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Agitated Thin Film Dryer 

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Introduction

Agitated Thin Film Dryer (ATFD) by Kerone is an advanced, high-efficiency drying system engineered for handling heat-sensitive, high-viscosity, and solvent-rich materials. In this technology, a thin film of product is continuously formed and agitated on a heated surface, ensuring rapid moisture or solvent evaporation under atmospheric or vacuum conditions. Kerone designs ATFDs with precise control over film thickness, residence time, and heat transfer to deliver consistent drying performance, even for complex rheological materials. With robust engineering, corrosion-resistant materials of construction, and optimized rotor design, Kerone’s agitated thin film dryers are ideal for demanding applications in chemical, pharmaceutical, effluent treatment, and specialty industries where conventional dryers fail to meet performance or quality standards.

Why Choose Kerone Agitated Thin Film Dryer

Kerone’s ATFDs are developed with a process-centric approach, where every design parameter—from heat transfer surface area to rotor configuration and vapour handling system—is tailored to the product characteristics and end-quality requirements. Decades of experience in thermal and mass transfer systems allow Kerone to offer dryers that achieve low final moisture content, high solvent recovery, and minimal product degradation. The systems are designed for continuous or batch operation, with options for high vacuum, explosion-proof design, solvent recovery integration, and clean-in-place (CIP) arrangements. Customers benefit from lower operating costs, reduced footprint, and stable performance even under fluctuating feed conditions, making Kerone ATFDs a reliable choice for critical drying duties.

Types and Features of Agitated Thin Film Dryer

Kerone offers agitated thin film dryers in vertical and horizontal configurations, with single or multi-stage operation depending on the evaporation load and product behaviour. Systems can be designed for water-based, solvent-based, or mixed feeds with varying viscosities, including slurries, pastes, and near-solid concentrates. Execution options include atmospheric, high-vacuum, steam-heated, thermal fluid–heated, or electrically heated jackets. The internal rotor can be fitted with hinged, rigid, or segmented blades to maintain uniform film formation and prevent fouling or scaling on the heating surface. Material of construction ranges from carbon steel with special linings to stainless steel grades and high-alloy materials for corrosive or high-purity applications.

Key Features

  • High heat transfer efficiency through formation of a continuously renewed thin product film.
  • Capable of handling highly viscous, sticky, or crystallizing products without severe fouling.
  • Vacuum-compatible design for low-temperature drying of heat-sensitive materials.
  • Modular construction with configurable heating media, surface area, and rotor types.
  • Integrated vapour–liquid separation and solvent recovery options for safe and efficient operation.
  • Optimized residence time and film thickness for consistent final moisture and product quality.
  • Low hold-up volume, enabling quick product changeovers and reduced product losses.
  • Robust mechanical design with easy access for inspection, maintenance, and optional CIP.

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Future-Ready Engineering Driven by AI & IoT

Our advanced AI, ML, and IoT technologies, this solution delivers smarter automation, real-time insights, and predictive intelligence to enhance efficiency and drive future-ready growth.

Real-Time Monitoring & Control

Continuous tracking of process parameters with instant adjustments.

Predictive Maintenance

Intelligent fault detection to prevent failures before they occur.

Adaptive Process Optimization

Dynamic tuning of operations for maximum output and efficiency.

Cloud Dashboards & Analytics

Unified access to real-time insights and performance trends.

Energy & Resource Savings

Smarter utilization of energy to cut costs and reduce waste.

Secure IoT Connectivity

Encrypted data flow with seamless integration across plant systems.

Applications of Agitated Thin Film Dryer

Kerone’s agitated thin film dryers are extensively used in industries requiring efficient removal of water or solvents from challenging feedstocks. Typical applications include:
  • Chemical

    • Drying of resins, polymers, plasticizers, intermediates, and high-viscosity chemical masses.

  • Pharmaceutical

    • Concentration and drying of APIs, intermediates, and solvent-rich reaction masses.

  • Effluent & Waste Treatment

    • Concentration and drying of ETP/RO reject, brine solutions, and mother liquors.

  • Food & Nutraceuticals

    • Drying of extracts, herbal concentrates, and thermally sensitive food ingredients.

  • Agro & Fertilizer

    • Drying of agrochemicals, suspensions, and specialty fertilizer slurries.

Kerone’s Agitated Thin Film Dryer is a specialised solution for industries that require high-performance drying of difficult-to-handle products. By combining advanced thermal design, mechanical reliability, and application-specific customization, Kerone delivers ATFD systems that help customers improve product quality, reduce operating costs, and enhance process sustainability. Whether for solvent recovery, effluent minimization, or high-value product drying, Kerone’s ATFDs offer a dependable and efficient answer to complex drying challenges.

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Frequently Asked Questions (FAQ)

  • An Agitated Thin Film Dryer is a high-efficiency drying system in which a rotating rotor spreads and agitates feed material as a thin film over a heated surface, enabling rapid evaporation of water or solvent under controlled conditions.

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