The "multi-stage spray dryer system," a two-stage drying device developed and manufactured by Japan Powder Company, is designed without a pipe loss structure. It achieves improved drying performance by selectively increasing the retention time of larger particles in the hopper section located at the bottom of the exhaust chamber. This design allows for better handling of materials that are typically difficult to process due to high cohesiveness or poor flowability, which conventional vertical nozzle spray dryers struggle with. The exhaust chamber height is less than 50% of that found in traditional models, enabling efficient single-stage drying and simplifying the overall process.
This dryer features a monolithic construction and is widely used by research institutions and small-scale manufacturers. It’s ideal for small-batch and multi-variety production. Key advantages include a compact footprint, cost-effectiveness, quick automatic cleaning, and a non-burning dual hot air heating system. The system also allows for adjustments in the diameter of the hot air inlet and outlet pipes, as well as temperature control, depending on the material being processed. A cyclone dust collector ensures the finished product is cooled effectively. These features have earned it strong market recognition, with companies like Riken Vitamin Co., Ltd.’s Chiba plant using it for small-batch, diverse product manufacturing.
In addition, the company has also developed and produced the "PJ Finikesi" flow drying device, which has received positive market feedback. Its main advantage is the ability to achieve continuous drying without the need for storage. Built with SUS304 stainless steel, it offers a hygienic design suitable for food-grade applications. It delivers excellent thermal efficiency, maintains high product quality, and avoids burning or discoloration. Its cost-effective nature makes it popular among small producers. Recently, Marukoya Co., Ltd. implemented this system for the continuous treatment of tofu residue.
Another notable product is the "Micro Spray Dryer" developed by Fujisaki Electric Co., Ltd. This device introduces a new drying technology capable of producing microparticles by spray-drying single-micron-sized droplets. While some experimental spray dryers can handle 1 μm droplets, they are difficult to scale up for mass production. Fujisaki's solution lies in its four-fluid nozzle technology, which has been patented in Japan, the U.S., and Europe.
Unlike traditional two-fluid nozzles that use compressed air, the four-fluid nozzle allows for precise control over droplet size, enabling consistent production of 1 μm particles. Additionally, different types of stock solutions can be mixed at the nozzle tip to complete the powdering process. The externally mixed nozzle design prevents clogging and enables long-term continuous operation. Various spray head sizes allow for flexible spray amounts.
The spray drying tester used in R&D can produce fine powders from small test quantities, and the same particle size can be achieved during full-scale production. The sprayer includes a glass window for visual confirmation of the material spray, and the data can be displayed on a screen, printed, and reviewed easily.
One of the key benefits of this atomization process is the short drying time and low temperature, which minimizes color and flavor degradation. It also simplifies the process of turning liquid materials directly into powder, reducing energy and labor consumption. The device itself is compact, requires minimal space, and has low equipment and transportation costs, making it an attractive option for many industries.
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