How to Increase the Output of Spray Dryers – A Practical Approach

2026/01/25

January 25, 2026

How to Increase the Output of Spray Dryers – A Practical Approach

Spray dryers are widely recognized for their high drying efficiency and excellent product quality, making them indispensable across industries such as food, pharmaceuticals, chemicals, and ceramics. However, many users face a common challenge: how to boost production capacity without increasing capital investment or operating costs.

Based on the working principle of spray drying, four key factors primarily influence dryer output:

Flow rate of the drying medium (hot air)
Operating time of the equipment
Inlet temperature of the drying medium
Solid concentration of the feed solution

Changzhou Yidu Drying Equipment Co., Ltd. has systematically evaluated each factor to identify the most cost-effective path to higher productivity:

Increasing hot air flow would require upgrading fans, cyclones, or bag filters—adding both cost and downtime.
Extending operating hours reduces time available for cleaning and maintenance, often leading to frequent wall adhesion and operational instability.
Raising inlet temperature can improve evaporation rates, but demands additional heating capacity and risks degrading heat-sensitive products.

This leaves increasing feed concentration as the optimal solution.

The Impact of Higher Feed Concentration

When feed solid content is increased, process parameters must be carefully re-optimized to maintain product quality and system stability. Yidu’s R&D team analyzed two critical concerns:

1. Heat Demand:
While higher solids mean more dry powder per unit time—and thus greater total heat consumption—theoretical calculations show that, with constant air flow and inlet temperature, the existing system can still operate effectively without overloading.

2. Wall Adhesion Risk:
It’s commonly believed that higher concentration leads to larger droplet size after atomization, increasing the risk of sticky deposits on chamber walls. However, through extensive in-house testing, Yidu discovered that adjusting the gas-to-liquid relative velocity—specifically by fine-tuning compressed air pressure in two-fluid nozzles—effectively compensates for increased viscosity and prevents adhesion.

By optimizing feed concentration alongside precise control of atomization parameters, Yidu has enabled clients to significantly increase spray dryer output—without equipment modifications or quality compromise.

At Yidu Drying, we believe true innovation lies not in bigger machines, but in smarter processes. Through deep technical collaboration and continuous experimentation, we help our customers achieve more output, better quality, and lower costs—one drop at a time.