A spray dryer works by atomizing the liquid into small droplets, which are then rapidly dried using hot media (air, gas, steam) to form a powder. SPX FLOW provides high-efficiency spray drying systems designed for quick evaporation, minimizing thermal degradation, and ensuring consistent product quality. They offer custom solutions tailored to specific industries such as dairy, food and beverage, pharmaceutical, and chemical.

There are various types of spray dryers, including: • Co-current Spray Dryers: The hot air and feed move in the same direction, ideal for heat-sensitive products. • Countercurrent Spray Dryers: The air flows opposite to the feed, allowing higher thermal efficiency. • Mixed Flow Spray Dryers: These combine the benefits of both co-current and countercurrent designs for specialized applications. SPX FLOW can help you choose the right type based on product needs.

Spray dryers typically include: • Feed systems with precise control • Advanced atomization technology (rotary or nozzle atomizers) • Energy-efficient air heating systems • Optimized drying chambers designs • Powder collection systems such as cyclone separators, bag filters or scrubbers • Safety and automation of the plants SPX FLOW designs all these components to work together seamlessly, ensuring efficient drying and consistent product quality.

A wide range of industries rely on spray drying configurations, including: • Dairy: For products like milk powders or other dairy powders (link to Dairy products) • Food and Beverage: For products like food ingredients, animal and vegetable proteins, carbohydrates, coffee, and flavors • Pharmaceutical : For active ingredients and drugs • Chemical: For special chemicals, batteries, etc. SPX FLOW’s experience in these sectors allows them to provide tailored solutions to meet the unique needs of each industry.

Factors such as feed composition, atomization, drying air temperature and airflow pattern influence efficiency. SPX FLOW's engineering expertise ensures the proper integration of all these factors through advanced control systems monitoring and optimizing drying parameters in real time for maximum efficiency.

Spray dryers offer rapid drying, uniform particle size and the ability to process heat-sensitive products. SPX FLOW designs systems that ensure these advantages while minimizing energy consumption and maximizing throughput. Their Equipment is designed for continuous, automated operation, reducing labor costs and improving overall productivity.

Common challenges include high energy consumption and difficulties with sticky or heat-sensitive products. SPX FLOW helps address these limitations by offering energy-efficient systems, optimized airflow design and specialized coatings or chamber configurations that reduce sticking and ensure smooth operation for challenging products.

Atomization breaks the liquid feed into fine droplets for drying. SPX FLOW offers various atomization methods, including high-performance rotary atomizers and nozzle systems. These centrifugal atomizers are designed to achieve uniform particle size distribution, improving the consistency and quality of the final product.

Particle size can be controlled by adjusting atomizer type, feed rate and drying conditions. SPX FLOW’s advanced control systems allow precise adjustments to these parameters, ensuring consistent particle size meeting specific product requirements.

Product loss can occur when powder sticks to the chamber wall or escapes with the exhaust air. We help customers minimize these losses by incorporating effective powder collection systems such as high-efficiency cyclone separators and bag filters. Additionally, our systems feature optimized chamber designs to reduce wall build-up and ensure maximum powder recovery.