Spray Drying Technology

GF Corporation Micro Mist Spray Dryers

How the GF Corporation Micro Mist Spray Dryers Work:

Spray Dry Test Spray drying is an advanced technology that converts a solution or liquid into a solid powder in just one step. This is achieved through the atomization of a liquid into a spray, or fine mist of droplets. These droplets are then met with a stream of hot air that causes evaporation and reduces the mist to a dried powder form.

By atomizing a liquid, a large surface area is created which can then be dried more rapidly and thoroughly. This method of spray drying is more consistent, more thorough, and can be performed at lower temperatures, allowing substances to better retain their natural properties (i.e. flavor in food products).

The GF Corporation Promise

Quality:

Create incredibly fine powder of only 5 to 15 microns, in small scale or bulk quantities.
High-volume, large-capacity production of incredibly fine powder with is made possible through GF Corporation’s Micro Mist Spray Dryer.

Speed:

Decrease residence time inside the equipment.
Our spray dryers eliminate the need for bulky drying beds that require space and extend the length of the drying process.

Accelerate your production through the uninterrupted use of our state-of the-art non-clogging nozzle.
Smooth and continuous spray of highly viscous liquid, up to 5000cp, is made possible through external mixing.

Efficiency:

- Reduce the scale of your equipment space requirements with our compact and efficient design.
- Increase heat efficiency by setting the exhaust temperature low. Eliminate the need for the pulverizing and classifying processes.

Superior/Advanced Capabilities:

- Create dried powder in fewer steps; Minimize undried/agglomerated particles; eliminate unwanted stickiness / moisture.
- Dry materials that are difficult to dry when using other drying techniques.
- Dry by reacting two liquids through the use of GF Corporation’s Four Nozzle System.
- Dry materials at low temperatures (below boiling point) to preserve material properties (particularly helpful for the Food Industry).
- Create uniform powder with very narrow particle size distribution.
- Control and adjust the droplet median diameter by changing gas-liquid ratio.
- Dry by combining two different liquids using the Four Fluid Nozzle System.

Practicality/Convenience:

- Increase user convenience with the Central Control Panel and Viewing Chamber.
- Reduce cleaning time through easy disassembly and setup of removable parts
(MMSD uses external mixing which also reduces the need for extensive cleaning of multiple parts as required by other spray dryers).

GF Corporation Micro Mist Spray Dryer Specs

Superior Features of the Micro Mist Spray Dryer

	MMSD-Micro Mist Spray Dryer	Other Spray Dryers
Nozzle Type	Four Fluid Nozzle	Two Fluid Nozzle	Pressure Nozzle	Rotary Atomizer
Droplet Particle Diameter	Fine particle	Fine particle	Coarse particle	Coarse particle
Droplet Particle Diameter	5 - 15µm	5 - 30µm	0 - 150µm	10 - 100µm
Atomization Uniformity	Even	Uneven	Slightly Uneven	Even
Method of Atomization	Compressed Gas	Compressed Gas	Pressurizing Pump	Motor
Atomization Energy	High	High	Low	Low
Liquid Processing Capacity per Nozzle	High	Low	Medium	High
Capacity for Droplet Diameter Control	◎	△	△	◎
Capacity for Droplet Diameter Control	High (at fine particle range)	Conditions Apply	Conditions Apply	High
Countermeasure against Viscosity Change	Air Pressure	Air Pressure	Fluid Pressure	Revolution
Ability to spray High-Viscosity Liquids	◎	○	×	○
Ability to spray High-Viscosity Liquids	Great	Mediocre	Incapable	Mediocre
Maintainability	◎	◎	○	△
Maintainability	High	High	Medium	Conditions Apply
Spray Angle	180°	Under 30°	Under 60°	180°
Spray Shape	Hollow cone	Hollow cone fine	Full cone fine	Hollow cone

GF Corporation will provide support and guidance from experimentation to the designing, manufacturing, and maintaining of your customized production machine. All Micro Mist Spray Dryers are designed to allow you to easily and cost-effectively scale up from small scale to commercial scale.

MMSD Micro Mist Spray Dryer compared to other Micro Fine Spray Dryers

	MMSD-Micro Mist Spray Dryer	Conventional Spray Dryer
Atomization Device	Four Fluid Nozzle	Two Fluid Nozzle, Rotary Atomizer
Nozzles required to Atomize a small amount	One Nozzle	One Nozzle
Nozzles required to Atomize a large amount	One Nozzle	Multiple Nozzles
Scale-up Potential	Designed to scale up easily Laboratory units are used to test issues and parameters for convenient scaling up	Scaling up is more problematic because of the multiple nozzles Issues such as gas-flow turbulence and droplet collision make scaling up a more difficult process
Drying Efficiency	Incredible drying efficiency through the use of the 180° hollow cone which eliminates unevenness in hot air contact	Poor drying efficiency The full cone requires much more time for droplets to contact the hot air
System Size	Compact: Drying chamber can be smaller due to the MMSD’s superior drying efficiency compared to the conventional spray dryers	Large: Drying chamber will be larger and require more space Uneven and less thorough drying
Continuous Operation	Continuous uninterrupted operation without nozzle clogging achieved through the external mixing/drying	Very high likelihood of nozzle clogging
Compressed Air Volume	Smaller; If the liquid processing rate is the same as a conventional spray dryer, the air flow rate of the four fluid nozzle will be less	Larger
Ease of Operation	Convenient and simple operation using the central touch panel control system	Generally less convenient / centralized System is complicated with many nozzles and liquid pumps
Maintenance	Easy maintenance and upkeep with fewer nozzles and liquid transmission pumps	Inconvenient and complex to maintain with many nozzles and liquid transmission pumps
Initial Cost	Competitive pricing with smaller system options available	Subject to cost increases if production becomes high-capacity
Running Cost / Energy Consumption	Electrical energy consumption of compressor will be 20% to 50% less	Electrical energy consumption of the compressor is huge

The Micro Mist Spray Drying Process compared to Spray Drying Alternatives

	MMSD-Micro Mist Spray Dryer	Other drying methods such as milling/pulverizing
Capacity for Fine Powder Manufacturing	Powder can be attained directly from the liquid	Many more steps required in the drying process When converting slurry to powder, disintegrating/pulverizing the liquid after dehydrating at the filter press and shelf drying is necessary
System Configuration	1 unit	Several units
For use in Research & Development	Great; Powder can be easily attained	Requires more time and more steps: pulverizing and classification
Operating System	Continuous operation for long sets of time	Requires separate batch operation
Operating Performance	Simple user interface Simple assembly and clean up	Operating knowledge is necessary for each device Washing and assembling is complex and difficult
Maintainability	Easy maintenance with the nozzle as the only necessary spare part	Knowledge of maintenance and spare parts is necessary for each device
Sanitary Factor	Highly sanitary contained system	Often unsanitary and open system
Initial Cost	The same or cheaper than pulverizing/milling systems once all setup costs are considered; generally a more simple system	With a broad range of devices and systems there is also a broad range in prices; could require more equipment for additional steps (air classification, etc.)
Operating Costs	Electrical energy required can be higher, but the machine requires less manpower to run	Often requires much more in manpower depending on the material flow between devices
Chance of Contamination	Zero	Extremely high
Fluid Capabilities	Will work with slurry and solution Ideal size for slurry particles is below 1 to 2 µm	Will work with slurry but difficult to work with solution (increasing concentration will be necessary)
Product Property	Spherical form; fine powder Porous, Low density	Formation is instable High density
Quality Control of the Product	Uniform product with little variation; easy to control product because there are fewer variables	Quality control is necessary on each device and ; huge range of variable factors
Residual Moisture	Almost every powder can observe the standard for complete drying	Sometimes final drying might be necessary
Control of Thermal Denaturation	Instant drying at low temperature below boiling point is possible	Extended and possibly damaging exposure to heat is required for thorough drying