Spray Dryers

Product Details:

This system can be more efficient, moisture which is to remain in the product is not so readily controlled.

We offer Counter Current Dryers. They are also used effectively as combined dryer/preheaters. However, since the final product is in contact with the gas at its highest temperature the counter-current dryer is often unsuitable for heat sensitive materials. Counter current dryers are more suitable for materials that must be dried to very low levels of moisture, where the last traces of moisture are difficult to remove, or where an elevated product temperature is desirable.

Product Details:

We offer Co-Current Flow Spray Dryer. The co-current flow enables the particles to have a lower residence time within the system and the particle separator (typically a cyclone device) operates more efficiently. In a co-current flow spray dryer, the spray is directed into the hot air entering the dryer and both pass through the chamber in the same direction.Spray evaporation is rapid, and the temperature of the drying air is quickly reduced by the vaporization of water.

 

 

Product Details:

We offer Counter Current Spray Dryers. The counter-current flow method enables a greater residence time of the particles in the chamber and usually is paired with a fluidized bed system. In this configuration, the spray and the air are introduced at opposite ends of the dryer, with the atomizer positioned at the top and the air entering at the bottom.

 

 

Product Details:

We offer Industrial Spray Dryer. A consistent particle size distribution is a reason for spray drying some industrial products such as catalysts. Air is the heated drying media. Spray drying being one of the most widely used industrial process for particle formation and drying we offer a wide range of Spray Drying Systems suited to continuous production of dry solids, granulate or agglomerate particle form from liquid feedstock in one stage.

 

We use a variety of feed atomization as below:

• Rotary Disc Atomization

 

Rotary atomizers use a high speed rotating disk, cup or wheel to disperse the liquid into a hollow cone spray. The rotational speed controls the drop size. Spray drying and spray painting are the most common uses of this technology. A high speed rotating throws the liquid outward tangentially at high velocities forming fine droplets / mist and at the same time it comes in contact with the hot air to produce dry solids, granulate or agglomerate particles.

 

• Nozzle Atomization

 

A spray nozzle is a device that facilitates the formation of spray. When a liquid is dispersed as a stream of droplets (atomization), it is called a spray. Various airflow patterns are possible with nozzle atomization systems.

 

Spray nozzles are used to achieve two primary functions: increase liquid surface area to enhance evaporation, or distribute a liquid over an area. Feed solution or slurry gets atomized at high pressure through a nozzle into fine droplets and then dried instantaneously.

 

Based on the clients specification and requirements as per the end usage, various configurations of Spray Dryers such as Multi-Stage Drying, Open Loop Drying and Closed Loop Drying are possible as per the process requirements.

 

A few components of Spray Drying System are:

• Feed pump
• Atomizer
• Air heater
• Air disperser
• Drying chamber
• Powder recovery system
• Exhaust air cleaning systems
• Process control systems

Product Details:

We offer Two Stage Spray Dryers with fluid bed dryer having the following components. The company specializes in the said product which is very much available in best value and price. It can lift, hold, compact, evacuate, move, dehydrate, agitate, actuate, form, rotate, filter, clean and simulate high altitude. The components include:

 

• Air
• Feedstock
• Dried product
• Cyclone
• Stationary fluid bed
• Fluid bed cyclone
• Transport cyclone

Product Details:

A Closed Cycle Spray Dryer recycles the drying gas and does not pass it to the atmosphere or input atmospheric air, which may be air or more commonly, an inert gas such as nitrogen.

 

Closed cycle dryers are used when:

 

• Explosion risks must be eliminated
• Pollution due to vapor, particulate emission or odor is prohibited
• Risk of powder degradation by oxidation during drying
• Product is toxic
• Feedstock consists of solids mixed with inflammable solvent
• Complete recovery of solvent is required

Product Details:

We offer Two Stage Spray Drying Systems like the two-stage dryer with vibrating bed dryer. These equipment are suited to continuous production of dry solids, granulate or agglomerate particle form from liquid feedstock in one stage. It has the following components

Features

• Air
• Feedstock.
• Dried product
• Cyclone
• Stationary fluid bed
• Fluid bed cyclone
• Transport cyclone

Product Details:

With nozzle atomization, co-current as well as counter-current mixed-flow can be obtained. In a Single Stage Dryer, the moisture is reduced to the target (typically 2% - 5% by weight) in one pass through the dryer. The single stage dryer is used in the majority of designs.

The basic system is a single stage co-current spray dryer with rotary or nozzle atomization. Product discharge can be either 1-point with the exhaust air from the cyclone or bag filter collector, or 2-point from chamber base and collector via a conveying / cooling system.

Used where the powder directly meets the quality specification. Otherwise, a vibrating fluid bed can be provided for post-drying / cooling of the chamber fraction.

 

Uses of a Single Stage Dryer

 

• For gentle drying of sticky, hydroscopic and thermoplastic products
• Produces non-dusty, agglomerated, easy-to-use powders
• Ideal for product development purposes or production of agglomerated powders

 

Applications of a Single stage Dryer

• Beverages / Food flavors
• Dairy foods
• Protein foods
• Flour
• Fruit / Vegetable pulps
• High fat powder ingredients
• Natural sweeteners

Product Details:

 

SAKA Engineering Systems Pvt. Ltd. is one of India’s leading spray dryer manufacturers with proven expertise in multi-stage spray drying technology. Our Three-Stage Spray Dryer is designed to deliver high-quality powders with excellent particle properties, solubility, and flowability while ensuring energy efficiency and gentle product handling.

 

 

How It Works

 

 

• Stage 1: Atomization and primary drying in the spray chamber.

• Stage 2: Controlled moisture removal in the integrated fluid bed dryer.

• Stage 3: Final drying, cooling, and conditioning in the external fluid bed dryer.

 

 

This three-step process ensures uniform particle size distribution (“P-particles”), reduced fines, and minimal thermal stress on sensitive products — making it ideal for food, dairy, nutraceutical, chemical, and pharmaceutical industries.

Key Advantages of SAKA Three-Stage Spray Dryers

•  Superior product quality – better solubility, dispersibility, and bulk density.

•  Energy-efficient operation – reduced drying costs compared to single-stage dryers.

•  Gentle drying of heat-sensitive materials – preserves flavors, aroma, vitamins, and actives.

•  Flexibility – can handle sticky, hygroscopic, or difficult-to-dry feed materials.

•  Safe & reliable – explosion protection, inert gas systems, CIP (clean-in-place), hygienic designs.

•  Agglomeration and instantization options – for instant powders

Heating & Fuel Options

We design dryers to work with multiple heating systems depending on customer needs:

 

• Hydrogen Gas

• LPG / Natural Gas

• Steam

• Hot Oil

• Electricity

• Biomass / Waste Heat

This makes our systems future-ready, eco-friendly, and adaptable.

In-House Manufacturing & Global Standards

All equipment is manufactured at our own state-of-the-art plant in Pune, India, ensuring full control on quality. We can build dryers to meet any international standard including ASME, PED, GMP, FDA, CE, ATEX, UL or other customer-specified codes.

 Contact us today to discuss your spray drying requirement or request a detailed proposal.

Additional Information:

• Production Capacity: custoised
• Delivery Time: 16 weeks

Product Details:

Two-Stage Spray Dryer – Advanced Drying and Cooling in One Compact System

At SAKA Engineering Systems Pvt. Ltd., we specialize in designing and manufacturing two-stage spray dryers that deliver the perfect balance of efficiency, product quality, and process control. Our two-stage configuration combines a tall-form nozzle-based spray dryer with an integrated fluid bed dryer and cooler, making it the ideal solution for heat-sensitive and high-value products.

In a two-stage spray drying system, atomized droplets from precision-engineered nozzles are introduced into a tall vertical drying chamber, where rapid moisture removal occurs through hot air contact.

Partially dried particles then pass to the vibrating fluid bed dryer located at the bottom of the tower. This second stage gently removes residual moisture and — through a dedicated cooling section — ensures that the final product reaches a stable temperature, ready for packaging or downstream processing.

 

Key Design Features

• Nozzle Atomization System – Uniform droplet distribution for consistent particle size and higher yield.

• Integrated Fluid Bed Dryer with Cooling Section – Controlled final drying and product cooling for improved stability.

• Fuel Flexibility – Available in HSD, PNG, FO, LDO, or biomass-based hot air generator configurations.

• Custom Air Handling System – Optional cyclone separator or bag filter system for optimal powder recovery and emission control.

• Advanced Automation – Fully PLC-based control panels, SCADA integration, and real-time process monitoring.

• World-Class Safety Systems – Includes rupture disc protection, flame-quenching valves, fire-fighting systems, and explosion isolation valves as per NFPA and ATEX guidelines.

• GMP and Food-Grade Finish – All contact parts in SS304/SS316, designed for easy cleaning and hygienic operations.

Applications

SAKA’s two-stage spray dryers are ideal for:

• Food and Dairy Powders (coffee, milk derivatives, flavours, starches)

• Pharmaceuticals and Nutraceuticals

• Chemicals and Catalysts

• Ceramic and Metallurgical Powders

• Agrochemicals and Detergents

• Advantage at a glance ; 

•  

  Parameter	Advantage
  Product Temperature	Controlled, gentle drying below degradation point
  Thermal Efficiency	10–15% higher than conventional single-stage dryers
  Footprint	Compact layout integrating drying and cooling
  Safety	Explosion-proof, NFPA-compliant design
  Automation	PLC-based with recipe storage and data logging
  Emission Control	Cyclone or bag filter system ensuring clean air discharge

  
  

   

   

   

  
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