To Spray Dry the clear feed solutions of fully dissolved particulates / Suspensions / emulsions / agglomeration in controlled conditions to develop a particulate of desired analytical & physical properties.

• - It is a continuous process that can be used as batch process.
• - The retention period of particulates under drying in the system is < 0.21 sec.
• - The vapour cloud is developed around the atomized liquid globule under drying and due to poor co-efficient of heat transfer from the external heat in drying chamber through the vapour cloud to the particulates under drying being less; the particulates under drying are not subjected to high drying inlet temp. & do not get affected / degraded.

OPEN LOOP

Ambient air is used as a heating media to dry aqueous feeds. The fresh ambient air is sucked through a hepa filter for heating the air in direct / indirect heating system for drying & after separation of the dried particulates it is exhausted to atmosphere.

TYPICAL P & I D OF OPEN LOOP SPRAY DRYING SYSTEM / SCREEN SHOT OF HMI

NOMENCLATURE

Feed Tank : To store the feed solution for spray drying.

Feed Pump : Feed Pump is for sucking feed solution from feed tank & for pumping it to spray atomizer.

Atomizer : It can be single fluid pressure nozzle / two fluid pressure nozzle with selected orifice tips / three fluid pressure nozzle / rotary disc atomizer.

Chamber : Drying chamber to dry the feed to form particulates.

Cyclone : Mono cyclone for dried particulates separation & collection.

Bag filter : It is a multi-bag filter for arresting / auto dedusting type & collecting ultrafine particulates, not separated in cyclone.

Hepa filter: Hepa filter is for arresting the ultrafine particulates escaping through bags of bag filter.

ID Blower: Is an induced draft blower sucking the hot gases for drying, entrained with dried particulates, maintaining desired vacuum of + 50 to -250 mm of wg in the system.

FD Blower: Is a forced draft blower sucking fresh ambient air through a hepa filter & forcing it on the heating system for heating the air for drying a feed in drying chamber.

Air Heater: Is either a electrical / steam / gas fired direct or indirect heating system to heat the fresh air for drying to drying chamber.

VARIABLE PARAMETERS

T1 – Inlet temp. – Temp. applied for drying the atomized feed.

T2 – Outlet temp. – Temp. of dried produce after drying chamber.

T3 – Produce temp. – Temp. of dried produce after cyclone separation to be collected below cyclone .

T4- Safety temp. – Safety temp. of hot air after heaters.

P – Atomization Pr. – Pressure applied to single / two fluid atomized for feed atomization.

V – Vacuum – Vacuum in the system.

CLOSED LOOP

The heating media used is 99.99% pure Nitrogen / Argon gas & it is used to dry organic, aqueous - organic feeds.

In this system the inert gas is re-circulated in system

The organic vapours are condensed & the condensate is separated / collected as spent solvents.

The oxygen ppm in heating gas is controlled to avoid oxidation of the produce.

This system is mainly used for Pharma API to comply with USFDA 21 CFR.

TYPICAL P & I D OF CLOSED LOOP SPRAY DRYING SYSTEM / SCREEN SHOT OF HMI

NOMENCLATURE

Feed Tank : To store the feed solution for spray drying.

Feed Pump: Feed Pump for sucking feed solution from feed tank & to pump it to spray atomizer.

Atomizer : It can be single fluid pressure nozzle / two fluid pressure nozzle with selected orifice tips / three fluid pressure nozzle / rotary disc atomizer.

Chamber : Drying chamber to dry the feed to form particulates.

Cyclone : Mono cyclone for dried particulates separation & collection.

Bag filter : It is a multi-bag filter for arresting & collecting dedusted ultrafine particulates, not separated in cyclone.

Hepa filter: Hepa filter is for arresting the ultrafine particulates excepting through bags of bag filter.

ID Blower: Is an induced draft blower sucking the hot gases for drying, entrained with dried particulates, maintaining desired vacuum of + 50 to -250 mm of wg in the system.

FD Blower: Is a forced draft blower sucking recirculated gases, devoid of solvent vapours, duly oxygen % controlled through a hepa filter & forcing it on the heating system for heating the gas for drying a feed in drying chamber.

Gas Heater: Is either a electrical / steam / gas fired direct / indirect heating system to heat the fresh gas for drying to drying chamber.

VARIABLE PARAMETERS

T1 – Inlet temp. – Temp. applied for drying the atomized

T2 – Outlet temp. – Temp. of dried produce after drying chamber.

T3 – Produce temp. – Temp. of dried produce after cyclone separation to be collected below cyclone.

T4- Safety temp. – Safety temp. of hot gas after heaters.

T5 –Chilling temp. for organic vapour condensation

O2 – Oxygen ppm of gases to be recirculated.

P – Atomization Pr. – Pressure applied to single / two fluid atomized for feed atomization.

V – Vacuum – Vacuum in the system.

- Is PLC-FLP HMI - IPC system, having safety interlocks; data logging , Trends logging, Alarm data, Fault audit, Engineering screen, P & ID screen with running / set values of variable parameters, PDF Data file generation, Licensed Scada and features in compliance with USFDA 21 CFR as may be required.

Single Room Concept : Where total spray drying system, equipment including FD/ID Blowers, Hepa Filters, Control Panel, chilling unit is located in single clean to atmosphere room.

Two Room Concept : Where only the Drying Chamber / Cyclone & Bag Filter are located in clean room & the FD/ID Blowers, Hepa Filters, Control Panel, and Chilling Unit are located in service area outside clean room.

Is cleaning in process system, it is controlled / operated from HMI of the system in a programmed way for both open / closed loop systems. It consists of a high pressure pump / CIP nozzles on equipments & ductings and / or CIP rotary ball. It consists of fresh CIP & spent CIP tanks.

Is a controlled steam supply station for sterilizing / sanitizing the wetted parts of spray drier coming in direct contact of produce. This is used for Onco / Steroids / Hormones & Injectable products.

Crystalline form

Amorphous form

Encapsulated form

Englobed form

Compatible for targeted delivery form

Slow release form

Nano particles form

Granules form

Standard Spray Drier : Having L/D ratio between 1:1 to 1:3 where “D” is inner diameter of the drying chamber & “L” is the straight shell height of drying chamber. This is used for particle size range of 3 to 180 microns on D90. Used for allied production.

Tall Tower Spray Drier : Having L/D ratio between 1:4 to 1:12. It is used to get particle size range of 180 to 2500 microns on D90 with higher bulk densities used for Fertilizers, Pesticides, Detergents etc.

Spray Prilling / CongealingSystem : A Spray Drier can be used to dry molten feed by using cold gas instead of hot gas for drying. Typical uses are for various Pharmaceutical / molten waxes, Sodium Butyrate feeds, Poultry / Kettle feeds with necessary flavours for Animal fats.

Jacketed Spray Drier : It is used to get desired produce, when the produce has critical glass transition temp., by circulating cold air through the jacket of drying chamber to keep the inner surfaces of the drying chamber at below glass transition temp. of the produce to avoid degradation of produce. Used for particularly API products, Fruit Juices, instant tea & coffee spray drying.