Spray drying systems are widely utilized in food & beverage, pharmaceutical, chemical, and plenty of other industries to produce fine and uniform micron size particles. Spray dryer needs massive quantities of hot air for drying. The quality of the final product (powder) is affected by the quality of inlet air coming into the dryer.
The Spray dryer mixes hot air with an atomized (sprayed) liquid stream in a drying chamber/atomizer that results in evaporation and produces free-flowing dry powder. The inlet air needs to be fresh and dry, freed from contamination and odourless. Since the ambient air changes throughout the year, the humid air can also enter the Spray dryer affecting its method. Thus, the drying temperature and time inside the dryer desires close observation to restrict loss because of variable humidity levels. These varying inlet conditions need to be monitored by an experienced operator to adjust the parameters for consistent output.
spray drying has become an essential technique for producing high-quality powders across industries such as food processing, pharmaceuticals, chemicals, and ceramics. However, the efficiency and consistency of spray drying operations depend heavily on one crucial factor—effective moisture and humidity control. Even slight fluctuations in ambient humidity or inlet/outlet moisture levels can impact product quality, drying efficiency, equipment performance, and overall production costs.
Effects of uncontrolled humidity
Due to high humidity, the powdered material tends to stick to the hopper conveyors and packing machine, resulting in frequent breakdowns in the conveyor drive mechanism. This hinders the free flow of powders/granules, making several downstream operations (e.g. packaging, filtering, and handling) difficult and expensive.
Some of the common problems faced by powder manufacturers are:
- Inconsistent powder quality
- Powder sticks to spray dryer walls
- Frequent breakdown of the spray drying system
- Increased drying cycle time
- Inconsistent powder quality
- Reduced throughput
KERONE has specially developed high-performance dehumidifiers for supplying controlled and consistent dehumidified air to the inlet point. This allows higher performance and output from spray dryers and improves the quality of the powder. Moreover, it reduces dependence on the operator for a constant adjustment of parameters on account of various outside atmosphere. It also reduces the energy consumption for heating the inlet air up to the desired temperature. Dehumidifying the inlet air also increases its temperature, as a results of that the heater should do less work to heat the air to the specified temperature.
Some of the Typical Spray Drying Applications
- Food Powder – Coffee, Spices and Seasoning, Fruits & Vegetables concentrate, Herbal Food, Milk, Tea, Spray Dried Eggs, etc.
- Industrial – Ceramic Material, Paint Pigments, Chemicals, etc.
- Pharmaceuticals – Antibiotics, Encapsulation, Enzymes, Vitamins, etc.
At KERONE, we understand that precision in moisture management is not just a technical requirement—it is a strategic advantage. With decades of expertise in designing state-of-the-art heating, drying, and automation solutions, KERONE helps industries optimize their spray drying processes through intelligent humidity control technologies, customized system integrations, and advanced monitoring tools. By mastering the balance of moisture and environmental conditions, manufacturers can ensure consistent particle size, improved product stability, reduced energy consumption, and enhanced operational reliability