A Caloris customer wished to extend the duration between CIP cleanings on two of their spray dryers from every 28 days to 90 days or more. A reduction in the amount of scorched particles would help accomplish this goal.

Caloris proposed the following tactics:

  1. Automation improvements to improve operational consistency of the production start-ups and shutdowns of the dryer to reduce wall build-up and scorched particles.
  2. Nozzle lance optimization to reduce build-up and scorch
  3. Air disperser modifications to improve airflow patterns to reduce wall build-up and scorch.
  4. Operations support to optimize operating procedures

Among the changes made, our engineers modified the air dispersers to make the air more laminar across the sprays. Cooling bed air flows and temperatures, inlet fan speeds and chamber pressure were also checked and adjusted. We eliminated intermediate nozzle flushes. Run durations were increased to 32 hours from 24 hours.

To improve the automation, Caloris identified the incremental changes needed in the timers and sequences of the current system for production and CIP.

For the feed system optimization, Caloris identified and implemented changes to spray nozzles, feed filters, the stuffing pump and related areas of the dryers.

The above modifications along with the process engineering and operations site support culminated in training for plant staff that covered the changes to the operating procedures. In the end, the targets were easily achieved and exceeded.

Experiencing Spray Dryer Challenges?

If you are seeking to optimize your spray drying process, contact Caloris at 410-822-6900 or problem.solved@caloris.com to arrange for a process assessment at your facility.

Meet The Engineers

Jim Kent

Jim Kent

Business Development Manager

Austin McPeek

Austin McPeek

Mechanical Design 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.