray drying extends the shelf life of perishable foods, reducing the risk of spoilage and microbial growth. This improves product stability and ensures quality throughout storage and distribution.


Capacity

Spray dryers can be custom designed to meet products throughput requirements, from small batch spray dryers to large scale dryers that generate thousands of pounds of product per hour. Dahmes exclusively designs custom spray dryers to fit the needs of our clients.


With an outstanding track record of innovation and proven success, Dahmes has established itself as a leading expert in dryers and evaporators. By combining cutting-edge engineering expertise with a deep understanding of client needs, we have consistently pushed the boundaries of technological advancements, revolutionizing the way dryers operate and optimizing our project delivery process. Our commitment to continuous improvement and customer satisfaction has positioned us as a trusted partner for businesses across various industries. When it comes to process solutions, Dahmes is a name you can count on for unparalleled quality, efficiency, and performance.



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