Japan Develops Multi-stage Spray Dryer System

The "multi-stage spray dryer system," developed and manufactured by Japan Powder Company, is a two-stage drying device designed without a pipe loss structure. It enhances the drying process by selectively extending the retention time of larger particles in the hopper area of the lower exhaust chamber. This innovation allows for more effective drying of materials that are typically difficult to process due to high cohesiveness or poor liquidity—materials that conventional vertical nozzle spray dryers struggle with. The compact design of this system, with an exhaust chamber height less than 50% of traditional models, makes it ideal for achieving a single-stage drying process efficiently. This monolithic dryer is particularly popular among research institutions and small-scale manufacturers who require flexibility for small-batch and multi-variety production. Its advantages include a small footprint, cost-effectiveness, quick automatic cleaning, and a non-burning binary hot air heating method. The system also allows for adjustments in the diameter of hot air inlets and outlets, as well as temperature control based on the material being processed. A cyclone dust collector ensures cooled, high-quality finished products. These features have earned it strong market recognition, including use at Riken Vitamin Co., Ltd.'s Chiba plant for small-batch, varied product manufacturing. In addition, the company’s flow drying device, the "PJ Finikesi," has also received positive market feedback. It enables continuous drying without the need for storage, making it efficient for ongoing production. Constructed from SUS304 stainless steel, it ensures a hygienic and safe environment suitable for food processing. It offers excellent thermal efficiency, maintains high product quality, and avoids burning or discoloration. Its low cost has made it a popular choice, such as for Marukoya Co., Ltd., which uses it to continuously process tofu residue. Fujisaki Electric Co., Ltd. has introduced the "Micro Spray Dryer," a cutting-edge device capable of producing microparticle powders by spraying droplets as small as one micron. While conventional spray dryers may feature experimental machines that can handle 1 μm droplets, mass production remains challenging. Fujisaki's breakthrough lies in its four-fluid nozzle technology, patented in Japan, the U.S., and Europe. This technology overcomes previous limitations by enabling consistent production of 1 μm droplets, with precise control over droplet size. Unlike traditional two-fluid nozzles that rely on compressed air, the four-fluid nozzle allows for greater versatility, including the ability to mix different types of stock solutions at the nozzle tip during the powdering process. The externally mixed, clean-type nozzle prevents clogging, ensuring long-term continuous operation. By adjusting the edge diameter of the spray head, various spray amounts can be achieved, enhancing operational flexibility. The spray drying tester used in R&D applications can produce fine powders from small test batches, and when scaled up, it maintains the same particle quality as the experimental model. The system includes a glass window for visual confirmation of the spray process, with data displayed on a screen and printable for record-keeping. One of the key benefits of this atomization technique is the short drying time and low temperature, which helps preserve the color, flavor, and overall quality of the product. It simplifies the process of turning liquid materials directly into powder, reducing energy consumption and labor costs. Additionally, the compact design of the equipment requires minimal space and lowers both initial investment and transportation expenses.

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