Ensuring Safe and Efficient Evaporators and Spray Dryers Through Preventative Inspections

Schedule a conversation with Jim Kent to discuss your spray drying process.

As a supplier and service provider for evaporators and spray dryers, we at Caloris know how critical it is to keep this equipment operating safely and efficiently.

Even minor cracks or metal fatigue in evaporator tubes or spray dryers can lead to product contamination, excessive downtime, and potentially catastrophic failures down the line. That’s why regular preventative inspections using specialized technologies are so important.

Watch a webinar on Eddy Current Testing.

For evaporator tubes, eddy current testing is an invaluable non-destructive inspection method. This technique uses electromagnetic induction to detect cracks, pits, wall thinning, and other defects in the tubes, allowing issues to be identified and repaired before they cause a failure and costly unplanned shutdown.

Eddy current testing can pinpoint problem areas with high accuracy while avoiding the need to take the entire system apart. This inspection technology reaches parts of the evaporator tubes that are not possible to visually inspect.

Meet The Engineer

Jim Kent

Jim Kent

Business Development Manager

Spray dryers, with their large surface area chambers, require a different inspection approach. One effective solution is to use a spray dye that is atomized and circulated through the chamber. Any cracks or pinholes will cause the dye solution to seep through.

Under a UV light, the dye clearly highlights areas of concern for repair or replacement of chamber panels. This non-destructive evaluation can reveal sources of air leaks or product buildup that are not cleanable and could otherwise go unnoticed.

Evaporator Tube Preventative Inspections – When to Inspect Using Eddy Current Testing

  • New evaporator tubes should get a baseline eddy current inspection before being put into service
  • After the baseline, eddy current inspections should be performed annually or bi-annually
  • For older evaporators (10+ years), more frequent inspections every 6 months may be warranted due to increased risk of tube degradation over time

Spray Dryer Preventative Inspections – Non-Destructive Dye Testing Recommended Schedule

  • New spray dryers should get an initial spray dye inspection after 1-2 years of operation
  • Subsequent inspections can be performed every 2-3 years for newer spray dryers (under 10 years old)
  • For older spray dryers (10+ years), annual inspections using spray dye are recommended
  • Any time significant exterior damage occurs, an immediate interior spray dye inspection is advisable

The exact inspection intervals can vary based on factors like the materials being processed, operating temperatures and pressures, and overall age/condition of the equipment. But in general, more frequent inspections are prudent as evaporators and spray dryers get older to identify potential issues before major failures occur.

Performing these preventative eddy current and spray dye evaluations on a regular basis according to the equipment’s age and usage patterns allows processors to stay ahead of any developing problems and schedule repairs proactively during scheduled downtimes

Investing in specialized preventative inspections saves processors from far more expensive emergency repairs and unplanned downtime. By proactively finding and fixing potential issues, evaporators and spray dryers can operate reliably and efficiently for years to come while ensuring the highest product quality standards are maintained.

Contact us today to schedule a comprehensive preventative inspection. Call 410-822-6900 or send email to problem.solved@caloris.com to be connected with an engineer.


About Caloris

Caloris transforms process systems design for the better with unexpected, future-focused solutions that solve real operational problems. We engineer efficient, dependable and productive solutions that also improve environmental sustainability where practical. Designed with the end user in mind to drive plant productivity. Caloris offers evaporation, membrane filtration and spray drying process systems for food and dairy industries, as well as for water reuse and wastewater treatment applications. Both Caloris’ custom and pre-engineered packaged systems are designed to meet our customers’ specific concentration/purification needs utilizing the most cost effective and energy efficient technologies available. Whether concentrating dairy, food or juice products at a high-volume production facility, or processing industrial wastewaters to reduce transportation and treatment costs and recover re-usable water, Caloris provides a range of options and technologies.