Problem: Solved | Correcting Spray Dryer Yield Issues

A customer approached Caloris because they were having spray dryer yield issues, evidenced by heavy loading of their scrubber. The system was being fed at 1300 lbs/hr of feed at 45% total solids, indicating that there should be 615 lbs/hr of powder being produced. We found that they were packaging at only about 450 lbs/hour — a yield of only 73%. Instruments were verified, but it was quickly evident that the powder was escaping the cyclones and going to the wet scrubber and therefore onward to wastewater.

The customer had slowed the dryer production rate down recently to accommodate a new product, which meant they had slowed the dryer airflow down. The client was not only losing product, but the situation was compounded by the lost production, creating high wastewater processing loads.

After a site visit to inspect the spray dryer and measure the performance of the cyclones, our engineer verified the operating conditions and the performance of the cyclones.

Cyclones are designed to operate with a certain airflow and, therefore, differential pressure, resulting in the high efficiency needed to capture 99% of the spray dried material. This efficiency drops off exponentially when the airflow is reduced.

At this plant, an experiment was carried out to achieve an airflow closer to the original design, in the hopes of correcting the spray dryer yield issues. The experiment proved that capture rate in the cyclones, and therefore yield, increased with the increase in airflow.

Over a period of continuing support, our engineer worked with the client to optimize the operating parameters for the new product so that yield was at target. Loading of the wet scrubber and also wastewater loading is now minimized as well.

Meet The Engineers

Jim Kent

Jim Kent

Business Development Manager

Dean Anderson

Dean Anderson

Project Manager

Experiencing Spray Dryer Challenges?

Are you experiencing spray dryer yield issues or other problems with your spray dryer? Contact Caloris at 410-822-6900 or to arrange for a process assessment at your facility.


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.