Spray Drying Equipment

Small scale pilot trials

Scale:1-10Kgs

Uses: Evaluation behaviour of ingredients, product formula optimisation and samples for analytical development etc.

Pilot scale UHT plant (150 L/Hr) with direct steam injection, infusion and indirect heating.
Small scale evaporator (42 kg WEC/Hr) and Single Stage Spray drier (10 kg WEC/Hr).

Intermediate scale pilot trials

Scale 10-50Kgs/ WEC: 20Kg/hr

The BFE is an integrated state-of-the-art facility for food technologists to separate, stabilise and deliver bioactive ingredients in beverages with commercial potential.

Multi-stage Spray Drier with fluidising capabilities.
Falling film evaporator – 60Kg WEC/Hr.
Multifunctional Membrane Filtration plant.
Microthermics heat exchanger & in-line homogenisers (30-200L/hr) + Clean fill unit.

Anhydro 750 Micraspray

Engineering function	Anhydro 750 Micraspray
Atomisation	2-Fluid Hi-PR Nozzle
Fluidisation	Integrated + External bed
Airflow Pattern	Top exhaust extension, Dew point measurement on inlet air Initial spiral flow followed by upward flow to extraction
Chamber Size / Features	Angle of cone favours airflow pattern/sticky prods Rotary valve PDR discharge Rotary valve cyclone – split powder returns CS 4.2m³ Cone Angle 50°
Cyclone	representative of commercial scale
Scale – Water Evaporation – Kg powder/h	20 kg powder/hr at 180°C air inlet / 75°C at end of first stage.Feed/water tank system ~80 L feed/ ~10 L water
Airflow	1,050 Nm³/h
Data acquisition	Sensors/transmitters for temperatures of pre-heater, inlet temperature, chamber outlet temperature, fluid bed temperatures, ambient air dew point with capability for advanced process control.
Fines return system	Pneumatic conveying of fines. Ability to inject fines into product stream at the atomiser. Agglomeration –Yes
Particle size	•In the range 50 – 250 microns •Large, free-flowing, dust-free agglomerates.

Large scale pilot trials

Scale 50-500Kgs / Niro Tall Form (TFD 20) / WEC:100 kg/hr

Concentration of fluid materials fractions, hydrolysates, fermentation products etc. by thermal evaporation.

Drying of protein fractions

Spray drying – regular and agglomerated powders. Option of lecithination, in-line dry dosing.
In-line homogenisation.
Powder blending.
Crystallisation.
Powder canning.

Equipment items

NIRO Tall Form Drier (100 kg H2O h-1). 2 x Vibro Fluidised Beds for agglomeration and lecithination.
New Dehumidification and humidification system commissioned in 2011.
Scrape surface heat exchanger, in-line or off line homogeniser, high pressure pump.
CO2 injection capability for bulk density variation.
Three effect NIRO thermal evaporator (800 kg H2O h-1) with FSH (up to 150c, tres=0.5 15 s).
Attrition drier (60 kg H2O h-1).
Powder Blenders (25 kg and 1500 kg).
Concentrate and crystallisation tanks.
Scrape surface heat exchanger.

Engineering function	NIRO TFD 20
Atomisation	3 Nozzles – Spray systems Choice up to 10 nozzles based on total solids and desired particle size
Fluidisation	2 External fluidised beds
Chamber Size / Features	Angle of cone favours airflow pattern/sticky prods Rotary valve PDR discharge
Cyclone	Representative of commercial scale, no bag filter
Scale – Water Evaporation – Kg powder/h	100 kg powder/hr at 180°C air inlet / 75°C Outlet Feed system ~300 L feed
Airflow	Inlet Air Flow 2500 m³/h
Data acquisition	SCADA System
Fines return System	Rotary Valve pneumatic system
Particle size	90-120um in regular mode Agglomeration