Fluidized bed technology increases product quality and capacity of spray dryers

Liquid turns solid: Spray dryers are used in many industries to dry liquids containing solids in powder form. However, conventional spray drying systems often reach their limits where specifically adjusting product properties or scaling production capacities is concerned. The complementary technology of fluidized bed agglomeration from AMANDUS KAHL not only optimizes product properties but also increases production output.

Every technology has its strengths – this applies to both spray drying and fluidized bed technology. But what is promising on its own only reveals its full potential in the right combination. Our Conti-FB system helps spray dryers to overcome their limitations.

1st step: Spray drying

The process starts with a liquid solution or suspension that is atomized in a spray dryer. The droplets dry at once in the hot air and leave behind a fine, dry powder. This product is precisely what causes issues in many applications: Since it is often very fine, dusty, and poorly flowing, further processing is quite difficult.

2nd step: Agglomeration in the fluidized bed

The powder from the spray dryer is now transferred to a fluidized bed dryer. It is whirled up with air there, and targeted spraying of liquid causes the fine particles to combine into larger, loose agglomerates. These are dried at the same time, which makes them more stable, flowable, and dust-free. This ensures easy and safe handling of the powder. Agglomerated powders are also much more soluble than fine, spray-dried powders. In the food and pharmaceutical industries in particular, this has the advantage that unnecessary additives can be avoided in the formulation.

Increased efficiency without structural changes

Use of the same spray liquid in the fluidized bed and in the spray tower as well as the additional drying capacity increase throughput rates by up to 60% and make the entire process significantly more efficient. In addition to improving product quality, production capacities can also be increased. Our continuous fluidized bed systems are a more compact and efficient alternative to an additional spray tower. This permits flexible expansion of production capacities without the need for extensive interventions in the existing building infrastructure. Fluidized bed technology is, therefore, particularly attractive for companies that already have a spray dryer.

Customized solutions and comprehensive advice

We offer extensive testing facilities at our technical center in Ganderkesee to check the optimization of spray-dried products using slurry. Initial product samples are produced on our batch laboratory systems, the formulations of which are later transferred to our continuous pilot plant. This creates a solid foundation for the production concept. Our team actively supports the entire process from concept development and cost estimation through to the successful implementation of the production plant.