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Organics

ORGANICS - SPRAY DRYING

Organics mainly consists of the spray drying process.

During the spray drying process, the extract is inserted through our SDX/Swirl Air nozzle into a flow of hot air at the top of a cylindrical drum. As the droplets meet the hot air, they dry to create a fine powder.The density of the powder can be determined by different conditions within the nozzle and dryer.

Please see below a number of our case study's.

Case Study 1:

PROBLEM:

  • Eliminate clogging, increased wear life 30 times, reduced number of nozzles, reduced pump pressure, and increased amount of dried product

Product Produced:

  • Binder additive for animal feeds.

Background Information:

  • The customer produces the above product in a milk dryer on a contract basis during the slack milk season. The dryer is normally operated 24 hours a day

Plant Equipment:

  • 1200-1300 pounds per hour produced by an 8 nozzle conventional dryer

Operating Conditions with Existing Equipment:

  • An operating pressure of 5000 psi was required to sufficiently required to atomize the 50% solid solution. The product contained cellulose fibres and many impurities which resulted in plugging problems. An average wear life of only 6 hours was obtained on a tungsten carbide slotted distributor type nozzle

Delavan Recommended:

  • SDX 3, 5 Range of Nozzle

Results of Operation with Delavan SDX Nozzle:

  • Whilst increasing the amount of dry product to 1500 pounds per hour, the operating pressure was reduced to 4000 psi to improve  pump operating costs, and the number of nozzles in service to 8, the biggest plus factors achieved were the elimination of plugging problems and the extension of wear life by 30 times that of existing nozzles. The wear life of each nozzle was extended to 180 hours minimum. The improvements achieved by the SDX greatly reduced the operating costs of the dryer to make it more profitable venture.

Case Study 2:

PROBLEM:

  • Uniform product with fewer larger particles that require re-processing, easier packing, and a lower pressure

Product Produced:

  • Detergents

Background Information:

  • The product is made at a plant producing soaps and detergents for a large nationally known supermarket chain

Plant Equipment:

  • Counter-current 4 nozzle drier, producing approximately 11,500 pounds per hour

Operating Conditions with Existing Equipment:

  • Running on 60% solids, customer wished to reduced his pump pressure, with no reduction in output, and to eliminate clogging

Delavan Recommended:

  • SDX 3, 5 range of nozzles

Results of Operation with Delavan SDX Nozzle:

  • The customer reports highly satisfactory results when compared to conventional nozzles previously used. Product quality is good with fewer tailings (oversized particles requiring reprocessing). There has been no powder packing in the holding bins, and this has improved packing procedures at more uniform weights. Difficulties in transferring the powder from storage to packing were also eliminated. The pump pressure was lowered from 900-600 psi with no clogging
  • Formerly nozzles were changed on a 10 week cycle, now this improved and increased to 17 weeks. A further advantage has been observed in connection with the weight and volume of the product produced. In addition to a fixed fill weight per container, a given volume must be held. Previously this requirement had necessitated some over packaging (overfill) averaging 0.249%. The SDX has served to reduce this loss to 0.0846%, amounting to annual savings of £33,000 of product per year.

Case Study 3:

Problem:

  • The customer main concern was extending the nozzles life span, secondary to that was the particle fines.

Product Produced:

  • Gum Arabic

Background Information:

  • The customer is a major producer of a wide line of food products and food ingredients

Plant Equipment:

  • A single nozzle, vertical dryer with co-current air flow is used in conjunction with a high pressure pump

Operating Conditions with existing equipment:

  • Running 30-50% solids emulsion, the customer experienced extreme nozzle wear with replacements required every 36-40 hours. It was necessary to monitor the operating pressure very closely to compensate for the accelerated wear rate. There is a severe problem with particle fines.

Delavan Recommended:

  • SDX 2, 5 range of nozzles

Results of operation with Delavan SDX Nozzle:

  • The fines problem has been eliminated. Nozzle life has been extended to several times that of the conventional nozzle previously being used.